TM-259 705A 2014−09

Eff w/ME360063E
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

Big Blue 800 )

Duo Air Pak

File: Engine Drive

Visit our website at

www.MillerWelds.com
 INFORMATION ON OLDER UNITS

 This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-8. AC Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Using The Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 18
4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 19
4-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 20
4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . 21
4-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 22
4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 23
4-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-15. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-16. Connecting To Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-17. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-3. Engine Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-4. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-5. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5-6. Low Open-Circuit Voltage (VRD) Switch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-8. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-9. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-10. Engine Block Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-11. Optional Air Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-1. North American Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-2. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-3. Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
 TABLE OF CONTENTS

7-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7-5. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-6. Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-8. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7-9. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7-10. Removing Optional Air Dryer For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-1. Measuring Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-2. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-3. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-4) . . . . . . . . . . . . . . . . 56
9-4. Troubleshooting Values For Circuit Diagram (Use With Section 9-3) . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9-5. Waveforms For Sections 9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9-6. Main Control Board PC1/PC21 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9-7. Main Control Board PC1/21 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9-8. Filter Board PC5/PC25 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-9. Filter Board PC5/25 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-10. IGBT Module LED Troubleshooting Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9-11. Engine Display Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-12. Meter Display Board PC2/22 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9-13. Meter Display Board PC2/22 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9-14. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9-15. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION 10 − SERVICING AND TROUBLESHOOTING AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 72
10-1. Component Location And System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10-2. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10-3. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-4. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-5. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10-6. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10-7. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-8. Troubleshooting Air Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SECTION 11 − SERVICING AND TROUBLESHOOTING OPTIONAL AIR DRYER . . . . . . . . . . . . . . . . . . . . 82
11-1. Component Location For JP Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11-2. Air Dryer Operation And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11-3. Replacing Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11-4. Troubleshooting Optional Air Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 12 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12-1. Disassembly For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12-3. Replacing IGBT Modules/Heat Sink Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SECTION 13 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SECTION 14 − TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14-1. Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
SECTION 15 − ENGINE INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SECTION 16 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
16-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
16-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
SECTION 17 − PARTS EFF W/MD360063E AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

OM-259 705G - 2014−04, safety_rtm 2013-09

DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions  Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
 Be careful not to short metal tools, parts, or
Only qualified persons should test, maintain, and repair this wires together during testing and servicing.
unit.

During servicing, keep everybody, especially children, away. STATIC (ESD) can damage PC boards.
 Put on grounded wrist strap BEFORE handling
boards or parts.
ELECTRIC SHOCK can kill.  Use proper static-proof bags and boxes to
store, move, or ship PC boards.
 Do not touch live electrical parts.
 Stop engine and remove input power plug from Using a generator indoors CAN KILL
receptacle (if applicable) before testing or re- YOU IN MINUTES.
pairing unit unless the procedure specifically
requires an energized unit.
 Generator exhaust contains carbon monoxide.
 Insulate yourself from ground by standing or working on dry insu- This is a poison you cannot see or smell.
lating mats big enough to prevent contact with the ground.
 NEVER use inside a home or garage, EVEN IF
 Do not leave live unit unattended.
doors and windows are open.
 If this procedure requires an energized unit, have only personnel  Only use OUTSIDE and far away from windows, doors, and
familiar with and following standard safety practices do the job. vents.
 When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
 Stop engine and let it cool off before checking or
SIGNIFICANT DC VOLTAGE exists in inverter power adding fuel.
sources AFTER stopping engine.  Do not add fuel while smoking or if unit is near
 Stop engine on inverter and discharge input capacitors according any sparks or open flames.
to instructions in Troubleshooting Section before touching any  Do not overfill tank; clean up any spilled fuel.
parts.
FIRE OR EXPLOSION hazard.
 Do not place unit on, over, or near combustible surfaces.
 Do not service unit near flammables.
MOVING PARTS can injure.
 Keep away from moving parts such as fans, BATTERY EXPLOSION can BLIND.
belts, and rotors.
 Always wear a face shield, rubber gloves, and
 Keep away from pinch points such as drive
protective clothing when working on a battery.
rolls.
 Stop engine before disconnecting or connect-
 Have only qualified people remove doors,
ing battery cables.
panels, covers, or guards for maintenance
and troubleshooting as necessary.  Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles.
 Keep hands, hair, loose clothing, and tools
away from moving parts.  Observe correct polarity (+ and −) on batteries.
 Before working on generator, remove spark plugs or injectors  Disconnect negative (−) cable first and connect it last.
to keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on genera- BATTERY ACID can BURN SKIN and EYES.
tor components.
 Reinstall doors, panels, covers, or guards when servicing is  Do not tip battery.
finished and before starting engine.  Replace damaged battery.
 Flush eyes and skin immediately with water.

Big Blue 800 Duo Air Pak TM-259 705 Page 1

  Have the installation regularly checked and maintained.
STEAM AND HOT COOLANT can burn.
 Keep high-frequency source doors and panels tightly shut, keep
 If possible, check coolant level when engine is spark gaps at correct setting, and use grounding and shielding to
cold to avoid scalding. minimize the possibility of interference.
 Always check coolant level at overflow tank, if
present on unit, instead of radiator. OVERUSE can cause OVERHEATING.
 If the engine is warm, checking is needed, and there is no overflow  Allow cooling period; follow rated duty cycle.
tank, follow the next two statements.  Reduce current or reduce duty cycle before
 Wear safety glasses and gloves and put a rag over radiator cap. starting to weld again.
 Turn cap slightly and let pressure escape slowly before completely  Do not block or filter airflow to unit.
removing cap.

ELECTRIC AND MAGNETIC FIELDS (EMF) SHOCK HAZARD from testing.

can affect Implanted Medical Devices.
 Stop engine or turn Off welding power source (if
 Wearers of Pacemakers and other Implanted applicable) before making or changing meter
Medical Devices should keep away from serv- lead connections.
icing areas until consulting their doctor and the  Use at least one meter lead that has a self-
device manufacturer. retaining spring clip such as an alligator clip.
 Read instructions for test equipment.
FALLING EQUIPMENT can injure.
 Use lifting eye to lift unit and properly installed READ INSTRUCTIONS.
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see  Use Testing Booklet (Part No. 150 853) when
Specifications). servicing this unit.
 Use equipment of adequate capacity to lift and support unit.  Consult the Owner’s Manual for welding safety
 If using lift forks to move unit, be sure forks are long enough to precautions.
extend beyond opposite side of unit.  Use only genuine replacement parts from the manufacturer.
 Follow the guidelines in the Applications Manual for the Revised  Read and follow all labels and the Technical Manual carefully be-
NIOSH Lifting Equation (Publication No. 94−110) when manu- fore installing, operating, or servicing unit. Read the safety in-
ally lifting heavy parts or equipment. formation at the beginning of the manual and in each section.
 Perform maintenance and service according to the Technical
Manual, industry standards, and national, state, and local codes.
HOT PARTS can burn.
 Reinstall injectors and bleed air from fuel system according to
 Do not touch hot engine parts bare-handed. engine manual.
 Allow cooling period before working on
equipment.
HYDRAULIC EQUIPMENT can injure
 To handle hot parts, use proper tools and/or
or kill.
wear heavy, insulated welding gloves and
clothing to prevent burns.  Before working on hydraulic system, turn off
and lockout/tagout unit, release pressure, and
be sure hydraulic pressure cannot be accident-
ally applied.
 Do not work on hydraulic system with unit running unless you are a
TILTING OR TIPPING can injure. qualified person and following the manufacturer’s instructions.
 Do not modify or alter hydraulic pump or manufacturer-supplied
 Do not put any body part under unit while lifting. equipment. Do not disconnect, disable, or override any safety
 Always use proper equipment (hoists, slings, equipment in the hydraulic system.
chains, blocks, etc.) of adequate capacity to lift  Keep away from potential pinch points or crush points created by
and support components (stator, rotor, engine, equipment connected to the hydraulic system.
etc.) as needed during job.
 Do not work under or around any equipment that is supported only
PINCH POINTS can injure. by hydraulic pressure. Properly support equipment by mechanical
 Be careful when working on stator and rotor assemblies. means.

EXPLODING PARTS can injure. HYDRAULIC FLUID can injure or kill.

 Failed parts can explode or cause other parts to  Before working on hydraulic system, turn off and
explode when power is applied to inverters. lockout/tagout unit, release pressure, and be sure
 Always wear a face shield and long sleeves hydraulic pressure cannot be accidentally applied.
when servicing inverters.  Relieve pressure before disconnecting or con-
necting hydraulic lines.
H.F. RADIATION can cause interference.  Check hydraulic system components and all con-
 High-frequency (H.F.) can interfere with radio nections and hoses for damage, leaks, and wear
navigation, safety services, computers, and before operating unit.
communications equipment.  Wear protective equipment such as safety
 Have only qualified persons familiar with elec- glasses, leather gloves, heavy shirt and trousers,
tronic equipment perform this installation. high shoes, and a cap when working on hydraulic
system.
 The user is responsible for having a qualified electrician promptly
 Use a piece of paper or cardboard to search for
correct any interference problem resulting from the installation.
leaks−−never use bare hands. Do not use equip-
 If notified by the FCC about interference, stop using the equipment ment if leaks are found.
at once.
TM-259 705 Page 2 Big Blue 800 Duo Air Pak
 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid. COMPRESSED AIR can injure or kill.
 Reinstall doors, panels, covers, or guards when servicing is  Before working on compressed air system,
finished and before starting unit. turn off and lockout/tagout unit, release pres-
 If ANY fluid is injected into the skin, it must be surgically removed sure, and be sure air pressure cannot be acci-
within a few hours by a doctor familiar with this type of injury or gan- dentally applied.
grene may result.  Relieve pressure before disconnecting or con-
necting air lines.
 Check compressed air system components
COMPRESSED AIR EQUIPMENT can and all connections and hoses for damage,
leaks, and wear before operating unit.
injure or kill.
 Do not direct air stream toward self or others.
 Before working on compressed air system, turn  Wear protective equipment such as safety glasses, hearing pro-
off and lockout/tagout unit, release pressure, tection, leather gloves, heavy shirt and trousers, high shoes, and a
and be sure air pressure cannot be accidentally cap when working on compressed air system.
applied.  Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
 Do not work on compressed air system with unit running unless found.
you are a qualified person and following the manufacturer’s in-  Reinstall doors, panels, covers, or guards when servicing is
structions. finished and before starting unit.
 If ANY air is injected into the skin or body seek medical help imme-
 Do not modify or alter compressor or manufacturer-supplied diately.
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system. TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
 Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.  Release air pressure from tools and system be-
 Do not work under or around any equipment that is supported only fore servicing, adding or changing attach-
by air pressure. Properly support equipment by mechanical ments, or opening compressor oil drain or oil fill
means. cap.

1-3. 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 & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling.
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields may interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

Big Blue 800 Duo Air Pak TM-259 705 Page 3

 SECTION 2 − DEFINITIONS

2-1. 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 2012−05

Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2012−05

Keep your head out of the fumes.

Safe6 2012−05

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012−05

Do not weld on drums or any closed containers.

Safe16 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

TM-259 705 Page 4 Big Blue 800 Duo Air Pak

 Do not work on unit if engine is running. Stop engine first.

Safe21 2012−05

Do not smoke while fueling or if near fuel.

Safe22 2012−05

Stop engine before fueling.

Safe23 2012−05

Do not fuel a hot engine.

Safe24 2012−05

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).

Safe25 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

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.

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

Read Owner’s Manual. Follow instructions to activate battery.

Safe48 2012−05

Big Blue 800 Duo Air Pak TM-259 705 Page 5

 0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.

Safe54 2012−05

50 h std
After the first 50 hours of operation, change the engine oil and filter.

Safe55 2012−05

Never use generator inside a home or garage, even if doors and win-
dows are open.

Safe87 2012−07

Only use generator outside and far away from windows, doors, and
vents.

Safe88 2012−07

Do not use ether. Using ether voids warranty. See engine Owner’s Manual.

Safe89 2012−07

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2012−07

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2012−07

2-2. Miscellaneous Symbols And Definitions

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Engine Battery (Engine) Air Cleaner Engine Oil

Radiator Spark Arrestor Engine Belt Filter

Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)

TM-259 705 Page 6 Big Blue 800 Duo Air Pak

 Certified/Trained
Positive Negative Welding Arc
Mechanic

Off On Air Compressor Remote

Air Temperature Or
Flux Cored Arc Alternating
Engine Output
Welding (FCAW) Current
Temperature

Stick (SMAW) MIG (GMAW) TIG (GTAW)

Lift Arc TIG
Welding Welding Welding

Time
h
Hours
s
Seconds
1 Single Phase

Read Operator’s Do Not Switch

3 Three Phase
Manual
Circuit Protection
While Welding

Suitable For Weld-

Engine-Driven,
ing In An Environ-
S ment With In-
creased Risk Of P1max Maximum Power
Consumption
G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz

Electric Shock

X Duty Cycle
U0 Rated No Load
Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed

n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current

Display Menu or
Direct Current Previous Display Next Display
Cancel Function

Change Display Enter or Engine

View Diagnostic

Big Blue 800 Duo Air Pak TM-259 705 Page 7

 SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the right side. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Weld, Power, And Engine Specifications

Maximum
Rated Output
Welding Rated Output Open-Circuit Fuel Tank
Dual Operator Generator Power Rating Engine
Mode Single Operator Voltage Capacity
(Each Side)
(Nominal)

Stick: 400A, 36 Independent of Weld Output

Stick: 800A, 38 Single-Phase,
VDC, 100% Duty
VDC, 100% Duty 4 kVA/kW, 34/17 A,
Cycle Deutz TD2.9L4
CC/DC Cycle 95* 120/240 V AC, 50/60 Hz
TIG: 400A, 26 Liquid-Cooled,
TIG: 800A, 38 VDC, 3-Phase Generator Four-Cylinder,
VDC, 100% Duty 25 gal
100% Duty Cycle (In Addition To Standard Turbo-Charged
Cycle (95 L)
4 kVA/kW Generator Power) 65.7 HP Diesel Engine
Single-Phase/ Tier 4 Final Compliant
Three-Phase,12/20 kVA/kW,
400A, 34 VDC, 800A, 38 VDC, 50/48 A, 120/240 VAC,
CV/DC 95
100% Duty Cycle 100% Duty Cycle 50/60 Hz

* With Low OCV Voltage Reducing Device (VRD) switch enabled, open−circuit voltage is 13 to 15 volts DC until arc initiation for Stick Welding.

3-3. Air Compressor Specifications

Compressor Model And Air Output At Effective Working Safety Relief

Factory Pressure Setting
Type Pressure Valve Rating

60 scfm (1.7 m3 min−1),

Ingersoll Rand CE55 G
100 psi (690 kPa), 125 psi (862 kPa) 150 psi (1034 kPa)
Rotary Screw
100% Duty Cycle

3-4. Environmental Specifications

IP Rating Operating Temperature Range

IP23S
This equipment is designed for outdoor use. It may be stored, but is −40 to 104°F (−40 to +40°C)
not intended to be used outside during precipitation unless sheltered.

Notes

TM-259 705 Page 8 Big Blue 800 Duo Air Pak

3-5. Dimensions, Weights, And Operating Angles
Dimensions
53.75 in. (1365 mm)
Height
(to top of exhaust)
G
28-1/2 in. (724 mm)
(mtg. brackets turned in)
Width
30-3/4 in. (781 mm)
(mtg. brackets turned out)
Depth 69.5 in. (1765 mm)
! Do not exceed tilt angles or engine could
A 69.5 in. (1765 mm) be damaged or unit could tip.

B* 57.9 in. (1470 mm) ! Do not move or operate unit where it could
tip.
C* 46.375 in. (1178 mm)
A
D* 11.5625 in. (294 mm) B C
E 27-1/2 in. (699 mm)
F 1 in. (25 mm)
30°
G 29-13/16 in. (757 mm)
H 30°
9/16 in. (14 mm) Dia.
H
4 Holes 20°
D 20°
* With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight E 907 535−1

No fuel: 2095 lb (950 kg) 802 161-A

W/fuel: 2275 lb (1032 kg)

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

3-6. Duty Cycle And Overheating

1 100% Duty Cycle

1
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.

 This unit is rated for welding at

400 amperes continuously in
dual operator mode or 800 am-
peres continuously in single
operator mode.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 9

3-7. Volt-Ampere Curves
The volt-ampere curves show the
A. Stick Mode minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
100 other settings fall between the
curves shown.

80
DC VOLTS

Parallel Mode
60

Dual Operator
40

20

0
0 100 200 300 400 500 600 700 800

DC AMPERES
B. TIG Mode

100

80
DC VOLTS

Parallel Mode
60

40
Dual Operator

20

0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
C. MIG Mode

50

30
DC VOLTS

10

0
0 100 200 300 400 500 600 700 800
DC AMPERES
259 678-A
−10

TM-259 705 Page 10 Big Blue 800 Duo Air Pak

3-8. AC Generator Power Curves
The AC power curve shows the
A. Single Phase 4 kW generator power in amperes.

280

260
AC VOLTS

240

220

200

180
0 10 20 30 40
AC AMPERES

B. Single Phase 12 kW
140 280
135 270
130 260
125 250
AC VOLTS

120 240
115 230
110 220
105 210

100 200
95 190
90 180
0 10 20 30 40 50 60 70 80 90 100
AC AMPERES

C. Three Phase 20 kW
280

260
AC VOLTS

240

220

200

180
0 10 20 30 40 50 60
AC AMPERES
253 021-A / 254 115-A / 254 114-A

Big Blue 800 Duo Air Pak TM-259 705 Page 11

3-9. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

4.50
4.25
4.00
3.75 With Air Output
3.50
3.25 No Air Output
3.00
US Gal./Hr.

2.75
2.50
2.25
2.00
1.75 Dual Weld Mode
1.50
1.25
1.00
0.75
IDLE
0.50
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800

DC WELD AMPERES AT 100% DUTY CYCLE

259 680-A

Notes

TM-259 705 Page 12 Big Blue 800 Duo Air Pak

 SECTION 4 − INSTALLATION

4-1. Installing Welding Generator

Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)

OR OR
18 in.
18 in. (460 mm)
(460 mm)

Location/Mounting

Welding Bolting
Unit In Unit In
Place 2 Place 3
2

OR

OR

1 1

Tools Needed:
9/16 in. install3 2013-06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

Movement ! Do not weld on base. Welding on 3 1/2 in Bolt And Washer (Minimum −
base can cause fuel tank fire or ex- Not Supplied)
! Do not move or operate unit where
plosion. Weld only on the four 4 3/8-16 x 1 in. Screws (Supplied)
it could tip.
mounting brackets or bolt unit
To Bolt Unit In Place:
 See Section 3-5 for lifting eye rating. down.
NOTICE − Do not mount unit by supporting Remove hardware securing the four
Airflow Clearance the base only at the four mounting brack- mounting brackets to the base. Reverse
NOTICE − Do not install unit where air flow ets. Use cross-supports to adequately brackets and reattach to base with original
is restricted or engine may overheat. support unit and prevent damage to base. hardware.

Location/Mounting 1 Cross-Supports Mount unit to truck or trailer with 1/2 in. (12
mm) or larger hardware (not supplied).
! Always securely fasten welding 2 Mounting Brackets (Supplied)
To Weld Unit In Place:
generator onto transport vehicle or Mount unit on flat surface or use cross-
trailer and comply with all DOT and supports to support base. Secure unit with Weld unit to truck or trailer only at the four
other applicable codes. mounting brackets. mounting brackets.

Big Blue 800 Duo Air Pak TM-259 705 Page 13

4-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

rot_grnd2 2012−03 − 800 652-D

! Always ground generator frame to frame. Always connect a ground 1 Equipment Grounding Terminal (On
vehicle frame to prevent electric wire from the generator equipment Front Panel)
shock and static electricity hazards. grounding terminal to bare metal on 2 Grounding Cable (Not Supplied)
the vehicle frame as shown.
! Also see AWS Safety & Health Fact 3 Metal Vehicle Frame
Sheet No. 29, Grounding of Portable
! Use GFCI protection when operat- Connect cable from equipment ground
And Vehicle Mounted Welding Gen-
ing auxiliary equipment. If unit does terminal to metal vehicle frame. Use #8
erators.
not have GFCI receptacles, use AWG or larger insulated copper wire.
! Bed liners, shipping skids, and GFCI-protected extension cord. Do
some running gear insulate the not use GFCI receptacles to power  Electrically bond generator frame to ve-
welding generator from the vehicle life support equipment. hicle frame by metal-to-metal contact.

4-3. Installing Exhaust Pipe

! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in. Ref. 907 535−1 / 907 535−3 / Exhaust3

TM-259 705 Page 14 Big Blue 800 Duo Air Pak

4-4. Connecting The Battery

+ −

Tools Needed:
1/2 in.

Conn_batt1 2013−04 802 168-E / S-0756-C

! Connect negative (−) cable last.  Do not allow the battery cables to  Never disconnect the battery while
NOTICE − Wait two minutes after engine touch opposing terminals. When connect- the engine is running.
shutdown before disconnecting battery or ing the battery cables attach the positive
(+) cable to the positive (+) battery termin-  Never use a quick battery charger to
engine controller may be damaged. start the engine.
al first, followed by negative (−) cable to
Battery is most easily accessed through negative (−) battery terminal.  Do not charge battery with Engine
the rear panel. Remove battery access Control switch On.
panel from rear panel. Connect battery,  Never start the engine when the
negative cable last. Reinstall battery ac- cables are loose or poorly connected to  Always disconnect the negative (−)
cess panel. the battery terminals. battery cable before charging battery.

4-5. Using The Battery Disconnect Switch

! Stop engine.
1 Battery Disconnect Switch
The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.

907 535−2

Big Blue 800 Duo Air Pak TM-259 705 Page 15

4-6. Engine Prestart Checks
NOTICE − Follow run-in procedure in
engine manual. If unburned fuel and oil
collect in exhaust pipe, see Section 16.

Full
Coolant
Overflow
Tank
Full

Diesel

Full

907 535−1 / 907 535−2

 Check all engine fluids daily. erate to rated load. Using light or no load for
extended periods of time may cause wet-
Coolant

 Automatic warning and shutdown indi- stacking or engine damage.

Check coolant level in coolant overflow
cators are displayed on the Engine Dis- Follow run-in procedure in engine manual.
tank. Coolant should touch bottom of neck
play. See Section 15 for engine display If unburned fuel and oil collect in exhaust
pipe.
information. pipe, see Section 16.
Fuel
Engine must be cold and on a level surface.
NOTICE − Do not use gasoline. Gasoline
 To improve cold weather starting:
Automatic shutdown system stops engine if
will damage engine.
oil pressure is too low or engine tempera- Keep battery in good condition. Store
ture is too high. Add fresh diesel fuel before starting (see battery in warm area.
engine maintenance label for fuel specifica-
 This unit has a low oil pressure shut- tions). Leave filler neck empty to allow room Use fuel formulated for cold weather
down switch. However, some condi- for expansion. (diesel fuel can gel in cold weather).
tions may cause engine damage before Contact local fuel supplier for fuel in-
the engine shuts down. Check oil level Engine stops if fuel level is low.
formation.
often and do not use the oil pressure Oil
shutdown system to monitor oil level. Use correct grade oil for cold weather
After fueling, check oil with unit on level sur-
NOTICE − Diesel engines in MILLER equip- face. If oil is not up to full mark on dipstick, (see engine maintenance label or en-
ment are meant to operate optimally at mod- add oil (see engine maintenance label). gine manual).

TM-259 705 Page 16 Big Blue 800 Duo Air Pak

4-7. 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:
3/4 in.  Do not place anything between weld
1 2 cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
1 Correct Weld Cable Connection
6
3 2 Incorrect Weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
4 weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
5

803 778-B

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 800 Duo Air Pak TM-259 705 Page 17

4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.
Welder A (Left) Side Welder B (Right) Side

1
1

258 836

! Stop engine. 1 Electrode Holder Cables For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
NOTICE − Do not exceed machine duty 2 Work Cables
Positive (+) terminals and electrode holder
cycle.
For Stick/TIG welding Direct Current Elec- cables to Negative (−) terminals.
 Use Dual Operator mode for CC and trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
CV welding (see Section 5-2).
trode holder cables to Positive (+) ter-  Be sure Process Selector switches
See Section 4-15 for proper cable size. minals. are set correctly. See Section 5-4.

TM-259 705 Page 18 Big Blue 800 Duo Air Pak

4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

1
2
1

258 836

! Stop engine. work cable must be able to carry combined other end of work jumper cable to Welder A
! Failure to properly size and connect weld output of both modules (see Section (left) Negative (−) terminal.
weld cables may cause excessive 4-15 for proper cable size).
Connect electrode holder cables to Positive
heat and start a fire, or damage your NOTICE − Do not exceed machine duty (+) terminals.
machine. cycle.
For Stick/TIG Direct Current Electrode
NOTICE − When making weld connections
with a common work cable, connect weld  Use Dual Operator mode for CC and Negative (DCEN), connect common work
cable of adequate size between Negative CV welding (see Section 5-2). cable and work jumper cable to Welder B
(−) weld output terminals, and connect a (right) Positive (+) terminal. Connect other
1 Electrode Holder Cables
single weld cable of adequate size from end of work jumper cable to Welder A (left)
Welder B (right) Negative (−) terminal to the 2 Work Jumper Cable Positive (+) terminal.
workpiece. 3 Common Work Cable Connect electrode holder cables to Nega-
NOTICE − When using these connections For Stick/TIG welding Direct Current Elec- tive (−) terminals.
as a common work terminal, all connec- trode Positive (DCEP), connect common
tions must be of the same polarity. work cable and work jumper cable to Weld-  Be sure Process Selector switches are
NOTICE − For common work connection, er B (right) Negative (−) terminal. Connect set correctly. See Section 5-4.

Big Blue 800 Duo Air Pak TM-259 705 Page 19

4-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

1
1

258 836

! Stop engine. 1 Wire Feeder Cables For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
NOTICE − Do not exceed machine duty
2 Work Cables cables to Positive (+) terminals and wire
cycle.
feeder cables to Negative (−) terminals.
 Use Dual Operator mode for CC and For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
CV welding (see Section 5-2).
cables to Negative (−) terminals and wire  Be sure Process Selector switches are
See Section 4-15 for proper cable size. feeder cables to Positive (+) terminals. set correctly. See Section 5-4.

TM-259 705 Page 20 Big Blue 800 Duo Air Pak

4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
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. weld output of both modules (see Section mon work cable and work jumper cable to
4-15 for proper cable size). Welder B (right) Negative (−) terminal.
! Failure to properly size and connect Connect other end of work jumper cable to
weld cables may cause excessive NOTICE − Do not exceed machine duty
Welder A (left) Negative (−) terminal.
heat and start a fire, or damage your cycle.
machine.
 For common work connection, work Connect wire feeder cables to Positive (+)
terminals.
NOTICE − When making weld connections cable must be able to carry combined
with a common work cable, connect weld weld output of both CC weld output ter-
For MIG and FCAW Direct Current Elec-
cable of adequate size between Negative minals (see Section 4-15 for proper
trode Negative (DCEN), connect common
(−) weld output terminals, and connect a cable size).
work cable and work jumper cable to Weld-
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the  Use Dual Operator mode for CC and er B (right) Positive (+) terminal. Connect
CV welding (see Section 5-2). other end of work jumper cable to Welder
workpiece. A (left) Positive (+) terminal.
1 Wire Feeder Cables
NOTICE − When using these connections Connect wire feeder cables to Negative (−)
as a common work terminal, all connec- 2 Work Jumper Cable
terminals.
tions must be of the same polarity. 3 Common Work Cable
NOTICE − For common work connection, For MIG and FCAW welding Direct Current  Be sure Process Selector switches
work cable must be able to carry combined Electrode Positive (DCEP), connect com- are set correctly. See Section 5-4.

Big Blue 800 Duo Air Pak TM-259 705 Page 21

4-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.
Welder A (Left) Side Welder B (Right) Side

3
2

258 836

! Stop engine. For Stick/TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect work Electrode Positive (DCEP), connect work
NOTICE − Do not exceed machine duty
cable to Negative (−) terminal and elec- cable to Negative (−) terminal and wire
cycle.
trode holder cable to Positive (+) terminal. feeder cable to Positive (+) terminal.
 Use Dual Operator mode for CC and For Stick/TIG Direct Current Electrode For MIG and FCAW Direct Current Elec-
CV welding (see Section 5-2).
Negative (DCEN), connect work cable to trode Negative (DCEN), connect work
See Section 4-15 for proper cable size. Positive (+) terminal and electrode holder cable to Positive (+) terminal and wire feed-
1 Electrode Holder Cable cable to Negative (−) terminal. er cable to Negative (−) terminal.

2 Wire Feeder Cable  Be sure Process Selector switches  Be sure Process Selector switches
3 Work Cables are set correctly. See Section 5-4. are set correctly. See Section 5-4.

TM-259 705 Page 22 Big Blue 800 Duo Air Pak

4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable

Tools Needed:

3/4 in.

 Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

3
2

Ref. 251 340-A / Ref. 802 292-A

! Stop engine. 4-15 for proper cable size). Connect electrode holder cable to one Pos-
! Failure to properly size and connect itive (+) terminal.
NOTICE − Do not exceed machine duty
weld cables may cause excessive cycle. Connect wire feeder cable to remaining
heat and start a fire, or damage your Positive(+) terminal.
machine.  Use Dual Operator mode for CC and  Be sure Process Selector switches are
NOTICE − When making weld connections CV welding (see Section 5-2).
set correctly. See Section 5-4.
with a common work cable, connect weld 1 Electrode Holder Cable
cable of adequate size between Negative For Direct Current Electrode Negative
(−) weld output terminals, and connect a 2 Wire Feeder Cable (DCEN), connect common work cable and
single weld cable of adequate size from work jumper cable to Welder B (right) Posit-
Welder B (right) Negative (−) terminal to the 3 Work Jumper Cable ive (+) terminal. Connect other end of work
workpiece. jumper cable to Welder A (left) Positive (+)
4 Common Work Cable
terminal.
NOTICE − When using these connections For Direct Current Electrode Positive
as a common work terminal, all connec- Connect electrode holder cable to one
(DCEP), connect common work cable and Negative (−) terminal, and wire feeder
tions must be of the same polarity. work jumper cable to Welder B (right) Neg- cable to remaining Negative (−) terminal.
NOTICE − For common work connection, ative (−) terminal. Connect other end of
work cable must be able to carry combined work jumper cable to Welder A (left) Nega-  Be sure Process Selector switches are
weld output of both modules (see Section tive (−) terminal. set correctly. See Section 5-4.

Big Blue 800 Duo Air Pak TM-259 705 Page 23

4-14. Making Single Operator CC Weld Connections

 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.

1
2

258 836

! Stop engine.  Use Single Operator mode for CC weld- For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
ing only. Welder B weld output termi-
to Negative (−) terminal and electrode hold-
NOTICE − Do not exceed machine duty nals are disabled in Single Operator
mode. (see Section 5-2). er cable to Positive (+) terminal.
cycle.
For Stick/TIG Direct Current Electrode Neg-
 Welder B (right) weld output terminals  See Section 4-15 for proper cable size. ative (DCEN), connect work cable to Posit-
ive (+) terminal and electrode holder cable
are disabled in Single Operator mode. to Negative (−) receptacle.
Connect only to Welder A (left) termi- 1 Electrode Holder Cable
nals for Single Operator mode opera-  Be sure Process Selector switch is set
tion. 2 Work Cable correctly. See Section 5-4.

TM-259 705 Page 24 Big Blue 800 Duo Air Pak

4-15. Weld Output Terminals And 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.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding Duty Duty 10 − 100% Duty Cycle
Amperes Cycle Cycle AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
Weld Output
Terminals 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
! Turn off power be-
fore connecting to 2x2/0 2x2/0
weld output termi- 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
nals.
2x2/0 2x3/0 2x3/0
! Do not use worn, 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
damaged, under-
sized, or repaired 2x2/0 2x3/0 2x3/0 2x4/0
cables. 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

2x2/0 2x3/0 2x4/0 2x4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)

2x2/0 2x3/0 2x4/0 3x3/0 3x3/0

500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)

2x2/0 2x3/0 2x4/0 3x3/0 3x4/0 3x4/0

600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
2x3/0 2x4/0 3x3/0 3x4/0 3x4/0 4x4/0
700 4/0 (120) 2x2/0 (2x70)
(2x95) (2x120) (3x95) (3x120) (3x120) (4x120)
2x3/0 2x4/0 3x4/0 3x4/0 4x4/0 4x4/0
800 4/0 (120) 2x2/0 (2x70)
(2x95) (2x120) (3x120) (3x120) (4x120) (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-K 2013−09

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 800 Duo Air Pak TM-259 705 Page 25

4-16. Connecting To Remote 14 Receptacle

Socket* Socket Information

 Not all models have contactor control. See description of front panel controls and
circuit diagram.

A 24 volts AC. Protected by supplementary protector.

24 VOLTS AC
B Contact closure to A completes 24 volt AC contactor
*The remaining sockets control circuit.
are not used.
C Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or TIG mode.

REMOTE D Remote control circuit common.

 Accessories depend OUTPUT
on unit capabilities. CONTROL
E DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.

F Current feedback: 1 volt per 100 amperes.

OR
H Voltage feedback: 1 volt per 10 arc volts.

K Chassis common.
GND

NEUTRAL G Circuit common for 24 volt AC circuit.

Rmt14_1 2010−04

Notes

TM-259 705 Page 26 Big Blue 800 Duo Air Pak

4-17. Connecting To The Air Compressor

! Stop engine and release air pres-

sure before servicing compressor.

Open Position
1

Closed Position

907 535−1

! 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. pressure. If air compressor is turned off,
front panel indicates air pressure. The compressor runs and air pressure is wait for air pressure to bleed off (about 60
available whenever the engine is running seconds) before turning air compressor on
1 3/4 in. NPT Air Pressure
and the front panel Compressor switch is again.
Fitting
moved to the On position (see Section 5-2).
Run engine at weld/power speed for maxi-
2 Air Shutoff Valve
mum air compressor output. Compressor  Using the air compressor does not sig-
Connect air hose with 3/4 in. NPT fitting (not output is reduced when engine is running at nificantly affect weld or generator pow-
supplied) to air shutoff valve. idle speed. er output.

Big Blue 800 Duo Air Pak TM-259 705 Page 27

 SECTION 5 − OPERATING WELDING GENERATOR

5-1. Front Panel Controls (See Section 5-2)

5 4 3

7 8 9 11 1

10

12

258 833 / 907 535−1

TM-259 705 Page 28 Big Blue 800 Duo Air Pak

5-2. Description Of Front Panel Controls (See Section 5-1)

Engine Starting Controls age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
 If a remote device connected to Remote
1 Engine Control Switch Receptacle is faulty or is disconnected
necessarily the welding arc due to resistance
during operation, the meters display Help
Use switch to start engine, select engine of cable and connections. 25 (see Section 7-9). Clear fault by stop-
speed, and stop engine. ping and restarting the unit or by turning
To set voltage, turn Process/Contactor switch
In Run position, engine runs at weld/power to MIG or FCAW position. Turn V/A control Process/Contactor switch to another
speed. In Run/Idle position, engine runs at until desired voltage is displayed on Voltme- position.
idle speed with no generator power or weld ter. When welding is finished, voltmeter dis- 10 Welder Selector Switch
load, and weld/power speed with load plays weld voltage and then defaults to preset
applied. voltage. Use switch to select Dual Operator or Single
Operator welding mode.
The air compressor load does not affect en- Weld Controls
gine speed. Run engine at weld/power speed Place switch in Welder A/Welder B (dual op-
5 Arc Control
for maximum air compressor output. erator) position for CC and CV output from
See Section 5-5 for Arc Control information. Welder A (left) and Welder B (right) weld out-
NOTICE − Diesel engines in MILLER equip- put terminals. Control the weld output from the
ment are meant to operate optimally at mod- 6 Voltage/Amperage Control
terminals on each side using the weld con-
erate to rated load. Using light or no load for With Process/Contactor switch in any Stick or trols on that same side.
extended periods of time may cause wet- TIG setting, use control to adjust amperage.
stacking or engine damage. If unburned fuel With Process/Contactor switch in any Wire Place switch in Welder A (single operator)
and oil collect in exhaust pipe, see Section 16. (MIG or FCAW) position, use control to adjust position for weld output from Welder A (left)
voltage. Control limits the remote amperage weld output terminals only.
To Start: see Section 5-3 for engine starting
sequence. in Stick or TIG mode, but has no effect in Wire
modes.
 Welder B (right) weld output terminals are
To Stop: turn Engine Control switch to Off disabled in Single Operator mode. Con-
7 Process/Contactor Switch nect only to Welder A (left) terminals for
position.
See Section 5-4 for Process/Contactor Single Operator operation.
2 Engine Display switch information. Compressor Controls
See Section 15 for engine display information. 8 24 Volts AC Overload Protection 11 Air Compressor Switch
Weld Meters See Section 7-8 for overload protection
Use switch to turn air compressor on and off.
information.
 Weld meters also work in combination to Air pressure is present at the compressor air
display troubleshooting help codes (see 9 Remote Control Receptacle shutoff valve whenever the compressor is
Section 7-9). running. The compressor shuts off when the
Use receptacle to connect remote controls,
engine stops. To use air, the compressor must
3 DC Ammeter wire feeders, and tools requiring 24 VAC.
be turned on each time the engine is started.
Ammeter displays preset amperage (Stick When a remote control is connected to the
Remote receptacle, the Auto Sense Remote The air compressor will not start if still under
and TIG only) when not welding, and actual pressure. If air compressor is turned off, wait
output amperage when welding. feature automatically switches voltage/am-
perage control to the remote control (see Sec- for air pressure to bleed off (about 60 sec-
To set amperage, turn Process/Contactor tion 5-9). onds) before turning air compressor on again.
switch to Stick or TIG position. Turn V/A con- 12 Air Shutoff Valve
trol until desired amperage is displayed on With remote control connected, weld output is
determined by a combination of front panel ! Air pressure is present at valve when-
Ammeter. When welding is finished, ammeter
and remote control voltage/amperage ever Air Pressure display (part of en-
displays weld amperage and then defaults to
settings. gine display, see Section 15) indicates
preset amperage.
air pressure.
If no remote control is connected to the
4 DC Voltmeter
Remote receptacle, the front panel Close valve to stop air flow when connecting
Voltmeter displays preset voltage (MIG weld- Voltage/Amperage control adjusts voltage or changing tools or air hoses (see Section
ing) with contactor off, and actual output volt- and amperage. 4-17).

Big Blue 800 Duo Air Pak TM-259 705 Page 29

5-3. Engine Starting Sequence

Wait to Start/Preheating

Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
1 Compressor Oil 0 Compressor Oil 495

NOTICE − Do not use ether. The Wait to Start display appears when the Once this message clears, the engine can
Engine Control switch is placed in the Run be started.
 If engine does not start, let engine or Run/Idle position. Glow plugs function Turn Engine Control switch to Start. Re-
come to a complete stop before at- automatically according to ambient tem- lease Engine Control switch when engine
tempting restart. starts.
perature. The operator needs to pause at
To Start: either switch position while the engine con- To Stop: turn Engine Control switch to Off
1 Wait to Start/Preheating Display troller goes through the preheat sequence. position.

5-4. Process/Contactor Switch

1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot
position and the engine is run-
ning.
Use switch to select weld process and
weld output on/off control (see table be-
low).
1
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the en-
gine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-8).

Ref. 258 833-A

TM-259 705 Page 30 Big Blue 800 Duo Air Pak

 Switch Setting Typical Process Applications (DC Only)

MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable
ELECTRODE HOT Electrode Hot – MIG VS back to the welding generator.

FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not re-
Electrode Hot – FCAW VS quire a control cable back to the welding generator.

Electrode Hot - Stick Stick welding with or without a remote amperage control. Strike an arc to start welding.

Lift Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
Electrode Hot – TIG Lift Arc welding generator to aid arc start. Can be used with or without a remote control.
REMOTE ON/OFF REQUIRED

High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with re-
Remote ON/OFF Required - TIG mote foot control allows remote On/Off and Amperage control. Another typical application
is a simple TIG rig with a remote control device.

Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can
Remote On/Off Required - Stick help eliminate accidental arc strikes.

FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a
Remote On/Off Required - FCAW Spoolmatic 30A with WC 24 control.

MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or
Remote On/Off Required - MIG use a Spoolmatic 30A with WC 24 control.

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 31

5-5. Arc Control
1 Arc Control
Stick
Control adjusts Dig when Stick is se-
lected on mode switch.
When control is set toward minimum,
1 short-circuit amperage at low arc
voltage is the same as normal weld-
ing amperage.
When set toward maximum, short-
circuit amperage is increased at low
arc voltage to help prevent the elec-
trode from sticking while welding.
Select setting best suited for applica-
tion.
FCAW/MIG
Control adjusts inductance when
FCAW or MIG position is selected on
the mode switch. Inductance deter-
mines the “wetness” of the weld
puddle. Increasing Arc Control set-
ting decreases inductance, thereby
increasing puddle fluidity (“wet-
ness”). Decreasing Arc Control set-
ting increases inductance, decreas-
ing puddle fluidity.
TIG
When the control is set below 1, Auto
Stop is a variable function of preset
weld amperage. This is used with a
short arc length where flare at arc
shutdown cannot be tolerated.
When the control is set above 1, Auto
Stop voltage threshold is a set value
based on preset-set weld amperage
(I) as follows:
I <= 50 A, V=17
I >50 to <=100 A, V=22
I >100 to <=190 A, V=25
I >190A, V=30
This allows for a longer arc length
(such as when “walking the cup”),
where nuisance shutdowns are un-
desirable.
Control is not functional when TIG
Remote mode is selected.

257 145-A

TM-259 705 Page 32 Big Blue 800 Duo Air Pak

5-6. Low Open-Circuit Voltage (VRD) Switch Mode
1 Voltage Reducing Device
(VRD) Switch
The VRD switch can be set for low
open-circuit voltage operation in
Stick mode. When the unit is con-
figured for low open-circuit voltage
operation only a low sensing
voltage (approximately 15 volts
DC) is present between the elec-
trode and workpiece prior to the
electrode touching the workpiece.

ON Unit is shipped from the factory with

the switch in the On position.

OFF
1

907 535-2

5-7. Stick Start Procedure − Scratch Start Technique

With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
1 electrode sticks to workpiece, use a
quick twist to free it.
VRD Turned On: Normal
open-circuit voltage is not present
before electrode touches workpiece;
only a low sensing voltage is present
2
between electrode and workpiece.
For optimal starting performance, a
good clean contact must be made be-
3 tween the electrode and workpiece.

Big Blue 800 Duo Air Pak TM-259 705 Page 33

5-8. Lift-Arct TIG With Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc Select Lift-Arc TIG at Process/
Contactor switch.
1 2
Turn gas on.
1 Touch or scratch.
2 Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and work-
piece contamination by using
Arc End With Auto-Stop
Auto-Stop to end the arc.
1 2 3 Arc End With Auto-Stop:
1 While welding.
2 Lift torch to start Auto-Stop.
Arc stops.
3 Move torch back down to
maintain gas coverage and
prevent contamination.

WM Marketing

Notes

TM-259 705 Page 34 Big Blue 800 Duo Air Pak

5-9. Remote Voltage/Amperage Control

1 Remote 14 Receptacle
2 3 Connect optional remote control to receptacle
(see Section 4-16).

 When a remote control is connected to the

Remote receptacle, the Auto Sense Re-
mote feature automatically switches volt-
age/amperage control to the remote con-
1 trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
2 Voltmeter
3 Ammeter

CC Welding

In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
85 205
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding

Connect Remote Set V/A Control

Control To Remote To Desired Maximum
Turn Remote Control On. Ad- Weld Output Using Weld
Receptacle RC14 just Optional Remote Meters
Set TIG or STICK Process Control to 100%

CV Welding Max (205 A DC)

Electrode Hot: Voltmeter tog-

gles between preset and ac-
tual output when not welding,
actual voltage while welding.
28 0 Min (20 A DC)

Adjust Optional Remote

Remote On/Off Required: Ammeter Shows Zero Control to desired
Voltage shown is preset. weld output

Connect Remote Adjust Optional Remote

Control To Remote Control to desired
Receptacle RC14 weld output
Set WIRE Process

0774 / Ref.246 345-B / Ref. 907 428−1

Big Blue 800 Duo Air Pak TM-259 705 Page 35

5-10. Engine Block Heater Operation

1 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-
Watts Volts ±10% gine block heater is on.
NOTICE −In extremely cold weath-
530 120 er, heater should be connected to
120 volts AC receptacle when en-
gine is warm.
! The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.

Coolant heater1 2012−05 907 535 / Ref. 803 145

Notes

TM-259 705 Page 36 Big Blue 800 Duo Air Pak

5-11. Optional Air Dryer Operation

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 welding genera-
tor is running.
See the supplied air dryer Owner’s
Manual for air dryer maintenance and
service information.

 When battery access is required,

disconnect and remove the air
dryer assembly as described in
Section 7-10.
1 Circuit Breaker CB14
CB14 protects the dryer heaters from
damage due to overload. If CB14
opens, the heaters do not work and the
dryer does not discharge moisture in
cold weather.
Press button to reset circuit breaker
2 CB14.

 When a circuit breaker opens, it

usually indicates a more serious
problem exists. Contact a Factory
Authorized Service Agent.
Start engine, and turn on air compres-
sor. Check fittings for air leaks and
tighten fittings if necessary.
2 Timer Control LED
Verify dryer solenoid is functioning by
listening for dryer canisters to purge, or
by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.

907 535−2 / 803 228 / 803 229

Big Blue 800 Duo Air Pak TM-259 705 Page 37

 SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. North American Auxiliary Power Receptacles

1
8 6 7

4 5
3 2
264 773-A

Single-Phase Generator Power erator winding from overload. If CB6 (240 V x 13 A) + (120 V x 7 A) =
! Use GFCI protection when operat- opens, RC1, RC2, GFCI1 and GFCI2 do 4.0 kVA/kW
ing auxiliary equipment. If unit not work. Place switch in On position to re-
6 120/240 V 50 A Receptacle RC5
does not have GFCI receptacles, set.
use GFCI-protected extension RC5 is connected to the three-phase gen-
CB7 protects GFCI1 from overload. If CB7 erator and supplies 60 Hz single-phase
cord. Do not use GFCI receptacles opens, GFCI1 does not work. Press but-
to power life support equipment. power at weld/power speed. Maximum
ton to reset. output from RC5 is 12 kVA/kW. Power
! Unplug power cord before attempt- available at RC5 is reduced when welding.
ing to service accessories or tools. CB8 protects GFCI2 from overload. If CB8
opens, GFCI2 does not work. Press but- Three-Phase Generator Power
1 120 V 20 A AC GFCI ton to reset.
Receptacle GFCI1 or GFCI2 7 240 V 50 A Three-Phase Receptacle
RC4
! Test GFCI monthly. See Section 6-2  If a supplementary protector contin-
for GFCI information and for reset- ues to open, contact Factory Autho- RC4 is connected to the three-phase gen-
ting and testing procedures. rized Service Agent. erator and supplies 60 Hz three-phase
power at weld/power speed. Maximum
2 240 V 30 A AC Twistlock
Receptacle RC1 or RC2  Generator power is not affected by output from RC4 is 20 kVA/kW. Power
available at RC4 is reduced when welding.
weld output.
Receptacles supply 60 Hz single-phase 8 Supplementary Protector CB1
power at weld/power speed. Maximum output is 2.4 kVA/kW from
GFCI1 and 4 kVA/kW from RC1. Maxi- Supplementary protector CB1 protects
3 Supplementary Protector CB6 three-phase receptacle RC4,
mum output from all receptacles is 4 kVA/
4 Supplementary Protector CB7 kW. single-phase receptacle RC5, and the
load wires from overload. If CB1 opens, all
5 Supplementary Protector CB8 EXAMPLE: If 13 A is drawn from RC1, only generator output stops and the recept-
CB6 protects RC1 and RC2, and the gen- 7 A is available at GFCI1: acles do not work.

TM-259 705 Page 38 Big Blue 800 Duo Air Pak

6-2. GFCI Receptacle Information, Resetting And Testing

2
3
4
! Test and reset GFCI
only at Run speed.

RotGFCI1 2012−05

! Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords,
ing auxiliary equipment. If unit does button pops out, and the circuit opens to plugs, etc. connected to the receptacle.
not have GFCI receptacles, use disconnect power to the faulty equipment. Start engine and operate at Run (weld/
GFCI-protected extension cord. Do A GFCI receptacle does not protect against power) speed. Press GFCI Reset button.
not use GFCI receptacle to power circuit overloads, short circuits, or shocks Reconnect equipment to GFCI receptacle.
life support equipment. not related to ground faults. Reset and test If GFCI Reset button pops out again, check
GFCI receptacle according to the following the equipment and repair or replace if faulty.
! Unplug power cord before attempt- procedures.
ing to service accessories or tools. Testing GFCI Receptacles
Resetting/Testing GFCI Receptacle
1 120 V 20 A AC GFCI Receptacle
! Test GFCI monthly. See Testing
 GFCI testing must be done with engine
2 GFCI Receptacle Test Button GFCI Receptacle. running at Run (weld/power) speed.

! Do not test or reset GFCI recept- Start engine and operate at Run (weld/
3 GFCI Receptacle Reset Button
acles at idle speed/low voltage or power) speed.
4 GFCI Indicator Light (LED) the GFCI will be damaged and not Press the GFCI Test button. The GFCI Re-
provide protection from electric set button should pop out.
GFCI Receptacles shock caused by a ground fault.
Press the GFCI Reset button.
GFCI receptacles protect the user from ! If LED blinks, stop using GFCI re-
electric shock if a ground fault occurs in ceptacle and have it replaced by a Have GFCI replaced by a Factory Au-
equipment connected to the receptacle. A Factory Authorized Service Agent. thorized Service Agent if any of the fol-
ground fault occurs when electrical current lowing occur:
Resetting GFCI Receptacles
takes the shortest path to ground (which GFCI does not trip when tested
could be through a person) rather than fol- If a GFCI fault occurs, stop engine and dis- LED blinks
low its intended safe path. connect equipment from GFCI receptacle. GFCI does not reset.

Big Blue 800 Duo Air Pak TM-259 705 Page 39

 SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
! Stop engine before maintaining.
 See Engine Manual and Maintenance Label
Recycle engine for important start-up, service, and storage
fluids. information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference

* To be done by Factory Authorized Service Agent
Every See engine Section 4-6
8 FUEL
WATER manual for fuel
Hours
specifications.

 Primary Fuel Filter  Fuel Level  Oil Level  Oil, Fuel Spills
 = Clean unit exterior, in-
cluding stainless steel, fre-
quently to prevent rust and
corrosion.
 Coolant Level
Every Section 7-4
100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element  Weld Terminals
Every Engine
250 1/2 in.
(13 mm) Manual
Hours

Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Every NOTICE − Change engine Section
500 oil and filter after initial 50 7-7, and
Hours to 75 hours of use. Engine
See engine manual for oil Manual
specifications.
 Oil  Oil Filter  Fuel Filters  Weld Cables
Every Section
FUEL
1000 OR 7-2, 7-7,
Hours and Engine
Manual
SLUDGE
 Slip Rings*  Inside Unit Valve Clearance*  Drain Sludge
 Brushes*
Every NOTICE − Use extended
2000 life coolant only.
Hours See engine manual for
coolant specifications.
Coolant
Every Every
3000 6000
Hours Hours or
5 Years
 Injectors*  Engine Timing Belt

DEUTZ Service: http://www.deutzamericas.com

To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer: http://www.deutzamericas.-
com/deutznew/distributors/index.htm.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. Customer in the
US and CANADA can also contact the service desk by calling our toll free number, 1-800-241-9886.
Our normal hours of operation are from 8:00 AM to 6:00 PM Monday through Friday EST. You may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us, please have available or provide specific engine information (serial number, model number etc.) as shown
on the Service Support Form.

TM-259 705 Page 40 Big Blue 800 Duo Air Pak

7-2. Checking Generator Brushes

! Stop engine and let cool.

1 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.
New Length:
1-1/4 in. (32 mm)

1
Replace
Damaged Brushes
GenBrush1 2012−05 / Ref 190 823

7-3. Battery Replacement

! Stop engine.
Tools Needed: 1 Battery Locator Bracket
Mounting Holes
Access battery as shown in Section
Larger Battery 4-4. Disconnect battery.
Remove J-bolts securing battery
and remove battery.
Battery locator brackets can be
moved to accommodate batteries
of different physical sizes.
Install and secure replacement bat-
tery.
! Connect negative (−) battery
cable last.

Smaller Battery

255 858

Big Blue 800 Duo Air Pak TM-259 705 Page 41

7-4. Servicing Air Cleaner

! Stop engine.
2 1 ! Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.

 Remove compressor air cleaner cov-

er and element to access engine air
cleaner.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
3 4 Never clean a safety element. Re-
5 6
place the safety element after servic-
ing the primary element three times.
1 Engine Air Cleaner
2 Compressor Air Cleaner
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
Optional cleanings.
7 3 Housing
4 Safety Element (Optional)
5 Primary Element
6 Cover
7 Dust Ejector
To clean air filter:
Wipe off cover and housing. Remove
Keep nozzle cover and dump out dust. Remove ele-
2 in. (51 mm) ment(s). Wipe dust from inside cover and
from element. housing with damp cloth. Reinstall cover.
! Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary ele-
Blow Inspect ment if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).

aircleaner1 9/02− ST-153 929-B / ST-153 585 / Ref. S-0698-B

7-5. Engine Speed Adjustment

 Engine functions are controlled by the engine ECU. Tampering with the engine ECU may void engine warranty. Contact engine Factory Authorized
Service Agent for engine adjustments.

TM-259 705 Page 42 Big Blue 800 Duo Air Pak

7-6. Oil Specifications

Synthetic Oil Viscosity Chart

 For any normal oil change interval, any en-

gine oil with a CJ-4 and low ash rating may
be used. After the initial run-in period, syn-
thetic oil may be used to replace oil
shipped in the engine.
Synthetic lubricating oils have a better tem-
perature and oxidation stability, better soot
dispersal properties, and a relatively low
cold viscosity making them suitable for use
in arctic temperatures.
Use table to select appropriate product.

All products listed comply with DQC IV-10LA and have Base Number (TBN) ≥9 mg KOH/g

Manufacturer Product Name SAE Class/Weight

Addinol Addinol Extra Truck MD 1049 LE 10W-40

Aral AG Aral Mega Turboral LA 10W-40 10W-40

BP Plc. BP Vanellus Max Eco 10W-40 10W-40

Castrol Limited Castrol Enduron Low SAPS 10W-40 10W-40

Chevron Global Lubricants Chevron Delo 400 LE Synthetic 5W-30 5W-30

Texaco Ursa Ultra XLE 5W-30 5W-30

ExxonMobil Corp. Mobil Delvac XHP LE 10W-40 10W-40

Fuchs Petrolub AG Titan Cargo Maxx 5W−30 5W-30

Titan Cargo Maxx 10W-40 10W-40

Hessol Lubrication GmbH Hessol Dimo Extra 10W-40

Lukoil Lubricants Lukoil Avantgarde Professional LS 5W-30

OMV OMV Truck Blue ET SAW 10W-40 10W-40

PHI Oil GmbH Motodor LSP Gold 5W-30 5W-30

Repsol Repsol Ecotech Premium Low SAPS W-40 10W-40

SRS Schmierstoff Vertrieb GmbH SRS Cargolub TLS 5W-30

Shell International Shell Rimula R6 LM 10W-40

Unil Opal Pallas 900 10W-40

Valvoline Valvoline ProFleet LS SAE 10W-40 10W-40

 For additional DQC IV-10LA oil products, see www.deutz.com/service/operating_liquids_brand_additives/deutz_quality_class.en.html.

Big Blue 800 Duo Air Pak TM-259 705 Page 43

7-7. Servicing Fuel And Lubrication Systems

Tools Needed:

4 5 3

907 535−2

! Stop engine and let cool. formation. on the Engine Display, see Sections 15-12
and 15-13.
! After servicing, start engine and To replace fuel filters:
check for fuel leaks. Stop engine, To drain sludge from fuel tank:
tighten connections as necessary, For primary fuel filter, disconnect water sen-
sor connection. ! Beware of fire. Do not smoke and
and wipe up spilled fuel.
keep sparks and flames away from
1 Oil Filter Turn filter counterclockwise. Remove filter. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose in an environmentally-safe manner.
Apply thin coat of fuel to gasket on new filter. Do not leave unit unattended while
3 Oil Fill Cap Fill filter with fuel. Install filter and turn clock- draining fuel tank.
4 Primary Fuel Filter wise. For primary fuel filter, reconnect water
sensor. Bleed air from fuel system accord- ! Properly lift unit and secure in a level
5 Secondary Fuel Filter ing to engine manual. position. Use adequate blocks or
stands to support unit while drain-
6 Fuel Tank Sludge Drain Valve
Inspect fuel line, and replace if cracked or ing fuel tank.
To change oil and filter: worn. Attach 1/2 ID hose to drain valve. Put metal
Route oil drain hose and valve through hole Close doors. container under drain, and use screwdriver
in base. See engine manual and engine to open sludge drain valve. Close valve
maintenance label for oil/filter change in- To reset service reminder intervals shown when sludge has drained. Remove hose.

TM-259 705 Page 44 Big Blue 800 Duo Air Pak

7-8. Engine/Generator Overload Protection

9
8

10

11
3
4

7
6
5

907 535−2 / 803 229

! Stop engine. 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. If F2
opens, weld output is low or stops entirely.
engine ECU. If CB11 opens, the engine will
stop. Since the ECU generates error mes-
cuit breaker or fuse opens, it usually in- 4 kVA/kW generator power is still available. sages, no error message may appear on
dicates a more serious problem exists. the Engine Display.
Contact Factory Authorized Service 5 Supplementary Protector CB14
Air dryer overload protection, see Section 10 Supplementary Protector CB12
Agent.
5-11. CB12 protects the fuel pump circuit. If
 See Section 10-5 for air compressor 6 Supplementary Protector CB3 CB12 opens, the fuel pump does not work
overload protection. and the unit will stop.
See Section 5-11 for air dryer overload 7 Supplementary Protector CB4
11 VRD Switch
protection. CB3 protects the engine weld control cir-
See Section 5-6 for VRD switch informa-
1 Supplementary Protector CB9/CB29 cuit. If CB3 opens, weld output stops,
tion.
CB9 and CB29 protect the 24 volt AC out- meters will be blank; however, generator
power is still available. 12 Circuit Breaker CB10 (Not Shown)
put to remote receptacles. If CB opens,
weld output and 24 volt output to remote re- CB4 protects the field flashing circuit. If CB10 protects the engine battery circuit. If
ceptacle stops. CB4 opens, the generator may not excite at CB10 opens, the engine will not crank.
start-up and weld and generator power out- CB10 automatically resets when the fault is
2 Supplementary Protector CB15 corrected.
put may not be available.
Compressor overload protection, see Sec- 13 Circuit Breaker CB13 (Not Shown)
tion 10-5. 8 Supplementary Protector CB2
CB13 protects the glow plug circuit. If
3 Fuse F1 CB2 protects the engine control circuit. If CB13 opens, the glow plug will not operate.
4 Fuse F2 CB2 opens, the engine does not crank. CB13 automatically resets when the fault is
F1 and F2 protect the stator exciter winding 9 Supplementary Protector CB11 corrected.

Big Blue 800 Duo Air Pak TM-259 705 Page 45

7-9. Voltmeter/Ammeter Help Displays

2
HL.P 20

3
HL.P 21
4 HL.P 22

5 HL.P 25
HL.P 26

Use the Voltmeter/Ammeter help displays side) on the heat sink has failed. If this dis- and then disconnected. Clear fault by stop-
to diagnose and correct fault conditions. play is shown, have Factory Authorized ping and restarting the unit or by turning
 When a help code is displayed normal- Service Agent check TH1 (each side), and
the wiring between TH1 and PC1/PC21.
Process/Contactor switch to another posi-
tion. If problem continues, have Factory
ly weld output has stopped but genera- Authorized Service Agent check the re-
tor power output may be okay. 3 Help 22 Display
mote device, filter board PC5/PC25, and
Indicates the IBGT module heat sink (each
 To reset help displays, stop unit and side) has overheated. If this display is
main control module PC1/PC21.
then restart. See item 4 below to reset 5 Help 26 Display
shown, check generator cooling system
Help 25 display. and/or reduce duty cycle. Keep engine ac- Indicates a fault when attempting to oper-
1 Help 20 Display cess door closed when running to maintain ate the unit in single operator mode (out-
proper cooling air flow past the heat sinks. puts internally paralleled). Help 26 indic-
Indicates a failure of meter display module
Allow unit to cool before restarting. If prob- ates a failure of either side A or side B or
PC2/PC22, or the wiring between
lem continues, have Factory Authorized the communications between them which
PC2/PC22 and main control module PC1
Service Agent check unit. prevents the unit from being operated in
(A Side)/PC21 (B Side), or PC1/PC21. If
the single operator mode. Return to dual
this display is shown, have Factory Autho- 4 Help 25 Display operator mode and check for output at both
rized Service Agent check PC1/PC21,
Indicates a remote device connected to sides. If output is normal, contact Factory
PC2/PC22, and the wiring between them.
Remote Receptacle RC14 may be faulty. Authorized Service Agent to check internal
2 Help 21 Display Help 25 is also displayed whenever a re- wiring and communications between
Thermistor TH1 in the IGBT module (each mote device has been connected to RC14 sides.

TM-259 705 Page 46 Big Blue 800 Duo Air Pak

7-10. Removing Optional Air Dryer For Service
 Follow this procedure whenev-
er the air dryer must be re-
moved to gain access to the
battery.
1 Air Line
2 Timer Control Cable
3 Air Dryer Heater Plug
4 Solenoid LED
Disconnect air line from dryer as-
sembly bottom inlet.
Disconnect heater cable from bot-
tom of air dryer assembly.
Loosen hardware securing battery
access panel to rear panel. Careful-
ly pull access panel/air dryer as-
sembly away from unit rear panel.
Support dryer assembly to relieve
strain on timer control cable.
3 Disconnect battery negative (−)
cable. When service is complete,
reconnect battery negative (−)
2 cable.
Reinstall battery access panel/air
dryer assembly. Reconnect air dry-
er heater cable.
Reconnect air line to dryer bottom
inlet.
Final-tighten all hardware, and
air line and air dryer fittings.
Start engine, and turn on air com-
pressor. Check fittings for air leaks
and tighten fittings if necessary.
Verify dryer solenoid is functioning
by listening for dryer canisters to
purge, or by checking solenoid
1 LED. LED lights at start-up and ev-
ery two minutes when the canisters
automatically purge.

803 511

Big Blue 800 Duo Air Pak TM-259 705 Page 47

 SECTION 8 − THEORY OF OPERATION
1 Engine
Engine supplies force to turn revolving 6
fields. 8
Supplementary AC
Control Relay CR5 Protector CB4 Receptacles
Energizes at start up to supply power to GFCI1, GFCI2,
the exciter circuit and Control Board RC1, RC2
5
PC1
7
2 Engine Control (ECU) Compo- Fuses F1, F2
nents 1 Supplementary
Protectors
Regulate engine speed in response to CB6 CB7, CB8
changes in weld or power load. Control Control Relay
interprets signal from engine sensors CR5
and maintains idle or weld/power speed. Current
Feedback
Control relay CR4 is energized by PC1 to PC1
to put signal engine can go into idle
mode. 1 3 4
3φ
3 Revolving Fields (Rotor) Revolving Exciter
Engine Fields

Weld
Turn at 1890 rpm maximum for weld and
(Rotor) Stator Windings
power. The speed and excitation current
of the field coils determine voltages in Generator Power
stator windings.
4 Stator Windings 10
37
Supply power to exciter, generator pow- Air Supplementary
er, and weld circuits. Compressor/ Protector
Clutch 7 CB9
5 Fuses F1 And F2
Protect exciter windings from overload. Supplementary
Protector 24 VAC
6 Supplementary Protector CB4 36 CB1
11
Protects the field flashing circuit. Control
8 Filter Board
7 Supplementary Protectors CB1, Relay
PC5/Remote
CB6, CB7, and CB8 CR10 AC Receptacle
Protect AC receptacles from overload. Receptacles RC14
RC4, RC5
8 AC Receptacles GFCI1, GFCI2 35
and RC1, RC2, RC4, RC5
Provide connection points and power for Air Pressure Current Feedback
auxiliary equipment. Switch
S11
9 Supplementary Protector CB3
9
Protects the power supply to control
board PC1. 34 Supplementary
Protector
 The following descriptions use Side Air Compressor CB3
A circuit diagram designators. Side Switch
B has identical components with dif- S10
ferent designators.
2
See circuit diagram.
10 Supplementary Protector CB9 Engine
Provides overload protection for 24 volts ECU
AC portion of Remote 14 receptacle
RC14. +10 VDC Output
17 Command Voltage
11 Filter Board PC5/Remote Recep-
tacle RC14 2 2
PC5 protects unit from high frequency, Control Fuel Pump Relay CR3
and RC14 connects remote amperage/ Relay
voltage and contactor controls to unit. CR4 Glow Plug Relay CR8
Control
When a remote control is connected to Board
the Remote receptacle, the Auto Sense PC1
Remote feature automatically switches
voltage/amperage control to the remote
control.
12 VRD Switch S5
Turns low open−circuit voltage circuit on
and off.
13 Voltage/Amperage Control R2
Adjusts weld output amperage or volt-
age level.

TM-259 705 Page 48 Big Blue 800 Duo Air Pak

 14 Process/Contactor Switch R1
AC Or DC Control Circuits Selects weld process and weld output
on/off control.
Weld Current Circuit 15 Arc Control R5
External Circuits or Adjusts dig and hot start for Stick weld-
Mechanical Coupling ing, inductance for MIG welding, and arc
stop parameters for Lift Arc TIG weld-
3φ Power ing.
16 Meter Board PC2
 Indicates Side A. Side B Displays preset and actual (rectified
has identical components and filtered) values of the weld voltage
with different designators. and amperage.
See circuit diagram. 17 Control Board PC1
Controls weld output by changing the
gate pulses to IGBT (power modules
PM1 and PM2) after comparing current
or voltage feedback to reference level
set by voltage/amperage adjustment
control or remote control connected
through RC14.

20 24 18 Main Rectifier
Changes AC weld current to DC.
Hall Device Positive (+)
Weld Output 19 Resistor R10
HD1 Terminal Provides a bleed path for a capacitor
bank C3.
20 Hall Device HD1
Provides current feedback signal to
23 Electrode PC1.
18 22 19 21 Stabilizer Z1
IGBT
Burden Smooths (filters) weld output current.
Capacitor Power
Main Resistor 22 Capacitor Bank C3
Rectifier Bank C3 Modules
R10
PM1 and Filters the DC output voltage of main
PM2 rectifier.
23 IGBT Power Modules PM1 And
PM2
Power modules use pulse width modu-
lation to control the amount of output
24 from the welding generator.
21
24 Positive (+) And Work (−) Weld
Work (−) Weld Output Terminals
Stabilizer Output
Z1 Terminal Provide weld output and allow manual
changing of output polarity.
25 Air Compressor Switch S10
Current Turns air compressor on and off.
IGBT Feedback Work
Gating 26 Air Pressure Switch S11
Signals Voltage Prevents control relay CR10 from ener-
Feedback gizing and compressor from running
17 when system pressure is above 20 psi.
27 Control Relay CR10
CR10 energizes when air compressor
switch is closed to supply power to com-
pressor clutch.
28 Air Compressor/Clutch
Clutch engages when energized to op-
erate compressor. (See Section 11 for
additional air compressor information.)

12 13 14 15 16
Voltage/ Voltage/ Process/
Arc Control Meter
Reducing Amperage Contactor Board PC2
Switch S5 Control R2 Switch R1 R5

Big Blue 800 Duo Air Pak TM-259 705 Page 49

 SECTION 9 − TROUBLESHOOTING

9-1. Measuring Capacitor Voltage

! Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
! Stop engine and disconnect
negative (−) battery cable.
Remove cover.
1 Side A Burden Resistors R 10
2 Side B Burden Resistor R210
Locate burden resistors.
3 Voltmeter
Check capacitor bank voltage
across burden resistors as shown.
Measure the DC voltage across
each burden resistor until voltage
drops to near 0 (zero) volts.
4 Side A Vault PC1
4
5 Side B Vault PC21
6
6 Side A Rectifier SR6
7 Side B Rectifier SR26
Proceed with job inside unit.
Reinstall cover and side panels, if
side panels are removed, when
finished.

5
1

2 7

Tools Needed:

3/8 in.
907535−TP1 / 907535−TP4

TM-259 705 Page 50 Big Blue 800 Duo Air Pak

9-2. Troubleshooting Tables
 See Section 9-3 for test points and values and Section 17 and follow-
ing for parts location.

 Use Testing Booklet (MILLER Part No. 150 852) when servicing this
unit.

 See the Partners of ITW web site for service memos that may aid in
the repair of this product.

 Equipment serviced may need to meet additional requirements as

specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic In-
spection and Testing.

 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 7-9). See Section 15 for engine display
information.

A. Welding

Trouble Remedy

No weld output; generator power output Check Voltmeter/Ammeter help displays (see Section 7-9) if available.
okay at AC receptacles.

Place Process/Contactor switch in an Electrode Hot position, or place switch in a Remote On/Off Re-
quired position and connect remote contactor to Remote 14 receptacle (see Sections 4-16).

Reset supplementary protector CB3 (see Section 7-8).

Reset supplementary protector CB9 (see Section 7-8). Check for faulty remote device connected to
Remote 14 receptacle.

Check and secure connections to Remote 14 receptacle (see Section 4-16).

Check filter board PC5 and connections (see Section 9-8).

Check fuse F2, and replace if open (see Section 7-8). Check brushes and slip rings, weld excitation cir-
cuit, and the rotor.

Check connections between Process Switch R1 and main control board PC1.

Check main rectifier (weld), and leads and connections. Replace main rectifier if necessary.

Check stabilizer Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.

Check current transducer HD1 and replace if necessary (see Sections 9-3 and 9-4).

Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).

Check VRD switch, voltage feedback wiring and main control board PC1. Repair or replace as necessary.

No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.

Check fuse F1, and replace if open (see Section 7-8). If F1 is open, check integrated rectifier SR2, capaci-
tor C6, and the rotor and brushes.

Check integrated rectifiers SR4 and SR5, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-14).

Disconnect leads 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and
tight.

Be sure weld cables have no nicks or gouges and no kinks.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Big Blue 800 Duo Air Pak TM-259 705 Page 51

 Trouble Remedy

Erratic weld output. Check main rectifier (weld), and leads and connections. Replace main rectifier if necessary.

Disconnect leads 42 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

High open-circuit voltage with VRD Check IGBT modules and main control board PC1.
switch S5 On.

High weld output. Repair or replace remote control device (if used).

Check position of Voltage/Amperage Adjust control.

Check voltage feedback circuit.

Check current transducer HD1, and replace if necessary (see Sections 9-3and 9-4).

Check main control board PC1 and connections, and replace PC1 if necessary.

Low weld output. Have authorized engine service agent check engine speed.

Check fuse F1, and replace if open (see Section7-8). If F1 is open, check capacitor C6, integrated rectifier
SR2, and the rotor and brushes.

Increase Voltage/Amperage Adjust control R2 setting.

Repair or replace remote control device.

Place VRD switch S5 in Off position and weld. If machine operates normally, check S5 and main control
board PC1.

Disconnect leads 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.

Check main control board PC1 and connections, and replace PC1 if necessary.

Low open-circuit voltage. Check position of VRD switch.

Check position of Process/Contactor switch.

Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).

Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
check engine speed.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 4-16).

No 24 volt AC output at Remote recep- Reset supplementary protector CB9 (24 volt) (see Section 7-8). If CB9 continues to open check devices
tacle RC14. connected to RC14.

Check filter board PC5, and replace if necessary.

With VRD Switch S5 On, machine does Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).
not return to low open−circuit voltage at
the end of weld.

B. Generator Power

Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 6-1). If they continue to open, check devices
tacles; weld output okay. connected to receptacles.

Press GFCI receptacle Reset button (see Section 6-2).

Check fuse F1, and replace if open (see Section 7-8). Check integrated rectifiers SR1 and SR2, resistor
R3, and capacitor C6.

Check resistance of generator power windings between leads 91 and 92. Replace stator if
necessary.

TM-259 705 Page 52 Big Blue 800 Duo Air Pak

 Trouble Remedy
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 7-8). If F1 is open, check transformer T1, integrated
rectifier SR5, and the rotor and brushes.

Reset supplementary protector CB4 (see Section 7-8). If CB4 continues to open check glow plug circuit.
Check Voltmeter/Ammeter help displays (see Section 7-9) if available.
Clean slip rings, and install new brushes if necessary (see Section 9-14).
Check integrated rectifier SR5, and replace if necessary.

Disconnect leads 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

High output at generator power AC Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
receptacles. check engine speed.

Adjust generator power field current resistor R3.

Low output at generator power AC Check fuse F1, and replace if open (see Section 7-8). If F1 is open, check capacitor C6, integrated rectifier
receptacles. SR2, and the rotor and brushes.

Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
check engine speed.

C. Three-Phase Generator Power

Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protector CB1 (see Section 6-1). If it continues to open, check devices
tacles; weld output okay. connected to receptacles.

Check wiring at receptacles RC4 and RC5. Check receptacles and replace if necessary.

No generator power or weld output. Check fuse F2, and replace if open (see Section 7-8). If F2 is open, check integrated rectifier SR4 and
the rotor and brushes.

Disconnect leads 108 and 105 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.

Disconnect stator excitation leads 103 and 104, and check continuity between leads. Replace stator if
necessary.

Check weld stator phase to phase voltage at main rectifier SR6. Check phase to phase voltage at
CB1. Replace stator if necessary.

High or low output at generator power Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
AC receptacles. check engine speed.

Adjust generator output resistor R8 (see Section 9-15).

D. Engine

Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections, clean and tighten if necessary.

Circuit breaker CB10 may be open. CB1 automatically resets when fault is corrected (see Section 7-8).
Check engine wiring harness and components.

Reset supplementary protector CB3 (see Section 7-8). Check engine alternator, engine harness, and
the fuel pump.

Check engine wiring harness plug connections.

Check continuity of Engine Control switch S1, and replace if necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Check control relay CR2: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR2 if necessary.

Big Blue 800 Duo Air Pak TM-259 705 Page 53

 Trouble Remedy
Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Check fuel pump according to engine manual.

Air in fuel system. See engine manual.

Have engine manufacturer’s authorized service agent check electronic speed control system.

Engine hard to start in cold weather. Use proper engine starting procedure (see Section 5-2).

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.

Use correct grade oil for cold weather (see engine manual).

Engine hard to start in cold weather. Check control relay CR8: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR8 if necessary.

Check glow plug for proper operation, and replace if necessary.

Install engine block heater option.

Engine suddenly stops. Check fuel gauge display. Check fuel level. Unit is equipped with low fuel level shutdown to prevent fuel
tank from running dry.

Check fuel gauge display. Check oil, and coolant levels. Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high (see Sections 4-6, and 15).

Check engine display for diagnostic codes (see Section 15). If other codes appear, contact engine
manufacturer’s factory authorized service agent.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section
7-8). Check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 7-8). Check engine alternator, engine harness,
and the fuel pump.

Check continuity of Engine Control switch S1, and replace if necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check fuel pump according to engine manual.

Check engine wiring harness and plug connections.

Have engine manufacturer’s authorized service agent check electronic speed control system.

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 7-4 and 7-7).

See engine manual.

Battery discharges between uses. Turn Engine Control switch S1 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.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Have engine manufacturer’s authorized service agent check electronic speed control system.
weld speed.

TM-259 705 Page 54 Big Blue 800 Duo Air Pak

 Trouble Remedy
Engine does not run at idle speed. Have engine manufacturer’s authorized service agent check electronic speed control system.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 16).
wetstacking occurs.

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 55

9-3. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-4)

! Measure capacitor bank C3 voltage according to Section 9-1, and

be sure voltage is near zero (0) before touching any parts.

V11 V11

V5, R3
V2, R2
V7
V13
V10, R9 V11, R8
V6, R4
V4, R5

V10, R10 V12

V3, R6

V1, R1 I2
I1

V9 V8
V9 Engine
control
Flashing V27 relay CR5
Diode
V8, R7

V17

V17
R12

V17

V15, R11

V33

Air compressor clutch

TM-259 705 Page 56 Big Blue 800 Duo Air Pak

 1 VDC/100 A Output

V14

V24

V16

V18

V28 V20 V25 V18 V20 V20

V21
V23 V26 V22
V27

V19

V13

See Section XX
for PC1 and PC21
Information

See Section XX for

RC14 and RC 214
Information

258 725-G

Big Blue 800 Duo Air Pak TM-259 705 Page 57

 V32
V29

I3
I3

TM-259 705 Page 58 Big Blue 800 Duo Air Pak

 V31
V17

V27, R13

V30

Auxiliary Power Available While Welding

120 VAC and 240 VAC From Exciter Stator 4kW Continuous, All Weld Loads

Deluxe Receptacles, Powered By Deluxe Windings on Weld Stator

Weld Power In Use Single Phase 240 VAC Three Phase 240 VAC
200 A at 28 V 12kW 11 kW
300 A at 32 V 9 kW 9.75 kW
400 A at 36 V 2.5 kW 3.5 kW
450 A at 38 V 0.5 kW 2.75 kW
500 A at 38 V 0 kW 0 kW

258 725-G

Big Blue 800 Duo Air Pak TM-259 705 Page 59

9-4. Troubleshooting Values For Circuit Diagram (Use With Section 9-3)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine (no warm-up); no load;
weld/power RPM unless noted
c) Reference − single arrow: reference to circuit common (lead 42);
double arrow: reference to points indicated
Resistance Values
d) Process/Contactor switch R1/21 in Electrode Hot − Stick position
unless noted a) Tolerance − ±10% unless
specified
e) Wiring Connections − see Table 13-1
b) Condition − 70°F (21°C); cold
V1 96 volts DC
machine (no warm-up)
V2 97 volts DC
c) Wiring Connections − see
V3 109 volts AC Table 13-1
V4 132 volts AC
d) Stop engine before checking
V5 132 volts AC resistance
V6 132 volts AC R1 22 ohms
V7 264 volts AC R2 14 ohms
V8 268 volts AC R3 thru R11 Less than 1 ohm
V9 133 volts AC R12 30 ohms = full fuel tank
240 ohms = empty tank
V10 21.5 volts AC R13 0.4 ohms
V11 64 volts AC R14 2.5 ohms
V12 43 volts AC
V13 58 volts DC
V14 95 volts DC Amperage Readings
V15 28 volts AC
a) Tolerance − ±5% unless specified
V16 12 volts DC at idle RPM
b) Condition − 70°F (21°C); cold
V17 12 volts DC, hot battery bus machine (no warm-up); no load;
V18 1.9 volts DC at 75°F weld/power RPM unless noted
V19 VRD switch S5 On = 0 volts, Off = +5 volts DC c) Process/Contactor switch R1/21
V20 5 volts DC Control Power Supply in Weld Terminals Always On −
Stick position unless noted
V21 0 to +5 volts DC from min to max of Voltage/Amperage control R2
V22 0 to +5 volts DC from Electrode Hot−Wire position to Remote−Wire position I1 4.4 Amps
of Process Contactor switch R1 (in 0.71 volt increments)
I2 7.0 Amps
V23 0 to +5 volts DC from min to max of Arc Control control R5
I3 50 Amps inrush, 30 Amps hot
V24 Open Circuit Voltage (See Chart)
V25 10 volts DC with respect to chassis ground
V26 0 to 10 volts DC min to max remote command input with respect to chassis
ground Open Circuit Voltage
V27 12 volts DC battery voltage V24 VRD On
V28 28 volts AC Stick Hot 15 volts DC
V29 12 volts DC with respect to chassis ground when glow plugs are energized TIG Hot 15 volts DC
FCAW MIG 13 to 39.9 volts DC
V30 12 volts DC when engine is running R2 Min to Max
V31 12 volts DC with relay CR5 energized V24 VRD Off
V32 12 volts DC when glow plugs are energized Stick Hot 95 volts DC
V33 12 volts dc with compressor running TIG Hot 15 volts DC
FCAW MIG 13 to 39.9 volts DC
R2 Min to Max

TM-259 705 Page 60 Big Blue 800 Duo Air Pak

9-5. Waveforms For Sections 9-3

 The waveforms represent the output of the welding generator. When unit is operating properly, the waveforms match those shown.

10 ms 50 V 10 ms 50 V

gnd gnd

A. CC/DC Open-Circuit Voltage, Process/Con- B. CV/DC Open-Circuit Voltage, Process/Con-

tactor Switch R1 In Electrode Hot − Stick Posi- tactor Switch R1 In Electrode Hot − Wire Posi-
tion, Voltage/Amperage Control R2 At Max tion, Voltage/Amperage Control R2 At Max

20 ms 20 V
20 ms 20 V

gnd gnd

C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro- D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Electrode Hot − cess/Contactor Switch R1 In Electrode Hot −
Stick Position, (Resistive Load) Wire Position, (Resistive Load)

Test Equipment Needed:

Oscilloscope Load Bank

Big Blue 800 Duo Air Pak TM-259 705 Page 61

9-6. Main Control Board PC1/PC21 Testing Information

Test Equipment Needed: ! Stop engine.

See Section 9-7 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Main Control Board PC1/21
2 Plug PLG6/26
3 Plug PLG7/27
4 Plug PLG11/211

4
1

Rear View Of Plug Where Leads Go Into Plug 3 And 4

2

907 535−TP2 / 193 183 / 193 184

TM-259 705 Page 62 Big Blue 800 Duo Air Pak

9-7. Main Control Board PC1/21 Test Point Values

a) Tolerance − ±10% unless specified

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power RPM unless noted
PC1/21 Voltage Readings d) Process switch R1/R21 in Stick position
e) Pins not listed are not used on this model

Plug Pin Value

PLG6/26 A1 Serial data line

A2 +5 volts DC output

A3 Arc Control signal input: 0 to +5 volts DC

B2 Command signal input: 0 to +5 volts DC input from min to max of Voltage/Amperage control R2

B3 Voltage feedback reference

C1 Serial data line

C2 Circuit common for Voltage/Amperage control R2/22

C3 Weld feedback with respect to pin PLG6/26-B3; same as OCV or load voltage

D3 Circuit common for Arc Control R5/25

E3 Current feedback for idle speed control; +1 volt AC or greater with respect to G3

F2 Voltage feedback: 1 volt DC per 10 arc volts

F3 Idle speed control signal from Engine Control switch S1: +12 volts DC in Run position

G1 VRD switch S5 input: On = 0 volts DC, Off = +5 volts DC

G2 Command reference: +10 volt DC

G3 Current feedback for idle speed control; +1 volt AC or greater with respect to E3

H2 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control

H3 Circuit common

J3 Circuit common

K1 +5 volts DC output

K3 24 volts AC input

PLG7/27 A1 0 to +5 volts DC from Weld Terminals Always On − Wire position to Remote Wire position of Process
Contactor switch R1/21 (0.71 volt increments)

A2 1 volt DC input per 100 amperes of weld output with respect to pin PLG7/27-C2

A3 +5 volts DC output

B1 Circuit common for Process/Contactor switch R1/21

B2 +15 volts DC output with respect to pin PLG7/27-C2

B3 Contactor control circuit: 24 volt AC input with respect to circuit common and closure on RC14/214
between pins A and B

C2 Circuit common

C3 Idle control signal: 0 volts DC at idle speed; +12 volts DC with welding load applied

D2 −15 volts DC with respect to pin PLG7/27-C2

E1 +12 volts DC power input

F3 Current feedback: 0 volts DC input per 100 arc amperes

PLG11/211 A1 Circuit common

A2 +5 volts DC

A3 +1.9 volts DC to RC10 Pin 7 at room temperature

B1 Circuit common

Big Blue 800 Duo Air Pak TM-259 705 Page 63

 Plug Pin Value
PLG11/211 B2 +5 volts DC

B3 +1.9 volts DC to RC20 Pin 7 at room temperature

C1 −24 volts DC with respect to pin PLG11/211-D1

C2 PWM drive (PM2) +18 volts dc with respect to pin PLG11/211-D1 at open circuit

D1 Reference for gate drive supply

D2 Reference for gate drive supply

D3 Reference for gate drive supply

E1 +24 volts DC with respect to pin PLG11/211-D1

E2 −9 volts DC with respect to pin PLG11/211-D1

E3 +18 volts DC with respect to pin PLG11/211-D1

F1 −9 volts DC with respect to pin PLG11/211-D1

F2 PWM drive (PM1) +18 volts dc with respect to pin PLG11/211-D1 at open circuit

F3 +18 volts DC with respect to pin PLG11/211-D1

9-8. Filter Board PC5/PC25 Testing Information

! Stop engine.
See Section 9-9 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Filter Board PC5/25
2 Receptacle RC8/RC28

Test Equipment Needed:

Plug PLG8/PLG28

907 535−TP7 / 217 008 / 231 708

TM-259 705 Page 64 Big Blue 800 Duo Air Pak

9-9. Filter Board PC5/25 Test Point Values

a) Tolerance − ±10% unless specified

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power RPM unless noted
d) Process switch R1/R21 in Stick position

PC5/25 Voltage Readings

Receptacle Pin Value

RC8/28 1 Not used on this model

2 Not used on this model

3 Not used on this model

4 Voltage feedback: 1 volt DC per 10 arc volts

5 Not used on this model

6 Command reference: +10 volt DC input

7 24 volt AC input with respect to pin RC6/26−J3

8 Command common

9 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control

10 Current feedback: 1 volt DC per 100 arc amperes

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 65

9-10. IGBT Module LED Troubleshooting Indicators
 All signals come from PC1.
1 IGBT Assembly
2 LED1 (Green)
1 Lit when +18 volts DC supply is
present.
3 LED2 (Green)
Lit when −9 volts DC supply is
present.
4 LED3 (Yellow)
Lit when PWM signal is present in-
3 dicating that weld contactor is on
driving IGBTs.
2

Ref. 907535−TP3 / 246 580-1A / 246 323-B

IGBT PM1/PM21 Information

PM1/21 Receptacle/ PC1 Plug/Socket Value
Pin
RC20/220 1 PLG11/211 F3 Power Supply: +18 volts DC from PC1, LED1 lights when supply is present

RC20/220 2 PLG11/211 F1 Power Supply: −9 volts DC from PC1, LED2 lights when supply is present

RC20/220 3 PLG11/211 D2 Circuit common from PC1

RC20/220 4 PLG11/211 F2 PWM signal from PC1, LED3 lights when signal is present

RC20/220 5 PLG11/211 A2 +5 volts DC to Pin 6

RC20/220 6 PLG11/211 A1 Circuit common

RC20/220 7 PLG11/211 A3 +1.9 volts DC to pin 6 at room temperature

RC20/220 8 N/A

IGBT PM2PM22 Information

Receptacle/Pin PC1 Plug/Socket Value
RC10/210 1 PLG11/211 E3 Power Supply: +18 volts DC from PC1, LED1 lights when supply is present

RC10/210 2 PLG11/211 E2 Power Supply: −9 volts DC from PC1, LED2 lights when supply is present

RC10/210 3 PLG11/211 D3 Circuit common from PC1

RC10/210 4 PLG11/211 C2 PWM signal from PC1, LED3 lights when signal is present

RC10/210 5 PLG11/211 B2 +5 volts DC to Pin 6

RC10/210 6 PLG11/211 B1 Circuit common

RC10/210 7 PLG11/211 B3 +1.9 volts DC to pin 6 at room temperature

RC10/210 8 N/A

TM-259 705 Page 66 Big Blue 800 Duo Air Pak

9-11. Engine Display Testing Information
1 Rear of Engine Display
See Section 15 for explanation of
engine display functions.
Wiring harness plugs PLG4 and
PLG12 connect to receptacles on
rear of display.
Test functions by checking pin in-
puts and outputs as specified.
Voltage readings tolerance ±10%.

Plug PLG4
Pin Description
1 +12 Volts DC Input
2 CAN Hi
3 CAN lo
4 +12 Volts DC to CR5
5 not Used
6 Ground
Plug PLG12
Pin Description
8 31 ohms = full fuel tank
237 ohms = empty fuel tank

Test Equipment Needed:

Ref. 907535−TP2 / 256 689

Big Blue 800 Duo Air Pak TM-259 705 Page 67

9-12. Meter Display Board PC2/22 Testing Information

! Stop engine.
See Section 9-13 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
1
1 Meter Display Board PC2/22
2 Receptacle RC1/21

Test Equipment Needed:

 Typical receptacle configuration.

Pin 1 is denoted by dimple.

PC Board Surface Dimple

907535−TP2 / 214 536

9-13. Meter Display Board PC2/22 Test Point Values

a) Tolerance − ±10% unless specified

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power RPM unless noted
d) Process switch R1/R21 in Stick position
PC2/22 Voltage Readings

Receptacle Pin Value

RC1/21 1 +12 volts DC input with respect to pin RC1/21-2

2 Circuit common

3 Serial data line

4 Serial data line

TM-259 705 Page 68 Big Blue 800 Duo Air Pak

9-14. Replacing Brushes And Cleaning Slip Rings

Tools Needed:

Minimum Length:
5/8 in. (16 mm)
New Length:
1-1/4 in. (32 mm)

907 535-5 / 255 861 / Ref: 190 823

1
Replace
Damaged Brushes

! Stop engine and let cool. 2 Slip Rings and clean rings with a commutator stone.
Remove as little material as possible.
1 Brush Holder Inspect slip rings. Under normal use, rings
Remove brush holder. Keep hardware for turn dark brown.
reinstallation. Inspect brushes. If brushes
! Stop engine.
are damaged or near minimum length, re- If slip rings are corroded or surface is un-
place brush holder. even, insulate brush leads, start engine, Install brush holder.

Big Blue 800 Duo Air Pak TM-259 705 Page 69

9-15. Checking Unit Output After Servicing

 Use output waveforms to check unit

output after servicing (see Section
9-5).
Check engine speeds. Engine speed ad-
1 justment must be done by the engine’s
factory authorized service agent.
1 AC Receptacles GFCI1, GFCI2
And RC1, RC2
2 Resistor R3
Start engine and run at weld/power speed
(1890 rpm).
Check voltage at each receptacle. With
no load applied, there should be 126 to
132 volts AC present at GFCI1, GFCI2
and 252 to 264 volts AC at RC1, RC2.
If correct voltage is not present, stop en-
gine and reconnect lead 102 to different
taps on R3.

 Connect R3 leads so at least half of

resistor length is in circuit.
Start engine and check GFCI1, GFCI2
and RC1, RC2 voltage. If necessary,
change R3 connections until correct volt-
age is obtained at receptacles without ex-
ceeding 4.6 amperes DC exciter revolv-
ing field current (see Section 9-2).
3 Resistor R8
Place Process Selector switch in the
Stick position. Place VRD switch S5 in Off
position.
Check open-circuit voltage across weld
output terminals. There should be 87 − 92
volts DC present. If correct voltage is not
! Stop engine before adjusting present, stop engine and reconnect lead
resistors R3 and R8. 112 and/or lead 103 to different taps on
R8.

 Connect R8 leads so at least half of

resistor length is in circuit.
2 Start engine and and run at weld/power
speed (1890 rpm). Check weld output
voltage. If necessary, change R8 connec-
tions until correct voltage is obtained.
3  Perform a load bank test to ensure
welding generator operates properly
after servicing. Be sure load bank is
capable of handling the rated output
of the welding generator being tested
(see load bank Owner’s manual).
The load bank will simulate a weld
load and the electrical demand on the
unit. See Specifications for rated
load.
If unit does not perform at rated load,
Test Equipment Needed: repeat troubleshooting procedures.
Pre-Operational Checks ! Stop engine.
Allow engine to cool, and then complete
Wipe engine surfaces clean. pre-operational checks in table.

Check labels; replace labels that are unreadable or damaged.

Check fuel and oil (see Section 4-5).

Check and correct any fluid leaks. Tools Needed:

Clean weld output and battery terminals. Tighten connections.

Clean outside of entire unit.
Ref. 803 832-C / 907 535-5

TM-259 705 Page 70 Big Blue 800 Duo Air Pak

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 71

 SECTION 10 − SERVICING AND TROUBLESHOOTING
AIR COMPRESSOR
10-1. Component Location And System Operation

Theory Of Operation

209 059-A

 See illustration on adjacent page and the Prevents air compressor from starting if sys-
tem air pressure is above 20 psi (138 kPa).
15 High Air Temperature Switch S12
sections referenced below to locate com- Stops compressor if compressor air/oil mix-
ponents. 8 Pressure Gauge Sender ture temperature exceeds 248° F (120° C).
1 Inlet Air Filter (Compressor Air Filter) Provides system air pressure information to 16 Thermostatic Control Valve
front panel air pressure gauge.
Removes contaminants from air entering Allows compressor oil to bypass oil cooler
compressor (see Section 10-4 for location). 9 Secondary Oil Separator (item 19) when oil temperature is cool; directs
Removes remaining oil from air supply. oil through cooler when oil temperature ex-
2 Inlet Valve Assembly ceeds 170° F (77° C).
10 Separator Scavenge Check Valve/Filter
Controls amount of air entering compressor Orifice 17 Oil Filter
after receiving signal from pressure regulator.
One way valve and filter controls flow of oil Removes contaminants from compressor oil.
3 Compressor (Oil-Cooled Rotary Screw) from secondary oil separator back to com-
pressor. 18 Oil Drain
Produces 125 psi (862 kPa) compressed air
when Air Compressor switch S10 is On. 11 Minimum Pressure Check Valve Provides convenient location to drain oil when
servicing compressor (see Section 10-6 for
4 Primary Oil Separator (Tank) Maintains 50 psi (345 kPa) at compressor out- location).
let to keep oil circulating through system.
Separates most of the oil from the air leaving 19 Oil Cooler (Radiator)
compressor. 12 Shutoff Valve
Controls air flow. Stops air flow when closed Cools compressor oil to help maintain correct
5 Oil Level Gauge system operating temperature.
(see Section 4-17 for location).
Indicates oil level in primary oil separator. 20 Oil Fill
13 Pressure Regulator
Read gauge only when compressor is Off
Monitors system air pressure and sends sig- Provides convenient location to add oil to
(see Section 10-6 for location).
nal to inlet valve assembly to control air flow compressor (see Section 10-6 for location).
6 Pressure Relief Valve (Safety Valve) into compressor. 21 Air Dryers (Optional) − Not Shown
Automatically releases air when system air 14 Blow Down Valve Remove excess moisture from compressed
pressure exceeds 150 psi (1034 kPa).
Relieves system air pressure when compres- air to prevent damage to tools and other equip-
7 Air Pressure Switch S11 sor stops. ment.

TM-259 705 Page 72 Big Blue 800 Duo Air Pak

 Component Location

19 2

3 1

15

4
11

13 14

2
19
12
1

20

16

4 17

5
10 18
9
12

255 862-A

Big Blue 800 Duo Air Pak TM-259 705 Page 73

 The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment. The compres-
sor will require service more often if used in dirty, humid conditions.

10-2. 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.

Notes

TM-259 705 Page 74 Big Blue 800 Duo Air Pak

10-3. Routine Air Compressor Maintenance
 See Section 7 for engine/generator maintenance information.

Recycle air
compressor
fluids.
! Stop engine before maintaining.

 Service air compressor more often if used in severe conditions.

 = Check  = Change  = Clean = Replace Reference
* To be done by Factory Authorized Service Agent
Every Section
8 10-6
Hours

 Spills  Oil Level

Every Section
250 10-4
Hours

Unreadable Labels  Belt Tension  Air Cleaner Hoses Air Filter Element

Worn or Damaged Air/Oil  Cooling System

Hoses
Every Section
500 10-6
Hours

 Oil  Oil Filter

Every Section
1000 10-6
Hours

 Air/Oil Separator

Big Blue 800 Duo Air Pak TM-259 705 Page 75

10-4. Servicing Compressor Air Cleaner

! Stop engine.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
1 Compressor damage caused by using a
damaged element is not covered by the
warranty.
1 Compressor Air Cleaner
 The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional air compressor
protection. Never clean a safety ele-
ment. Replace the safety element af-
ter servicing the primary element
three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
2 3 4 5 place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element
4 Primary Element
5 Cover
6 Dust Ejector
To clean air filter:
6 Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.
NOTICE − Do not clean housing with air
hose.
Keep nozzle
2 in. (51 mm) Clean primary element with compressed
from element. air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).

Blow Inspect

aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B

TM-259 705 Page 76 Big Blue 800 Duo Air Pak

10-5. 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 7-8 for engine/genera-

tor overload protection.
1 Circuit Breaker CB15
Circuit breaker CB15 protects the air
compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.
Press button to reset breaker.

907 535−2

Big Blue 800 Duo Air Pak TM-259 705 Page 77

10-6. Servicing Air Compressor

Tools Needed:
Air Compressor Assembly Right Side 7/8, 15/16 in.

7
4

Too
High
2

Full Full

3
Too
Low
1

907 535−2 / 2555 862-A

! Stop engine and let cool. Wait 60 sec- To change compressor oil and filter: Add recommended oil until oil level indicator
shows system is full (see compressor mainte-
onds for system pressure to drop be-
fore changing oil.
 The engine oil drain and compressor oil nance label for oil specifications). Reinstall oil
drain hoses are located together in the fill cap. Tighten cap with wrench.
1 Air Compressor Oil Filter base. Be sure to select the correct hose
when draining compressor oil. To replace secondary air/oil separator:
2 Secondary Air Compressor Air/Oil  Be sure o-rings at oil drain and oil fill fit-
Separator tings are in place before reinstalling caps. Loosen nut securing oil scavenge tube on
separator base. Lift oil scavenge tube from
Drain compressor oil while compressor is still separator. Turn filter counterclockwise. Re-
3 Air Compressor Oil Drain Hose warm. move filter.
w/Removable Cap
Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Re- Apply thin coat of oil to gasket on new filter.
4 Air Compressor Oil Fill Cap move cap from oil drain hose and drain oil into Install filter and turn clockwise. Reinstall oil
a suitable container. Reinstall oil drain hose scavenge tube.
5 Air Compressor Oil Level Indicator cap. Tighten cap with wrench.
Remove filter by turning filter counterclock- Start engine, run air compressor, and check
6 Air Compressor Primary Air/Oil for oil leaks.
Separator Tank wise. Remove filter. Apply thin coat of oil to
gasket on new filter. Install new filter and turn
7 Oil Scavenge Tube clockwise until tight. ! Stop engine.

TM-259 705 Page 78 Big Blue 800 Duo Air Pak

10-7. 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: 1 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).

 Maximum weld output is reduced

if compressor air pressure is set
above 125 psi (862 kPa).
Tighten nut.
2 Pressure Relief Valve
Pressure relief valve opens and re-
leases pressure at 150 psi (1034
kPa). The pressure relief valve is not
adjustable.

Air Compressor Assembly Left Side

255 862-A / Ref: 803 228

Big Blue 800 Duo Air Pak TM-259 705 Page 79

10-8. Troubleshooting Air Compressor System
 See Sections 10-1 thru 10-7 for normal air
compressor maintenance procedures See
Section 17 and following for parts location.

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.

Reset supplementary protector CB15 (see Section 11-2).

Check compressor belt tension. Be sure correct belt is used and is properly installed.
Check continuity of Air Compressor switch S10, and replace if necessary.
Check control relay CR10: Check all connections, check coil continuity, check for proper coil voltage,
and check contact voltage (input to common and output to common) to ensure contacts are operating.
Replace CR10 if necessary.

Check for proper operation of air pressure switch S11. S11 closes (continuity) when air compressor is
off. S11 opens (infinity) when air compressor is on and air pressure is above 20 psi (138 kPa).
Check for proper operation of air temperature switch S12. S12 closes (continuity) when compressor air/oil
mixture is below 248° F (120° C). S12 opens (infinity) when compressor air/oil mixture exceeds 248° F
(120° C).

Check compressor air pressure. Pressure relief valve opens if air pressure is above 125 psi (862 kPa).
If pressure relief valve continues to open, verify secondary oil separator is not plugged. Replace pressure
relief valve if necessary.

Verify secondary air/oil separator is not plugged. Replace separator if necessary.

Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Replace inlet valve if necessary.
Check minimum pressure check valve and replace if necessary.
Check air compressor clutch and replace if necessary.
Air compressor stops after short period Check compressor oil level (see Section 10-6). Automatic shutdown stops compressor if compressor
of operation. temperature is too high.
Clean debris from outside of radiator. Automatic shutdown stops compressor if compressor temperature
is too high.
Low air pressure. Check for leaks in air lines and hoses.
Check air compressor air cleaner (see Section 10-4).
Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Lubricate piston with compressor oil or replace inlet valve if
necessary.

Adjust compressor air pressure (see Section 10-7).

Check compressor for rated output, and replace if necessary.
High air pressure. Be sure control line is connected at regulator valve and inlet valve.
Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Lubricate piston with compressor oil or replace inlet valve if
necessary.

Adjust compressor air pressure (see Section 10-7).

Erratic air pressure regulation when air is Check air/oil separator filter for restriction. Replace if necessary (see Section 10-6).
first used.
Air pressure drops to 50 psi when sir sys- The application or tool being used requires more air than can be provided; air compressor is not large
tem is in use. enough.
Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195 117).
moisture in compressed air.

TM-259 705 Page 80 Big Blue 800 Duo Air Pak

 Trouble Remedy
Oil in air from compressor. Check compressor oil level (see Section 10-6). If oil level is too high, system becomes saturated with oil.
Change compressor secondary air/oil separator (see Section 10-6).
Check connections of red, white, and blue control lines (see compressor circuit diagram in Section 10-1).
Check for blocked separator scavenge check valve/filter orifice. Be sure lines are clear between oil sepa-
rator and compressor.
Oil in compressor air cleaner.  Close air shutoff valve before shutting unit down to prevent oil burpback into air filter.
Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Lubricate piston with compressor oil or replace inlet valve if
necessary.

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 81

 SECTION 11 − SERVICING AND TROUBLESHOOTING
OPTIONAL AIR DRYER
WARNING
AIR DRYER EXHAUSTS AT HIGH PRESSURE. NOISE AND FLYING DIRT AND SMALL OBJECTS can cause
injury and damage.
• Always vent air dryer exhaust to safe area.
• Wear safety glasses when servicing dryer or working around unit.
• Alert others nearby to be prepared for loud noises each time the air dryer discharges.

11-1. Component Location For JP Models

1 3/4 NPT To 3/4 JIC Female Adapter

2 3/4 NPT To 3/4 JIC Male Adapter
3 Air Hose
4 3/4 NPT Street Elbow
5 3/4 NPT Nipple
6 Air Shutoff Valve
7 Timer Control
8 Thumbscrew

4
5

1
8
7
6
2

3
803 338-B

TM-259 705 Page 82 Big Blue 800 Duo Air Pak

11-2. Air Dryer Operation And Overload Protection
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 welding genera-
tor is running.
The timer control regulates the drying
JP Models and regeneration cycles of the air dry-
er. The timer control energizes and
de-energizes the air control valve at
two-minute intervals during normal op-
eration. At start-up, this cycle repeats
at 15-second intervals four times.
The air control valve controls airflow
direction through the dryer. During op-
eration, one cartridge is drying air and
the other is being regenerated.
During operation there will be a light
flow of air from one exhaust port; this is
normal regeneration. Every two
minutes there will be a momentary
burst of air from one of the exhaust
ports as the timer control cycles.
The system includes a valve body
heater. If this is not operating properly,
the valve can freeze and not allow the
system to cycle.
1 Circuit Breaker CB8
CB8 protects the dryer heaters from
damage due to overload. If CB8 opens,
the heaters do not work and the dryer
does not discharge moisture in cold
weather.
Press button to reset circuit breaker
CB8.
2 Timer Control LED
Verify dryer solenoid is functioning by
2 listening for dryer canisters to purge, or
3 by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.
3 Screw
Screw is used to manually override the
Timer Control for certain troubleshoot-
ing functions.

907 535−2 / 803 229 / 236 974

Big Blue 800 Duo Air Pak TM-259 705 Page 83

11-3. Replacing Desiccant Cartridge

! Stop engine and let cool. Wait

20 seconds for system pres-
sure to drop before working
on any part of the air dryer
system.
Tools Needed:
1 Desiccant Cartridge
The expected life of the desiccant
cartridge is two to three years de-
pending on operating condition and
usage. Replace cartridge as follows:
Be sure system pressure is relieved.
Using a strap wrench, remove desic-
cant cartridge.

 An excessive accumulation of
oil in the air dryer or desiccant
cartridge indicates the com-
1 pressor may require service.
Contact the Factory Service De-
partment.
Remove and discard O-ring from
adapter plate stud. Clean adapter
plate surface and threaded stud.
Apply a light coating of grease to the
new O-ring and install on threaded
stud.
Apply a generous coating of grease
on the new desiccant cartridge gas-
ket surface.
Thread new desiccant cartridge onto
stud, turning clockwise. Hand tight-
en until gasket contacts adapter
plate. Turn cartridge 1/2 to 3/4 turn
more.

 Do not overtighten cartridge as

it may be extremely difficult to
remove.

803 511-B / 236 974

11-4. Troubleshooting Optional Air Dryer System

! Stop engine and let cool. Wait 20 seconds for system pressure
to drop before working on any part of the air dryer system.

Trouble Remedy
Air dryer system does not purge. Desiccant cartridge saturated. Replace cartridge.

Valve body heaters not working. Reset circuit breaker CB8 (see Section 11-2). Check for 12 volts DC at
heaters. Check resistance of the heater element; with the heater assembly removed from the valve body,
resistance should be approximately 2 ohms. Contact the Factory Service Department.

Check for valve malfunction: With system pressurized, turn the brass screw (see Section 11-2) to the right
(clockwise) 1/2 turn to horizontal. If air purge does not occur, see air dryer Service Manual available at
www.dry−air−systems.com.

O−rings and seals worn. Replace worn parts, see air dryer Service Manual available at www.dry−air−sys-
tems.com.

TM-259 705 Page 84 Big Blue 800 Duo Air Pak

Notes

Big Blue 800 Duo Air Pak TM-259 705 Page 85

 SECTION 12 − DISASSEMBLY AND REASSEMBLY

12-1. Disassembly For Service

Lift Here

 Control box removed for il-

lustration. Control box may
remain attached to brace.

907 535-5 / 907 535−TP10

TM-259 705 Page 86 Big Blue 800 Duo Air Pak

 ! Stop engine and let cool. Disconnect Remove exhaust pipe and fuel tank cap. Re- 5 Control Box
battery negative (−) cable. move top cover, left side panels, and right 6 Resistors R3 And R8
side panels. Replace fuel tank cap.
Use Section 9-2 to determine if trouble is in 7 Stabilizer Z1
stator, rotor, engine or combination of these 2 Exhaust Bracket
Disconnect plug at control box.
components. 3 Engine Controller
4 Fuel Filter/Pump Bracket Disconnect resistors R3 and R8.
These instructions will remove components
surrounding the engine/generator assembly; Remove hardware securing exhaust bracket Disconnect stabilizer Z1.
thereby allowing the engine/generator as- to center upright. Disconnect engine wiring harnesses.
sembly to remain on the unit base. Remove hardware securing engine con- Disconnect ground leads attached to base.
When the front panel assembly and compo- troller to center upright.
Remove screws securing control box to
nents up to the center upright are removed, Remove hardware securing fuel filter/pump base.
the center upright needs to be supported. bracket from center upright.
Prepare proper supporting blocks. Remove hardware securing front panel and
 To aid in reassembly, mark leads before center upright to base and pull assembly up
Should it be necessary to remove the stator disconnecting. See lead list summary in and out of unit.
or engine, prepare proper supporting blocks Table 13-1, for connection information.
to shim under the engine adapter Go to Section 12-2.
Disconnect leads 11, 12, and 13 from main Proceed with engine service/repair. When
1 Auxiliary Power Panel rectifier SR6. service/repair is complete, reverse proced-
Remove hardware securing auxiliary power Disconnect remaining leads coming from the ure to reinstall upright. Tighten center upright
panel. Tilt panel forward. stator. assembly hardware to 30 ft lb (41 N.m).

Big Blue 800 Duo Air Pak TM-259 705 Page 87

12-2. Disassembly Of Generator

3
C

1
Torques:

A 30 ft lb (41 N.m)
D B 18 ft lb (24 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)

255 861

NOTICE − Do not damage stator or rotor win- 3 Endbell with Exciter Stator Reassembly Instructions:
dings during this procedure.
Exciter stator comes off with endbell. Reinstall engine and generator parts as
1 Brushes needed using torque values in table.
4 Rotor
Remove brushes from brushholder assembly Reinstall upright assembly. Reconnect fuel
If engine must also be removed, remove en-
before disassembling generator. line.
gine from base mounts.
2 Stator Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
With engine properly supported, remove
from moving and hot parts.
hardware securing stator to engine. Remove
the following parts as needed: Reconnect negative (−) battery cable. Rein-
stall panels, doors, and exhaust pipe.

TM-259 705 Page 88 Big Blue 800 Duo Air Pak

12-3. Replacing IGBT Modules/Heat Sink Assembly
A. Removing Vault And Bracket

! Stop engine and let cool. Discon-

nect battery negative (−) cable.
Remove top cover, left side panels, and
right side panels.
1 Vault
2 IGBT/Capacitor Assembly
Disconnect plugs from vault and IGBT/
capacitor assembly. Disconnect output
leads at IGBT/capacitor assembly. Re-
move top IGBT/capacitor assembly. Re-
pair if necessary.
3 Vault Mounting Bracket
4 Vault And Capacitor Pan
Remove hardware securing bracket to
pan. Remove bracket.
Disconnect plugs and output leads at
lower vault and IGBT/capacitor as-
sembly.
2
Remove hardware securing IGBT/Ca-
pacitor assembly to the pan and remove
assembly from unit.
1

907 535-5 / 907535−TP4 / 907535−TP6

Big Blue 800 Duo Air Pak TM-259 705 Page 89

B. Replacing IGBT Modules/Heat Sink Assembly

1 Capacitors/Buss Plates As-

sembly
2 IGBT Modules/Heat Sink As-
sembly
Remove capacitor assembly from
IGBT modules/heat sink assembly.
A Replace IGBT modules/heat sink
assembly.
Reassemble capacitor assembly
onto IGBT modules/heat sink as-
2 sembly.
When reassembling the capacitor
assembly to the IGBT assembly,
torque screws according to table
below.
NOTICE − Apply Noalox joint com-
pound to the positive and negative
contact surfaces of the capacitors
and to the top surface of the stan-
doffs.
Reassemble unit.

C C

Torques:

B
A All Hardware To C
IGBT Modules

55 in lb 45 in. lb 70 in. lb
(6.2 N⋅m) (5.1 N⋅m) (7.9 N⋅m)

252 915-C

TM-259 705 Page 90 Big Blue 800 Duo Air Pak

 SECTION 13 − ELECTRICAL DIAGRAMS
 The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Model Serial Number Circuit Diagram Wiring Diagram

Big Blue 800 Duo Air Pak MD360063E and following 258 725-G See Table 13-1

Big Blue 800 Duo Air Pak TM-259 705 Page 91

 Figure 13-1. Circuit Diagram For Welding Generator − Part 1
TM-259 705 Page 92 Big Blue 800 Duo Air Pak
 258 725-G

Big Blue 800 Duo Air Pak TM-259 705 Page 93

 Figure 13-2. Circuit Diagram For Welding Generator − Part 2
TM-259 705 Page 94 Big Blue 800 Duo Air Pak
 258 725-G

Big Blue 800 Duo Air Pak TM-259 705 Page 95

 Table 13-1. Lead List Summary For Big Blue 800 Duo Air Pak Eff w/ME270030E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−− ATTACH END A TO 22 GA ON CT 42O RC98 (9) TO TE2 (A/B)
NEGC BUSS PLATE (−) TO R3 42Q BRUSH (FRONT) TO R3
POSC BUSS PLATE (+) TO R3 42Q PLG26 (J1) TO EXIT
11A WELD STATOR TO SR6 42R R3 TO PLG98 (9)
12A WELD STATOR TO SR6 42S PLG26 (F3) TO TE2 (A/B)
13A WELD STATOR TO SR6 42T PLG26 (H3) TO TE2 (A/B)
15A BUS PLATE (−) TO SR6 (−)(MASTER) 42TT S5 (BOT) TO TE2 (A/B)
16A Z1 TO MOD1/MOD2 BUS BAR (MASTER) 42U CR10 (B) TO GND STRIP (TOP)
18A BUS PLATE (+) TO SR6 (+)(MASTER) 42UU S5 (BOT) TO TE2 (A/B)
18C S3 (1) TO POS OUTPUT STUD (A+) 42W COMPRESSOR (CLUTCH) TO GND STRIP (MID)
18D PLG6 (C3) TO RC30 (4) 42X GND STRIP (MID) TO C10/D10
18D POS OUTPUT STUD (A) TO POS BUS PLATE (LOOSE) 42Y GND STRIP (MID TO GND STRIP (BOT)
18F S3 (1) TO PLG30 (4) 42Z GND TO TE2 (A/B)
20A Z21 TO MOD21/MOD22 BUS BAR 43A PLG13 (CR1[30]) TO STARTER
21A WELD STATOR TO SR26 44A CR5 (1) TO CB2
22A WELD STATOR TO SR26 44B CR5 (1) TO PLG13 (CR1[87])
23A WELD STATOR TO SR26 44C CB10 (SILVER) TO CB14
24A BUS PLATE (+) TO SR26 (+)(SLAVE) 44D CR5 (1) TO CB10 (SILVER)
24B S3 (2) TO POS BUS PLATE (B+)(LOOSE) 44E CB14 TO CR10 (4)
24C PLG26 (C3) TO RC30 (2) 45A CB13 (SILVER) TO CR8 (87)
24E S3 (2) TO PLG30 (2) 46A PLG400 (1) TO CB11
25A BUS PLATE (−) TO SR26 (−)(SLAVE) 46B PLG400 (3) TO CB11
26A PLG26 (B3) TO RC30 (3) 46C PLG400 (5) TO CB11
26B S3 (5) TO Z2 (LOOSE) 47B TE3 TO CB11
26C S3 (5) TO PLG30 (3) 47D TE3 TO CB13 (COPPER)
27A S3 (3) TO POS OUTPUT STUD (B+) 47E CB13 (COPPER) TO ALT
28A S3 (6) TO NEG OUTPUT STUD (B−) 47F TE3 TO CB12
30B PLG6 (B3) TO RC30 (8) 48A LEAD 48B TO PLG409 (S1 (L))
30C S3 (4) TO PLG30 (8) 48B PLG6 (F3) TO LEAD 48A
30D S3 (4) TO NEG OUTPUT STUD (A−) 49A CR5 (5) TO PLG409 (S1 (I))
30E NEG OUTPUT STUD (A) TO Z1 (LOOSE) 49B CR5 (5) TO PLG4 (I)
40A CB3 TO TE2 (C) 49C CR5 (5) TO PLG406 (A)
40B PLG15 (CR4 (85)) TO TE2 (C) 50A SPLICE 50 TO PLG400 (74)
40C PLG7 (E1) TO TE2 (C) 50B SPLICE 50 TO PLG15 (CR4 (87A))
40D PLG5 (1) TO TE2 (C) 50C SPLICE 50 TO PLG16 (CR24 (87A))
40E PLG27 (E1) TO TE2 (C) 51A CR5 (6) TO PLG4 (4)
40F PLG25 (1) TO TE2 (C) 52A CR5 (3) TO PLG409 (S1 (B))
40G CB3 TO CR24 (85) 52B CR5 (3) TO CB2
41A SPLICE 41 TO PLG400 (80) 53A PLG14 (CR3 (30)) TO CB12
41B SPLICE 41 TO PLG15 (CR4 (30)) 54A PLG14 (CR3−87) TO PLG410 (1)
41C SPLICE 41 TO PLG16 (CR24 (30)) 54B FUEL PUMP (+) TO RC409 (1)
42AA GND STUD TO RC1 (GRN) 56A PLG400 (35) TO PLG409 (S1 (S))
42AB RC1 (GRN) TO RC2 (GRN) 57A STARTER (+) TO CB10 (COPPER)
42AC RC2 (GRN) TO GFCI 1 (GRN) 60A SR5 (AC) TO ALT
42AD GFCI 1 (GRN) TO GFCI 2 (GRN) 61A SR5 (−) TO CR14 (86)
42AE GROUND STUD TO RC5 (GREEN) 61B CR5 (4) TO PLG400 (88)
42AG CR14 (85) TO GND STRIP (TOP) 61C CR5 (4) TO SR5 (NEG)
42AG GROUND STUD TO NEUTRAL STUD 61J SR5 (−) TO S10 (6)
42AH TERM STRIP (BOT) TO SPLICE (WHITE LEAD) 66A PLG6 (E3) TO CT LEAD
42AH GROUND STUD TO RC4 (GREEN) 67A PLG6 (G3) TO CT LEAD
42AK SPLICE (AIR DRY KIT) TO GND STRIP (MID) 71A PLG12 (8) TO FUEL LEVEL SENDER
42AM CR15 (1) TO GND STRIP (TOP) 72B SPLICE (74A) TO PRESSURE SENDER
42BA CHASSIS GND TO GND (BOTTOM) 73A TE4 TO PLG407 (1)
42BB CHASSIS GND TO GND STUD (AUX POWER PANEL) 73B TE4 TO PLG401 (23)
42BB CHASSIS GND TO GND STUD (AUX POWER PANEL) 73C TE4 TO PLG407 (2)
42BC CHASSIS GND TO TE1 (F−LEFT) 73D TE4 TO CR8 (30)
42EB PLG410 (2) TO GND 74A PLG12 (7) TO LEAD 74B (AIR PAK)
42EC GND TO FUEL LEVEL SENDER 74A PLG7 (C3) TO PLG16 (86)(CR4)
42ED GND TO PLG4 (6) 80 PC6−80 TO TE1−80
42EE PLG400 (2) TO BASE 80A EXCITER STATOR TO TE1 (E−LEFT)
42EF PLG400 (4) TO BASE 80B TE1 (F) TO PC5 (LEAD 80)
42EG PLG400 (6) TO BASE 80C TE1 (F) TO PC25 (LEAD 80)
42EH PLG406 (B) TO GND 81A EXCITER STATOR TO TE1 (F−LEFT)
42EJ FUEL PUMP (−) TO RC409 (2) 81B TE1 (E) TO CB9
42H S3 (7) TO PLG30 (1) 81C PLG6 (K3) TO CB9
42I GND (TOP) TO GND (BOT) 81D CB9 TO CB29
42J PLG6 (H3) TO TE2 (A/B) 81E PLG26 (K3) TO CB29
42K RC30 (1) TO TE2 (A/B) 82A EXCITER STATOR TO PLG99 (1)
42L PLG5 (2) TO TE2 (A/B) 82B RC99 (1) TO SR3 (AC)
42M PLG25 (2) TO TE2 (A/B) 83A EXCITER STATOR TO PLG99 (2)
42N PLG25 (8) TO TE2 (A/B) 83B PLG11 (D1) TO RC99 (2)
TM-259 705 Page 96 Big Blue 800 Duo Air Pak
 Table 13-1. Lead List Summary For Big Blue 800 Duo Air Pak Eff w/ME270030E And Following
Lead Connections Lead Connections
84A CB7 TO GFCI 1 (BRASS) 143A PLG11 (B2) TO PLG10 (5)
85A CB8 TO GFCI 2 (BRASS) 148 PC6−148 TO RC2−2
86A EXCITER STATOR TO PLG99 (3) 148A PC6−148A TO RC13 (2)
86B RC99 (3) TO SR3 (AC) 150 PC6−150 TO RC2−7
87 PC6−87 TO CB7 150A PLG7 (B3) TO PLG8 (7)
87A PLG11 (E1) TO SR3 (+) 160A PLG7 (B1) TO RC3 (6)
88A PLG11 (C1) TO SR3 (−) 161A PLG7 (A1) TO RC3 (5)
89A STATOR TO EXIT 162A PLG6 (K1) TO RC3 (4)
89B NEUTRAL STUD TO RC5 (WHITE) 163A CR10 (A) SPLICE TO S12
90A EXCITER STATOR TO TE1 (C−LEFT) 163D CR10 (A) SPLICE TO CR15 (1)
90B TE1 (C−RIGHT) TO CB6 (TOP−LEFT) 164A S10 (2) TO S10 (5)
91A EXCITER STATOR TO TE1 (B−LEFT) 164B S10 (2) TO CR10 (9)
91B TE1 (B−RIGHT) TO NEUTRAL STUD 165A CR15 TO COMPRESSOR (CLUTCH)
91C GFCI 1 (SILVER) TO GFCI 2 (SILVER) 165A PLG6 (C2) TO PLG2 (1)
91D GFCI 2 (SILVER) TO NEUTRAL STUD 165B C10/D10 TO CB15
92A EXCITER STATOR TO TE1 (A−LEFT) 166A PLG6 (B2) TO PLG2 (2)
92B TE1 (A−RIGHT) TO CB6 (TOP−RIGHT) 167A PLG6 (A2) TO PLG2 (3)
93A STATOR TO EXIT 168A CR10 (6) TO S11
96A CB6 (LEFT−LINE) TO RC2 (TOP−LEFT) 168B S11 TO S12
96B CB6 (LEFT−LINE) TO RC1 (TOP−LEFT) 169A S10 (3) TO S11
96C CB6 (LEFT−LINE) TO CB7 170A PLG6 (D3) TO PLG9 (1)
97A CB6 (RIGHT−LINE) TO RC2 (BOTTOM−RIGHT) 171A PLG6 (A3) TO PLG9 (2)
97B CB6 (RIGHT−LINE) TO RC1 (BOTTOM−RIGHT) 172A PLG7 (A3) TO PLG9 (3)
97C CB6 (RIGHT−LINE) TO CB8 175A CR10 (7) TO CB15
98A STATOR TO EXIT 181A PLG6 (G1) TO S5 (POLE)
99A STATOR TO EXIT 181B PLG26 (G1) TO S5 (POLE)
100A EXCITER STATOR TO PLG98 (1) 182A PLG26 (H1) TO EXIT
100B F1 TO RC98 (1) 183A PLG6 (E1) TO RC30 (6)
101A EXCITER STATOR TO RC98 (2) 183B PLG26 (E1) TO RC30 (7)
101B RC98 (2) TO SR2 (AC) 183C S3 (8) TO PLG30 (6)
102A R3 TO PLG98 (3) 183D S3 (8) TO PLG30 (7)
102B RC98 (3) TO C6 (−) 190A PLG6 (A1) TO PLG5 (3)
102C SR2 (−) TO C6 (−) 190B PLG5 (5) TO PLG25 (3)
103A EXCITER STATOR TO R8 190D PLG25 (5) TO PLG26 (A1)
104A EXCITER STATOR TO PLG98 (5) 191A PLG6 (C1) TO PLG5 (4)
104B F2 TO RC98 (5) 191B PLG5 (6) TO PLG25 (4)
105A BRUSH (CENTER) TO PLG98 (6) 191D PLG25 (6) TO PLG26 (C1)
105B RC98 (6) TO C6 (+) 220A PLG211 (C2) TO PLG210 (4)
105C SR2 (+) TO C6 (+) 221A PLG211 (F2) TO PLG220 (4)
105D SR1 (+) TO SR2 (+) 222A PLG211 (D3) TO PLG210 (3)
105E SR4 (+) TO SR1 (+) 223A PLG211 (D2) TO PLG220 (3)
106A F1 TO SR2 (AC) 224A PLG211 (E2) TO PLG210 (2)
107A SR4 (AC) TO F2 225A PLG211 (F1) TO PLG220 (2)
108A BRUSH (REAR) TO PLG98 (7) 226A PLG211 (E3) TO PLG210 (1)
108B RC98 (7) TO SR4 (−) 227A PLG211 (F3) TO PLG220 (1)
110A CB4 TO SR1 (AC) 229A PLG211 (A3) TO PLG220 (7)
111A CB4 TO CB3 230A PLG211 (A2) TO PLG220 (5)
111B CB3 TO CR5 (2) 231A PLG211 (A1) TO PLG220 (6)
112A R8 TO PLG98 (4) 233A PLG211 (B1) TO PLG210 (6)
112B SR4 (AC) TO RC98 (4) 234A PLG211 (B3) TO PLG210 (7)
120A PLG11 (C2) TO PLG10 (4) 235A PLG26 (G2) TO PLG28 (6)
121A PLG11 (F2) TO PLG20 (4) 236A PLG26 (J3) TO PLG28 (8)
122A PLG11 (D3) TO PLG10 (3) 237A PLG26 (H2) TO PLG28 (9)
123A PLG11 (D2) TO PLG20 (3) 240A PLG27 (F3) TO TE2
124A PLG11 (E2) TO PLG10 (2) 240B PLG28 (10) TO TE2
125A PLG11 (F1) TO PLG20 (2) 240C PLG7 (E2) TO TE2
126A PLG11 (E3) TO PLG10 (1) 241A PLG26 (F2) TO PLG28 (4)
127A PLG11 (F3) TO PLG20 (1) 243A PLG211 (B2) TO PLG210 (5)
129A PLG11 (A3) TO PLG20 (7) 250A PLG27 (B3) TO PLG28 (7)
130A PLG11 (A2) TO PLG20 (5) 260A PLG27 (B1) TO RC23 (6)
131A PLG11 (A1) TO PLG20 (6) 261A PLG27 (A1) TO RC23 (5)
132 PC6−132 − CB8 262A PLG26 (K1) TO RC23 (4)
133A PLG11 (B1) TO PLG10 (6) 265A PLG26 (C2) TO PLG22 (1)
134A PLG11 (B3) TO PLG10 (7) 266A PLG26 (B2) TO PLG22 (2)
135 PC6−135 TO RC2−6 267A PLG26 (A2) TO PLG22 (3)
135A PC6−135A TO RC13 (1) 270A PLG26 (D3) TO PLG29 (1)
135A PLG6 (G2) TO PLG8 (6) 271A PLG26 (A3) TO PLG29 (2)
136 PC6−136 TO RC2−8 272A PLG27 (A3) TO PLG29 (3)
136A PC6−136A TO RC13 (3) 274A PLG27 (C3) TO PLG17 (CR24)(86)
136A PLG6 (J3) TO PLG8 (8) 282A EXCITER STATOR TO PLG99 (4)
137 PC6−137 TO RC2−9 282A RC99 (4) TO SR23 (AC)
137A PLG6 (H2) TO PLG8 (9) 283A EXCITER STATOR TO PLG99 (5)
140 PC6−140 TO RC2−10 283A PLG211 (D1) TO RC99 (5)
140A PLG7 (F3) TO PLG8 (10) 286A EXCITER STATOR TO PLG99 (6)
141 PC6−141 TO RC2−4 286A RC99 (6) TO SR23 (AC)
141A PLG6 (F2) TO PLG8 (4) 287A PLG211 (E1) TO SR23 (+)
Big Blue 800 Duo Air Pak TM-259 705 Page 97
 Table 13-1. Lead List Summary For Big Blue 800 Duo Air Pak Eff w/ME270030E And Following
Lead Connections Lead Connections
288A PLG211 (C1) TO SR23 (−) 421A PLG401 (19) TO PLG402 (47) TWISTED PAIR 420/419
300A CB1 (TOP−LEFT) TO RC5 (X) 422A PLG400 (56) TO PLG402 (34)
300B CB1 (TOP−LEFT) TO RC4 (X) 423A PLG400 (61) TO PLG402 (17)
301A CB1 (TOP−CENTER) TO RC5 (Y) 424A PLG400 (85) TO PLG402 (46)
301B CB1 (TOP−CENTER) TO RC4 (Y) 425A PLG400 (82) TO PLG402 (51)
302A CB1 (TOP−RIGHT) TO RC4 (Z) 426A PLG400 (44) TO PLG402 (50)
311A CB14 TO CR14 (30) 429A PLG404 (1) TO PLG400 (57)
311B CR14 (30) TO CR15 (4) 430A PLG404 (2) TO PLG400 (64)
400A PLG401 (33) TO PLG402 (62)(TWISTED PAIR 400/401) 431A PLG400 (13) TO PLG405 (3)
401A PLG401 (16) TO PLG402 (35)(TWISTED PAIR 400/401) 432A PLG400 (87) TO PLG405 (2)
402A PLG401 (48) TO PLG402 (42)(TWISTED PAIR 402/403) 433A PLG400 (29) TO PLG405 (1)
403A PLG401 (18) TO PLG402 (37)(TWISTED PAIR 402/403) 434A PLG400 (68) TO PLG400 (15)
404A PLG401 (32) TO PLG402 (38)(TWISTED PAIR 404/405) 435A PLG4 (2) TO SPLICE 435 (TWISTED PAIR 435A/436A)
405A PLG401 (2) TO PLG402 (61)(TWISTED PAIR 404/405) 435B PLG400 (54) TO SPLICE 435 (TWISTED PAIR 435B/436B)
406A PLG401 (46) TO PLG402 (40)(TWISTED PAIR 406/407) 435C PLG406 (M) TO SPLICE 435 (TWISTED PAIR 435C/436C)
407A PLG401 (3) TO PLG402 (41)(TWISTED PAIR 406/407) 436A PLG4 (3) TO SPLICE 436 (TWISTED PAIR 435A/436A)
408A PLG401 (5) TO PLG402 (20)(TWISTED PAIR 408/409) 436B PLG400 (76) TO SPLICE 436 (TWISTED PAIR 435B/436B)
409A PLG401 (4) TO PLG402 (19)(TWISTED PAIR 408/409) 436C PLG406 (F) TO SPLICE 436 (TWISTED PAIR 435C/436C)
410A PLG401 (25) TO PLG402 (31) 437A PLG406 (H) TO PLG400 (75) TWISTED PAIR 437/438
411A PLG401 (26) TO PLG402 (25) 438A PLG406 (G) TO PLG400 (53) TWISTED PAIR 437/438
412A PLG401 (7) TO PLG402 (32) 439A PLG14 (CR3 (86)) TO PLG400 (90)
413A PLG401 (28) TO PLG402 (24) 440A PLG14 (CR3 (85)) TO PLG400 (26)
414A PLG401 (40) TO PLG402 (28) 441A PLG13 (CR1[85]) TO PLG400 (28)
415A PLG401 (27) TO PLG402 (29) 442A PLG13 (CR1[86]) TO PLG400 (73)
416A PLG401 (24) TO PLG402 (22) 443A CR8 (85) TO PLG401 (35)
417A PLG401 (43) TO PLG402 (23) 444A CR8 (86) TO PLG401 (45)
418A PLG401 (44) TO PLG402 (26) 445A PLG403 (1) TO PLG408 (1)
419A PLG401 (29) TO PLG402 (27) 446A PLG403 (2) TO PLG408 (2)
420A PLG401 (20) TO PLG402 (48) TWISTED PAIR 420/419 447A PLG403 (4) TO PLG408 (4)

TM-259 705 Page 98 Big Blue 800 Duo Air Pak

 Table 13-1. Lead List Summary For Big Blue 800 Duo Air Pak Eff w/ME270030E And Following
Lead Connections To CR15 Prior To ME270030E
42AM CR15 (4) TO GND STRIP (TOP)
163B CR10 (A) SPLICE TO CR15 (1)
165A CR15 TO COMPRESSOR (CLUTCH)
172A CR15 (3) TO TM (BLACK)
311B CR14 (30) TO CB15 (2)

Big Blue 800 Duo Air Pak TM-259 705 Page 99

 SECTION 14 − TORQUE SPECIFICATIONS
14-1. Torque Specifications

 All tolerances +10% unless specified.

260 717-C

Part No. Description Qty. Where Used Torque

Required
Engine
260731 Screw, M 8−1.25x 75 soc hd−Pln 12.9 pld 1 Tensioner Bkt To Engine 15 ft−lbs
260732 Screw, M12−1.75x 75 soc hd−Pln 12.9 pld 2 Tensioner Bkt To Engine 60 ft−lbs
120359 Screw, M12−1.75x 50 hex hd−Pln 8.8 pld 4 Eng Adapter Plate To Engine Rear 60 ft−lbs
259997 Stud, Stl m10−1.5 x 52mm gr8.8 4 Rotor To Engine 30 ft−lbs1
070008 Screw, M14−2.0x 30 hex hd−Pln 8.8 pln 6 Engine Mounts To Engine 100 ft−lbs
070004 Washer, Lock .559idx0.945odx.118t stl split14mm 6 Engine Mounts To Engine −−−
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 4 Rotor To Engine −−−
086787 Nut, M10−1.5 17hex 8h stl pld 4 Rotor To Engine 30 ft−lbs
605579 Screw, M 8−1.2x 20 hex hd−Pln 8.8 pld 4 Fan Blade To Water Pump Pulley 15 ft−lbs
602211 Washer, Lock .318idx0.586odx.078tstl pld split.312 4 Fan Blade To Water Pump Pulley −−−
261205 Screw, M12−1.75x 20 Hex Hd−Pln 12.9 Pln 2 Air Cleaner Bkt To Compressor 60 ft−lbs
602216 Washer, Lock .502idx0.879odx.151tstl pld split.500 2 Air Cleaner Bkt To Compressor −−−
198447 Screw, M10−1.5x 20 hex hd−Pln 8.8 pln 4 Doc Bkt To Eng Adapter Plate 30 ft−lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 4 Doc Bkt To Eng Adapter Plate −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 8 Doc To Doc Bkt 15 ft−lbs
210821 Screw, M10−1.5x 60 soc hd−Pln 8.8 pld 1 Belt Tensioner 30 ft−lbs
602242 Washer, Flat .375idx0.875odx.083tstl pld blk 2 Air Cleaner To Air Cleaner Bkt −−−
604535 Screw, 312−18x1.50 Hex Hd−Pln Gr5 PlD 2 Air Cleaner To Air Cleaner Bkt −−−
260082 Clip, Nut retaining 2 Air Cleaner To Air Cleaner Bkt −−−
049525 Nut, .312−18 u−Nut multi−Thread 2 Air Cleaner To Air Cleaner Bkt −−−
199849 Screw, .625−11x4.00 hex hd−Pln gr5 pld 2 Engine Mounts To Base (Left & Right) 100 ft−lbs
071731 Washer, Flat .656idx2.250odx.187tstl pld 3 Engine Mounts To Base −−−
135205 Nut, 625−11 .94hex .77h stl pld elastic stop nut 3 Engine Mounts To Base −−−
260854 Screw, .625−11x4.50 hex hd−Pln gr5 pld 1 Engine Mount To Base (Left Only) 100 ft−lbs
220343 Pin, Spring cs .312 x 1.000 1 Plate Support,Engine To Base −−−
260103 Screw, .625−11x1.75 flathd−Soc stl 1 Plate Support,Engine To Base 100 ft−lbs
135205 Nut, .625−11 .94hex .77h stl pld elastic stop nut 1 Plate Support,Engine To Base −−−
602085 Screw, 008−32x .75 hexwhd.34d stl pld slffmg tap−Rw 4 Engine Harness To Bkt 30 in−lbs
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 2 Engine Harness Bkt To Compressor Side 10 ft−lbs
Bkt
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 5 Control Boxes To Frame 85 in−lbs
210821 Screw, M10−1.5x 60 soc hd−Pln 8.8 pld 4 Crankshaft Pulley To Engine 30 ft−lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 4 Crankshaft Pulley To Engine −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 2 Fan Guard To Fan Shroud 15 ft−lbs
261159 Pin,.Spring Spiral M8 X 32mm 2 Alignment For Engine To Eng Adapter Plate −−−
198447 Screw,.M10−1.5x 20 hex hd−Pln 8.8 pln 1 Idler Pulley To Engine 30 ft−lbs
602243 Washer,.Flat .438idx1.000odx.083tstl pld 1 Idler Pulley To Engine −−−
108940 Screw, .250−20x .75 hexwhd.61d gr5 pld 1 Engine Harness Cush Clamp To Center Up- 85 in−lbs
right
152461 Nut, .250−20 .44hex .23h stl pld sem cone wshr.65d 1 Engine Harness Cush Clamp To Center Up- −−−
right
108942 Screw, .250−20x1.25 Hexwhd.61d Gr5 Pld 4 Engine Ecu To Center Upright 85 in−lbs
152461 Nut, .250−20 .44hex .23h stl pld sem cone wshr.65d 4 Engine Ecu To Center Upright −−−
260826 Screw, M10−1.5x 80 hex hd−Pln 8.8 pld 2 Alternator Bkt To Compressor Bkt 30 ft−lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 2 Alternator Bkt To Compressor Bkt −−−
198447 Screw, M10−1.5x 20 hex hd−Pln 8.8 pln 2 Alternator Bkt To Compressor Bkt 30 ft−lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 2 Alternator Bkt To Compressor Bkt −−−
232889 Screw, .312−18x .50 hexwhd.66d stl tap−R w/Ann ring 4 Starter Hole Covers To Barrel 15 ft−lbs
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 1 Cush Clamp (Engine Manifold) To Comp 10 ft−lbs
Bkt
604433 Nut, .312−18 .56hex .45h Stl Pld Elastic Stop Nut 2 Vibration Mt To Center Upright
602159 Screw, .312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw 2 Exhaust Bkt To Vibration Mt
602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 2 Exhaust Bkt To Vibration Mt −−−
049525 Nut, .312−18 u−Nut multi−Thread 9 Radiator To Rear Upright −−−
080389 Screw, .312−18x1.00 hexwhd.66d stl pld slffmg tap−Rw 9 Radiator To Rear Upright 15 ft−lbs
602159 Screw, .312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw 1 Air Intake Hose To Fan Guard −−−
TM-259 705 Page 100 Big Blue 800 Duo Air Pak
 Part No. Description Qty. Where Used Torque
Required
Fuel
156734 Nut, .010−32 .31hex .13h stl pld sem cone wshr.38d 4 Fuel Pump To Bkt 30 in−lbs
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 4 Fuel Tank Brackets 10 ft−lbs
604433 Nut, .312−18 .56hex .45h stl pld elastic stop nut 4 Filters To Fuel Filter Bkt 10 ft−lbs
602242 Washer, Flat .375idx0.875odx.083tstl pld blk 4 Filters To Fuel Filter Bkt −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 3 Fuel Filter Bkt To Center Upright 15 ft−lbs
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 1 Fuel Filter Bkt To Frame 85 in−lbs
Frame
201006 Bolt, J stl .312−18 x 8.000 pld 2 Battery −−−
604433 Nut, .312−18 .56hex .45h stl pld elastic stop nut 2 Battery −−−
232889 Screw, .312−18x .50 hexwhd.66d stl tap−R w/Ann ring 4 Hole Cover, Base To Base 10 ft−lbs
232889 Screw, .312−18x .50 hexwhd.66d stl tap−R w/Ann ring 2 Hose Bkt To Base 10 ft−lbs
199849 Screw, .625−11x4.00 hex hd−Pln gr5 pld 2 Generator Mounts To Base 100 ft−lbs
135205 Nut, .625−11 .94hex .77h stl pld elastic stop nut 2 Generator Mounts To Base −−−
071731 Washer, Flat .656idx2.250odx.187tstl pld 2 Generator Mounts To Base −−−
602159 Screw, .312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw 16 Stab To Bkt & Bkt To Base 10 ft−lbs
049525 Nut, .312−18 u−Nut multi−Thread 15 On Uprights −−−
191914 Screw, .375−16x1.00 Hexwhd.66d Stl Pld Slffmg 8 Front/Rear Uprights To Base 30 ft−lbs
004454 Screw, .625−11x1.00 hex hd−Pln gr5 pld 4 Base To Center Upright 140 ft−lbs
604224 Screw, .250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−Rw 4 Front Top Cover To Front Upright 85 in−lbs
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 4 Braces To Front & Center Uprights 15 ft−lbs
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 4 Resistors To Base 85 in−lbs
190058 Nut, .250−20 u−Nut multi−Thread 16 Front Panel Assys To Front Upright −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 4 Box Cover To Front Upright 10 ft−lbs
604224 Screw, .250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−Rw 2 Switch Bkt To Base 85 in−lbs
602085 Screw, .008−32x .75 hexwhd.34d stl pld slffmg tap−Rw 1 Switch Bkt To Base 30 in−lbs
255975 Bolt, Crg stl .312−18 x .750 gr2 pld short neck 2 Battery Bracket To Base −−−
134711 Nut, .312−18 .50hex .28h stl pld ser flange .68d 2 Battery Bracket To Base 10 ft−lbs
604224 Screw, .250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−Rw 1 Cush Clamp, Right Eng Mt Tower (+ Bat 85 in−lbs
Cable)
604224 Screw, .250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−Rw 1 Ground Wires On Left Engine Mount Tower 85 in−lbs
604224 Screw, .250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−Rw 1 Ground Wires On Left Frame 85 in−lbs
208041 Spacer, Stl .323 Id X .625 Od X .141 Thk 2 Battery Holddown
Weld Control
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 3 Pan To Rails 85 in−lbs
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 12 Various Pan Bkt/Weld Module/Rect Bkt 85 in−lbs
232889 Screw, .312−18x .50 hexwhd.66d stl tap−R w/Ann ring 1 Grd Strap To Endbell 15 ft−lbs
217283 Bolt, Crg stl .250−20 x .750 gr5 pld 6 Leads To Cap Ckt 85 in−lbs
152461 Nut, .250−20 .44hex .23h stl pld sem cone wshr.65d 6 Leads To Cap Ckt −−−
602085 Screw, .008−32x .75 hexwhd.34d stl pld slffmg tap−Rw 4 Hd1/Hd2 To Pan/Vault Bkt 30 in−lbs
108940 Screw, .250−20x .75 hexwhd.61d gr5 pld 10 Leads To Rectifier 85 in−lbs
152461 Nut, .250−20 .44hex .23h stl pld sem cone wshr.65d 10 Leads To Rectifier −−−
136420 Screw, .008−32x .37 hexwhd.34d stl pld slffmg tap−Rw 4 Resistor To Pan/Vault Bkt 30 in−lbs
190058 Nut, .250−20 u−Nut multi−Thread 8 Vault To Pan/Vault Bkt −−−
044710 Screw, .250−20x3.25 hex hd−Pln stl pld 8 Vault To Pan/Vault Bkt 85 in−lbs
602241 Washer,.Flat .281idx0.625odx.065tstl pld ansi.250 8 Vault To Pan/Vault Bkt −−−
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 2 Control Box Cover To Control Boxes 85 in−lbs
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 2 Rectifier Bkt To Pan 85 in−lbs
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 3 Rectifier Bkt To Vault Bkt 85 in−lbs
Case
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 29 Front Panel Assys To Front Upright 85 in−lbs
190199 Rivet, Al .187 dia x .126−.250 grip blk blind dome 4 Plastic Neck Filler To Cover −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 39 Case Parts To Frame/Uprights 15 ft−lbs
049525 Nut, 312−18 u−Nut multi−Thread 2 Various Hold Downs For 602159 −−−
Generator
172555 Screw, M10−1.5x 50 hex hd−Pln 8.8 pld 6 Barrel To Engine Adapter 30 ft−lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 6 Barrel To Engine Adapter −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 6 Barrel To Engine Adapter 15 ft−lbs
132053 Screw, .375−16x1.50 hex hd−Pln gr5 pld blk 6 Endbell To Barrel 30 ft−lbs
183387 Washer, Cone .380idx .860odx.109t stl pld 4000lbs 6 Endbell To Barrel −−−
604534 Screw, .312−18x1.25 hex hd−Pln gr5 pld 2 Brushholder To Endbell −−−
602211 Washer, Lock .318idx0.586odx.078tstl pld split.312 2 Brushholder To Endbell −−−
602242 Washer, Flat .375idx0.875odx.083tstl pld blk 2 Brushholder To Endbell −−−
Big Blue 800 Duo Air Pak TM-259 705 Page 101
Part No. Description Qty. Where Used Torque
Required
Aux Group
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 1 Term Blk Assy To Frame 85 in−lbs
156734 Nut, .010−32 .31hex .13h stl pld sem cone wshr.38d 5 Leads To Term Blk Assy −−−
Compressor
044772 Screw,.M12−1.75x 30 hex hd−Pln 8.8 pln 2 Compressor Front Bkt To Engine 60 ft−lbs
602216 Washer, Lock .502idx0.879odx.151tstl pld split.500 2 Compressor Front Bkt To Engine −−−
260383 Screw,.M12−1.75x 50 soc hd−Pln 12.9 pln 2 Compressor To Compressor Front Bkt 60 ft−lbs
602216 Washer, Lock .502idx0.879odx.151tstl pld split.500 2 Compressor To Compressor Front Bkt −−−
260382 Screw,.M12−1.75x 30 soc hd−Pln 12.9 pln 1 Compressor To Compressor Front Bkt 60 ft−lbs
602216 Washer, Lock .502idx0.879odx.151tstl pld split.500 1 Compressor To Compressor Front Bkt −−−
044772 Screw,.M12−1.75x 30 hex hd−Pln 8.8 pln 2 Compressor Front Bkt To Side Bkt 60 ft−lbs
602216 Washer, Lock .502idx0.879odx.151tstl pld split.500 2 Compressor Front Bkt To Side Bkt −−−
120359 SCREW,.M12−1.75X 50 HEX HD−PLN 8.8 PLD 2 Compressor Side Bkt To Engine Adapter 60 ft−lbs
044772 SCREW,.M12−1.75X 30 HEX HD−PLN 8.8 PLN 1 COMPRESSOR SIDE BKT TO REAR BKT 60 ft−lbs
602154 Screw, .250−20x .50 hexwhd.50d stl pld slffmg tap−Rw 1 Cushion Clamp To Standoff 85 in−lbs
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 1 Cushion Clamp To Side Rail 85 in−lbs
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 4 Air Tank To Base 15 ft−lbs
198447 SCREW, M10−1.5X 20 HEX HD−PLN 8.8 PLN 2 Compressor Filter To Filter Bkt 30 ft lbs
083883 Washer, Lock .402idx0.709odx.087tstl pln split10mm 2 Compressor Filter To Filter Bkt −−−
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 1 Filter Bkt To Base 15 ft−lbs
049525 Nut, .312−18 u−Nut multi−Thread 1 Filter Bkt To Base −−−
604224 Screw, .250−20x .75 hexwhd.50d stl pld slffmg tap−Rw 1 Filter Bkt To Base 85 in−lbs
602159 Screw, .312−18x .75 hexwhd.66d stl pld slffmg tap−Rw 4 Box, Valve Ball To Front Upright 10 ft−lbs
208424 Screw, M 6−1.0x 90 Soc Hd−Hex Pld 12.9 Din 912 3 Compressor Rear Bkt To Compressor 10 ft−lbs
602242 Washer, Flat .375idx0.875odx.083tstl pld blk 2 Air Cleaner To Air Cleaner Bkt −−−
604535 Screw, .312−18x1.50 Hex Hd−Pln Gr5 Pld 2 Air Cleaner To Air Cleaner Bkt −−−
260082 Clip, Nut retaining 2 Air Cleaner To Air Cleaner Bkt −−−
049525 Nut, .312−18 u−Nut multi−Thread 2 Air Cleaner To Air Cleaner Bkt −−−
Misc.
199505 Oil Drain To Engine 35 ± 3 ft−lbs
210360 Clamps For Fuel Lines 40 in−lbs
DEUTZ Screw, M6 1 Remove & Reinstall W/259853 Bracket 69 in−lbs
DEUTZ Exhaust Clamp 1 Install To Engine W/Bellows 254724 106 ± 9 in−lbs
DEUTZ Exhaust Clamp 2 Doc To Bellows/Flex Ex Pipe To Bellows 106 ± 9 in−lbs
DEUTZ Screw, M8 −1.0 X 20 4 Remove & Reinstall W/258537 Fan Adapter 169 in−lbs
DEUTZ Clamp, Doc Mtg 2 Tighten Clamp Around Doc 106 ± 9 in−lbs
DEUTZ Rotating Alternator Housing 32 in−lbs

1 Use Locktite 242 (MILLER Part No. 009 425).

TM-259 705 Page 102 Big Blue 800 Duo Air Pak
 SECTION 15 − 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.

15-1. Display Layout And Controls

1 Engine Information Display
2 Engine Control Switch
3 Function Buttons
4 Yellow LED
5 Red LED
The Engine Information Display
turns on whenever the Engine Con-
trol switch is in either Run or Run/
Idle with the engine not running.

 When starting the engine,

1 pause Engine Control switch in
Run or Run/Idle position for
several seconds. The engine
controller initiation sequence
must occur. If glow plugs are on
4 5
(automatically determined by
ambient temperature), also
wait until the initial Wait to Start
3 2 message on the display is
cleared (see Section 15-4).
Function buttons are used to navi-
gate through menus, increment/
decrement, and select (see Section
15-2).
The yellow LED lights as part of se-
quences used to alert the operator
to errors or conditions that will affect
operation, such as low fuel.
The red LED lights as part of a shut-
down sequence, such as when fuel
is too low or oil pressure is too low
to continue operation without dam-
aging the engine.

MurphyDisplay 2014−03 / 258 833-D

15-2. Function Buttons

Function Button Previous Next Menu/Cancel View Enter/Diagnostic

6-Up Display None None Menu Go to 1-Up Engine Diagnostics
1-Up Display Previous Next Menu Go to 6-Up Engine Diagnostics

Big Blue 800 Duo Air Pak TM-259 705 Page 103
15-3. 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 condi-
tion exists for 5 minutes or longer,
the RPM signal failed message ap-
1 pears. Place Engine Control switch
in Off position to reset.

RPM SIGNAL FAILED

Hide

15-4. Service Reminder Screen

Wait to Start/Preheating 2
1

Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
Compressor Oil 0 Compressor Oil 495

 Glow plugs turn on automatically as de- switch position while the engine controller
goes through the preheat sequence. Once
a few seconds. It can also be found as a
1-up screen (see Section 15-7).
termined by ambient temperature.
this message clears, the engine can be The 6-Up Display then appears as the de-
Compressor oil information appears
only on models with air compressor. started. fault. The engine can be started when the
1 Wait to Start/Preheating Display 2 Service Reminder Display 6-Up Display appears.
The Wait to Start display appears when the The Service Reminder display shows ser- If the Enter/Diagnostic function button is
Engine Control switch is in the Run or Run/ vicing intervals in hours counting down pressed while in this display, the DM2 dia-
Idle position and glow plugs are functioning. from engine manufacturer recommended gnostic screen appears. (see Section
The operator needs to pause at either service intervals. This display appears for 15-11).

TM-259 705 Page 104 Big Blue 800 Duo Air Pak
15-5. 6-Up Display

1
0 PSI 0.0 H 0 PSI 0.0 H
9
3

32 F 0% 32 F 0%
8
4

0 RPM 0 VDC 0 PSI 0 VDC

6 7
5
n/min

1 6-Up Display With Engine RPM 2 6-Up Display With Air Compressor 4 Engine Coolant Temperature
Pressure (Models With Air 5 Engine RPM
This is the default screen configuration. If Compressor)
6 Compressor Air Pressure
the operator wants to toggle to the 1-Up The air compressor must be on and air
pressure must be available for this display 7 Battery Voltage
Display, press the View function button.
The Oil Pressure 1-Up Display appears to appear. 8 Fuel Level
(see Section 15-6). 3 Engine Oil Pressure 9 Engine Hourmeter

15-6. Getting To 1-Up Display

1 View Function Button
From 6-Up Display, press the
View function button to go to 1-Up
Display.
2 1-Up Oil Pressure Display
0 PSI 0.0 H 45 60 To increment to the next display,
press the Next function button. To
30 75 return to the 6-Up Display, press
32 F 0%
15 90 the View function button.

0 105
0 RPM 0 VDC
0 PSI
n/min
2
Oil Pressure

Big Blue 800 Duo Air Pak TM-259 705 Page 105
15-7. 1-Up Displays
1 1-Up Machine Hours Display
To increment to the next display,
press the Next function button. To
return to previous display, press
1 the Previous function button. To
return to the 6-Up Display, press
the View function button.

0H
Machine Hours

15 18
12
9
125 6
100 150 3
75
50
175
200 0 0V
25 225
250 Battery Potential
0F
Coolant Temperature
125
100
75

100 50
75 25
50 0 0%
25 Percent Load@RPM
0 0%
Fuel Level

Engine Oil
1000 1500
500 2000
0H
n/min

2500 Service Reminders

0 RPM
Engine Speed

TM-259 705 Page 106 Big Blue 800 Duo Air Pak
15-8. 1-Up Compressor Displays (Models With Compressor Only)
1 Air Compressor Pressure
1-Up Display
To increment to the next display,
press the Next function button. To
1 return to previous display, press the
Previous function button. To return
to the 6-Up Display, press the View
function button.
80 120
 Air Pressure display does not
40 160 appear if the air pressure input
is less than 50 PSI.
200
0 PSI
Air Pressure

0H
Compressor Oil Compressor Hours
0H
Engine Oil
0H
Service Reminders

Big Blue 800 Duo Air Pak TM-259 705 Page 107
15-9. 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
15-10 and 15-11).
0 PSI 0.0 H
1 6-Up Display
2 1-Up Fuel Level Display
1 3 Low Fuel Warning

32 F 0% The low fuel warning indicator ap-

pears and begins to flash when fuel
level reaches 10%. It continues to
flash until fuel level falls to 0%.
4 Yellow LED
0 RPM 0 VDC The yellow LED begins to flash when
the low fuel warning appears. It con-
tinues to flash until 0% is reached.
5 Red LED
The red LED turns on and stays lit
when fuel level reaches 0%. The en-
gine will shut down.
6 No Fuel Display
This display appears at engine shut-
down. Turn Engine Control switch to
3 Off, refuel, and restart.

100
2
75
50

25
0

Fuel Level

4 5

NO FUEL

Hide

TM-259 705 Page 108 Big Blue 800 Duo Air Pak
15-10. Warning or Shutdown Display
1 Oil Pressure Display
2 Fault Warning Indicator
The warning symbol appears on the
display when an engine condition
approaches a shutdown condition.
45 60 3 Fault Shutdown Indicator
30 75 The shutdown symbol appears on
the display when a severe engine
1 15 90 2 fault can cause shutdown.
3
105 The 6-up or 1-up screen with fault
0 PSI indicator is shown briefly and
automatically advances to the
fault display.
Oil Pressure 4 Fault Display
5 Level Of Fault
6 Indicates Number Of Faults
7 Suspect Parameter Number
8 Failure Mode Identifier
The SPN and FMI numbers are
generated by the engine controller
according to the J1939 standard.
4
Typical faults are listed in
Table 15-1.
5 9 Diagnostic Description
6
10 Occurrence Count
For non−critical faults, the number
0 of 0 Warning of occurrences can accumulate
8
7 11 Previous Function Button
SPN: 0 FMI 0
12 Next Function Button
9 13 Hide Function Button
Dm1. DiagnosticString
Non−critical faults can be hidden.
14 Acknowledge Function Button
To acknowledge the fault and ad-
10 vance the display to the 1-up or
OC: 0 6-up display, press the Ack function
button and then the Hide function
button.

Prev Next Hide Ack  The condition that caused the

warning or shutdown must be
remedied before operation can
11 14 continue.

12 13

1 of 1 Warning

SPN: 100 FMI 1

Low oil pressure warning threshold
exceeded

OC: 1

Prev Next Hide Ack

Big Blue 800 Duo Air Pak TM-259 705 Page 109
 Table 15-1. 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.

SPN FMI Description of Fault

Tier 3 or Tier 4 Interim Engines

100 2 Low oil pressure; warning threshold exceeded

110 2 High coolant temperature; warning threshold exceeded

Tier 4 Final Engines

94 1 Low fuel pressure; warning threshold exceeded

100 1 Low oil pressure; warning threshold exceeded

110 0 High coolant temperature; warning threshold exceeded

111 1 Coolant level too low

168 2 High battery voltage; warning threshold exceeded

174 0 High low fuel temperature; warning threshold exceeded

175 0 High oil temperature; warning threshold exceeded

15-11. Engine Diagnostic Display

 Engine diagnostic codes are
for use by the engine Factory
Authorized Service Agent only.
Attempting engine repair may
1 void engine warranty.
2
1 Diagnostic Display
2 Indicates Number Of Faults
0 of 0 Engine Diagnostics
4 3 Suspect Parameter Number
3 4 Failure Mode Identifier
SPN: 0 FMI 0
The SPN and FMI numbers are
5 generated by the engine controller
Dm2. DiagnosticString according to the J1939 standard.
5 Diagnostic Description
6 Requesting/Ok
6 7 Requesting appears on the display
Ok OC: 0 as the display communicates with
the engine controller. Once all diag-
nostic codes are available, Ok ap-
Get pears on the display.
Prev Next Hide Faults 7 Occurrence Count
For non−critical faults, the num-
8 11 ber of occurrences of each fault
can accumulate.
8 Previous Function Button
9 Next Function Button
9 10 10 Hide Function Button
Non−critical faults can be hidden.
11 Get Faults Function Button

TM-259 705 Page 110 Big Blue 800 Duo Air Pak
15-12. Main Menu Access Code
1 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
1 ENTER PASSWORD 2 Access Code (Password)
The factory set access code is
2 1000. This access code is not pro-
grammable and cannot be
0000 changed.
3 Increase Number Function
Button
4 Go to Next Number Function
Button
Use the increase function button to
increase the value underlined. Use
4
the > function button to move to the
+ > Cancel Enter next digit.
3 5
5 Cancel Function Button
6 6 Enter Function Button

15-13. Main Menu Options − Resetting Hours At Oil Change

1 Main Menu
2 Cursor
3 Scroll Function Buttons
1 Use scroll function buttons to move
cursor.
Brightness 0% 4 Select Function Button
Contrast 0 When the cursor is in desired posi-
2 tion, press Select function button to
Units English go to sub-menu.
Reminders 5 Service Reminders Display
Move cursor to select engine or
OEM compressor and press Select func-
Version tion button. The appropriate
Change Oil display appears.
Stored Codes 6 Reset Function Button
Language English Press the Reset function button to
reset Remaining Hours after chan-
4 ging oil.
3

Change Engine Oil

Service Reminder IntervalRemaining

Engine Oil 500 0
Compressor Oil 1000 490

Modify Reset Cancel

6

Big Blue 800 Duo Air Pak TM-259 705 Page 111
15-14. Main Menu Options: Brightness, Contrast, And Units
1 Main Menu
2 Cursor
3 Scroll Function Buttons
2 Use scroll function buttons to move
1 cursor.
4 Select Function Button
When the cursor is in desired posi-
Brightness 0% tion, press Select function button to
go to sub-menu.
Contrast 0
5 Brightness Menu Display
Units English Use scroll function buttons to in-
Reminders crease or decrease display
brightness. When desired per-
OEM centage is reached, press Select
function button.
Version
6 Contrast Menu Display
Stored Codes Use scroll function buttons to in-
Language English crease or decrease display con-
trast (lightness/darkness). Con-
4 trast range is 0 to 175. Viewing
angle affects appearance of dis-
play. When desired contrast is
reached, press Select function
button.
7 Units Menu Display
Use scroll function buttons to scroll
through choices:
3 English (PSI, F)
5
Bar (Bar, C)
Kpa (Kpa, C)
Brightness 0%
When desired units configuration
is reached, press Select function
button.

Contrast 0 7
Units English

TM-259 705 Page 112 Big Blue 800 Duo Air Pak
15-15. Main Menu Options − Reminders
1 Main Menu
2 Cursor
3 Scroll Function Buttons
Use scroll function buttons to move
1 2 cursor.
4 Select Function Button
When the cursor is in desired posi-
tion, press Select function button to
Brightness 0% go to sub-menu.
Contrast 0 5 Service Reminders Display
Units English Move cursor to select engine or
compressor and press Select func-
Reminders tion button. The appropriate
Change Oil display appears.
OEM
6 Reset Function Button
Version
Press the Reset function button to
Stored Codes reset Remaining Hours after chan-
ging oil.
Language English
7 Modify Function Button
4 NOTICE − The service interval can
be modified. Shorter service inter-
vals may be appropriate during
heavy use or in certain environ-
ments (such as dusty or extreme
temperatures). Lengthening ser-
vice intervals is not recommended
and could result in voiding engine
5 warranty.
3
8 Increase Number Function
Button
9 Go to Next Number Function
Button
Service Reminder IntervalRemaining Use the increase function button to
Engine Oil 500 0 increase the value underlined. Use
the > function button to move to the
Compressor Oil 1000 490 next digit.
10 Cancel Function Button
11 Enter Function Button

Change Engine Oil

Change Engine Oil

000000H

+ > Cancel Enter 11

8

Modify Reset Cancel

6

7
9 10

Big Blue 800 Duo Air Pak TM-259 705 Page 113
15-16. 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.
1 2 4 Select Function Button
When the cursor is in desired posi-
tion, press Select function button to
go to sub-menu.
Brightness 0% 5 OEM Menu Option
Contrast 0 This menu option is for Factory Au-
thorized Service Agents only and is
Units English password protected.
Reminders 6 Version Menu Display
OEM The information in this display may
5 be requested by a Factory Author-
Version ized Service Agent during
troubleshooting.
Stored Codes
7 Stored Codes
7 Language English
Stored codes can also be accessed
4 when the initial Service Reminder
8 display appears as the engine con-
troller is initiating (see Sections
15-4 and 15-11).
8 Language Menu Display
Use scroll function buttons to
scroll through choices: English,
French, Italian, Spanish, and
3 Brazilian Portuguese. When de-
sired language is reached, press
Select function button.

Configuration 0.0.0.0
Bootloader 00.00. 00.00
Firmware 00.00. 00.00
Part Number XX−XX−XXXX

Version

TM-259 705 Page 114 Big Blue 800 Duo Air Pak
 SECTION 16 − RUN-IN PROCEDURE
run_in2 2013−10

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.

16-1. Wetstacking
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
1 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welding genera-
tor is kept loaded during run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.

Big Blue 800 Duo Air Pak TM-259 705 Page 115
16-2. Run-In Procedure Using Load Bank Or Resistance Grid

2
1

+
3 6

S-0683 / S-0684

! Stop engine. Connect load bank or resistor grid to For Resistance Grid
! Do not touch hot exhaust pipe, en- generator Side A weld output terminals Set grid switches and then adjust gen-
gine parts, or load bank/grid. using proper size weld cables with correct erator A/V control so load equals rated
connectors. Observe correct polarity. voltage and current of the generator
! Keep exhaust and pipe away from
4 Resistance Grid (see nameplate, rating label, or the
flammables.
specifications section in this manual).
NOTICE − Do not perform run-in Use grid sized for generator rated output.
Check generator and meters after first five
procedure at less than 20 volts weld output Turn Off grid. minutes then every fifteen minutes to be
and do not exceed duty cycle or equipment sure generator is loaded properly.
damage may occur. 5 Voltmeter
NOTICE − Check oil level frequently during
1 Load Bank 6 Clamp-On Ammeter run-in; add oil if needed.
Turn all load bank switches Off. If needed, Connect voltmeter and ammeter as It is recommended to run the welding
connect load bank to 115 volts ac wall shown, if not provided on generator. generator for two hours minimum and up to
receptacle or generator auxiliary power four hours under load. Place A/V control in
receptacle. Start engine and run for several minutes. minimum position, then shut down load
2 Welding Generator For Load Bank bank or grid to remove load. Run engine
Place Welder Selector switch in the A several minutes at no load.
Set load bank switches and then adjust
position (Single Operator) and rotate A/V ! Stop engine and let cool.
generator A/V control so load equals
control to minimum. Place Process Select- rated voltage and current of generator 7 Engine Exhaust Pipe
or switch in Stick position. (see nameplate, rating label, or the Repeat procedure if wetstacking is pres-
3 Weld Cables specifications section in this manual). ent.

TM-259 705 Page 116 Big Blue 800 Duo Air Pak
 TM-259 705A 2014−09

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
)

Big Blue 800 )

Duo Air Pak

Eff w/MD360063E And Following

For OM-259 705 Revisions A Thru G

File: Engine Drive

Visit our website at

www.MillerWelds.com
SECTION 17 − PARTS EFF W/MD360063E AND FOLLOWING
 Hardware is common and not
available unless listed.

33

29 31
32
28 30

27
26

25
12 24
13
15
34
14
16
11 17

10 35
18 22
19
9 21 23 99
20

7 8

100
101
6

102

5 103
107 106
3 4 108
116 115 104
109
111 110 105
2 117

113 112
114
1

118

119

Figure 17-1. Main Assembly

TM-259 705 Page 118 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following

69
68

70

67
66
65
64

51 63
46
62
52

45 50 71
49
54
44 53 55
43
42 61
73
41 59
40 48 56 60 72
47
57
39 58
74 76 77
87 75 78
38
37 79
80
36 89 88
90

86
98
85
97 81
91
96

95
82

94 92 83
93

84

907 535−3

Big Blue 800 Duo Air Pak TM-259 705 Page 119
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Weld Output Panel see Figure 17-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Power Panel see Figure 17-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . Engine & Weld Control Front Panel see Figure 17-3 . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 252195 . . Bracket, Mtg Strip Term 6 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . SR6, SR26 . 248933 . . Rectifier, Si 3ph 300 Amp 600 Piv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . 259039 . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . HD1, HD21 . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 2
. . . 9 . . R10, R210 . 188067 . . Resistor, Ww Fxd 100 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . PC1, PC21 . 258544 . . Module, Main Control/Igbt Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . 260581 . . Panel, Generator Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 259533 . . Panel, Engine Extension Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 250348 . . Bus Bar, Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 250350 . . Bus Bar, Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 250323 . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 245378 . . Buss Bar, Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 247093 . . Stand-off, Conductive Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 18 . . . C3, C23 . . 246841 . . Capacitor, Elctlt 35000 Uf 100 Vdc Can 3.00 Dia . . . . . . . . . . . . . . . . . . . . . 4
. . . 19 . . . . . . . . . . . . . . 239547 . . Washer, Flat Nylon .516 Id X 1.250 Od X .062 Thk . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . 256489 . . Bracket, Mtg Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 250346 . . Bracket, Mtg Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 247407 . . Heat Sink Assy, Igbt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 218086 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . +255669 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . +259206 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw-on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 254108 . . Tank, Fuel (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 189912 . . . . Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189913 . . . . Fitting, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259536 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259499 . . Ftg, Stand Pipe Hose .500 X 9.265 Lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 084173 . . Clamp, Hose .460 - .545 Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190142 . . . . Sender, Fuel Gauge 9.7500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189910 . . . . Fitting, Stand Pipe Hose .3125 X 9.260 Lg 90deg Zinc . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . Generator see Figure 17-7
. . . 37 . . . . . . . . . . . . . . 258901 . . Bracket, Mtg DOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 3
. . . 39 . . . . . . . . . . . . . . 259691 . . Plate, Support Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 3
. . . 41 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 42 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 43 . . . . . . . . . . . . . . 259687 . . Bracket, Mtg Engine Lh Hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 3
. . . 45 . . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TM-259 705 Page 120 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly (Continued)

. . . 46 . . . . . . . . . . . . . . 206606 . . Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . . . . . . . . . . 253827 . . Adapter, Engine Deutz 2.9l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 256692 . . Engine, Deutz Dsl Elec 8556 Td 2.9l 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199507 . . Hose, Oil Drain Assy 20 In (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8-18nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 176529 . . . . Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xc Oil (Order By Ft) . . . . . . . . . . . . . . . . . . 2ft
. . . . . . . . . . . . . . . . . . . . 176528 . . Fitting, Hose Brs Barbed Elbow Fem 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173336 . . Fitting, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Available Through Engine Manufacturer) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259883 . . Heater,Block Engine 120v 530w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 254730 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 259354 . . Hose, Air Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 255768 . . Air Cleaner, Intake (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 254977 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 260285 . . Hose, Rbr .875 Id (Water Pump To Expansion Tank) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 255770 . . Bracket, Mtg Alternator To Compressor Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 253942 . . Pulley, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 253963 . . Pulley, Idler 76mm Od 17mm Id 33mm W . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 253941 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 258014 . . Bracket, Mtg Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 253958 . . Tensioner, Auto Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 253940 . . Pulley, Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . *253944 . . Belt, Micro-v 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 8 Blade Suction . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . . . . . . . . Compressor Assembly see Figure 17-8
. . . 64 . . . . . . . . . . . . . . 255666 . . Hose, Radiator Upper Deutz (2013 2.9 Liter) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 255667 . . Hose, Radiator Lower Deutz (2013 2.9 Liter) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . +259302 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210229 . . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 254726 . . Radiator/Oil Cooler 3 Row Core 1.500 In/Outlet (Ch) . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 255549 . . Tank, Radiator Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 261866 . . Sensor, Coolant Level Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 243038 . . Washer, Seal Oil Cu .560 Id X .840 Od X .042 T . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173818 . . Ftg, Hose Brs Barbed Elbow M 1/4 Tbg X 1/4 Npt . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 254275 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 260226 . . Extrusion, Rubber W/Adhesive .750 X .750 X 27.000 . . . . . . . . . . . . . . . . . 2
. . . 70 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 255756 . . Guard,Fan Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 209612 . . Lever,Switch Lockout Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 209611 . . Switch,Disc Battery 2p 6-36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . *255765 . . Filter, Fuel Secondary (D2013 2.9l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 259335 . . Bracket, Mtg Fuel Filters/Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 206604 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 209092 . . Bracket, Mtg Saftey Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 209090 . . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 80 . . . . . . . . . . . . . +259532 . . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 260658 . . Label, Maintenance Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 800 Duo Air Pak TM-259 705 Page 121
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 257145 . . Label, Suggested Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 209059 . . Schematic, Air System (Big Blue Air Pak) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 260007 . . Label, Maintenance Deutz D2.9l4/Td2.9l4 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 210681 . . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 259402 . . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 259406 . . Panel, Generator Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 260961 . . Bracket, Mtg Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . *255764 . . Filter, Fuel Pre (D2013 2.9l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 255767 . . Pump, Fuel (D2013 2.9l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 253929 . . Bracket, Mtg Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 259997 . . Stud, Stl M10-1.5 X 52mm Gr8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 90 . . . . . . . . . . . . . . 259855 . . Block, Mtg Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 91 . . . . . . . . . . . . . . 256251 . . Mount,Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 92 . . . . . . . . . . . . . . . . . . . . . . . . Clamp, V Band (Order from engine manufacturer) . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 254724 . . Pipe, Exhaust Bellows Flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . . . . . . . . . . . . DOC (Order from engine manufacturer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . . . . . . . . . . . Clamp, V Band (2 Sets) (Order from engine manufacturer) . . . . . . . . . . . . 2
. . . 96 . . . . . . . . . . . . . . 261816 . . Reducer, Exhaust Flex 3 In Marmon To 1-7/8 St . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 255774 . . Pipe, Exhaust Elbow 3.000 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 258895 . . Cover, Base 4.563 X 12.625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42.000 No 1 Awg W/Clamp & .400 Rng . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 264019 . . Cable, Bat Pos 24” No 1 Awg/8ga Aux W/Clamp & .400 . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 264794 . . Bracket, Battery Holddown (Group 31 Size) (Prior to ME020269E) . . . . . 1
. . 102 . . . . . . . . . . . . . 264793 . . Bracket, Battery Holddown (Group 24 Size) (Prior to ME020269E) . . . . . 1
. . 102 . . . . . . . . . . . . . 266385 . . Bracket, Battery Holddown (Eff w/ME020269E) . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Eff w/ME020269E) . . . . . . . . . 2
. . 104 . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 660 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 264924 . . Bracket, Battery Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 107 . . . . . . . . . . . . . 259182 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 109 . . . . . . . . . . . . . 258656 . . Label, Rating
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . R3, R8 . . . 189699 . . Resistor,Ww Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . . . . . . . . . . . . Control Box Assembly see Figure 17-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . Z1, Z21 . . . 249772 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 114 . . . . . . . . . . . . . 248940 . . Bracket,Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CT1 . . . . 105370 . . Xfmr. Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . . 256487 . . Pan, Vault & Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 117 . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 207096 . . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . . 254117 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
♦OPTIONAL
*Recommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

TM-259 705 Page 122 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following

 Hardware is common and not available unless listed.

2

1
3
4 8
5
7

9
31

24 11 10
23 12
29
22 20
30 28 21
25 19 13
16 14
18
26 15
27
17

907 535−4

Figure 17-2. Control Box Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-2. Control Box Assembly (Figure 17-1 Item 112)

... 1 . . . . . . . . . . . . . . 258576 .. Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 258577 .. Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . CB11 . . . . 093997 .. Supplementary Protector, Man Reset 1p 30a 250vac . . . . . . . . . . . . . . . . 1
... 4 . . . . CB12 . . . . 093996 .. Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 1
... 5 . . . . CB2 . . . . 139266 .. Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 1
... 6 SR1−SR4,SR23 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 7 . CR4, CR24 . 173069 .. Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . . 2
... 8 . . CR1, CR3 . . 258445 .. Relay, Encl 12vdc Spdt 50a/14vdc W/Diode 5pin . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . CR8 . . . . 258446 .. Relay, Encl 12vdc Spst 70a/14vdc W/Diode 4pin . . . . . . . . . . . . . . . . . . . . 1
... 10 . CB10, CB13 . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . TE3, TE4 . . 072253 .. Stud, Connection Single 10−32 X .500 X 1.250 Mtg . . . . . . . . . . . . . . . . . 2
... 12 . . . . SR5 . . . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . CR5 . . . . 223710 .. Relay, Encl 12vdc Dpst−No 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . 258582 .. Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 260105 .. Label, Component Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CR15 . . ♦172015 .. Time Delay Relay (Prior to ME270030E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CR15 . . ♦268474 .. Relay, Delay Fix 12vdc Spst (N.O.) 10a 30sec (Eff w/ME270030E) . . . . . 1
... 17 . . . . . . . . . . . . . . 177136 .. Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . C6 . . . . . 087110 .. Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 204737 .. Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 20 . . . . CR10 . . . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . 1
... 21 . . . . CR14 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 22 . . C10/D10 . . 189701 .. Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . TE2 . . . . 190210 .. Block, Term 5−3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . . 2

Big Blue 800 Duo Air Pak TM-259 705 Page 123
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-2. Control Box Assembly (Continued)

. . . 25 . . . . CB15 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . CB14 . . ♦139266 . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 1
. . . 27 . . CB3−CB4 . . 139266 . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .805 Od X .510 Id X .220 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . S5 . . . . . 028111 . . Switch, Tgl Dpst 20a 250v Spd Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . F1−F2 . . . 256852 . . Holder, Fuse Mintr W/10a Slo−Blo Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . *085874 . . . . Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

 Hardware is common and 6

not available unless listed.
5
2

3
1

19
8
10
9
18 11

17

12
16
14 13
15 259 461

Figure 17-3. Panel, Front Engine & Weld Controls

TM-259 705 Page 124 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-3. Panel, Front Engine & Weld Controls (Figure 17-1, Item 3)

. . . 1 . . . . . . . . . . . . . . 258833 . . Label, Nameplate Engine/Weld Control Airpak . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 258684 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . R1, R21 . . 246961 . . Switch, Rotary 8 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . . . 2
. . . 4 R2,R5,R22,R25 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . PC2, PC22 . 251527 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 258683 . . Enclosure, Dual Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . PC5, PC25 . 242263 . . Circuit Card Assy, Connector/Receptacle (R) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . CB9, CB29 . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .805 Od X .510 Id X .220 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S10 . . . . 206624 . . Switch, Tgl Sptt 6a 125vac (On)−On−(On)Spd Term . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . DISPLAY . . 256689 . . Display, Lcd Alphanumeric Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 218764 . . Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 242579 . . Screw, K40x 10 Pan Hd−Phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 134201 . . Stand−Off Support, Pc Card .312/.375w/Post&Lock .43 . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . 5
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 800 Duo Air Pak TM-259 705 Page 125
 Eff w/MD360063E And Following

 Hardware is common and 11

not available unless listed.

10

10 12

9
7

6 8

5
14
4
13
3
2
1

15

16
17 259 364

Figure 17-4. Panel, Weld Output

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-4. Panel, Weld Output (Figure 17-1, Item 1)

. . . 1 . . . . . . . . . . . . . . 005107 . . Bolt, Crg Stl .250−20 X .750 Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 2 . . . . . . . . . . . . . . 108941 . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 6 . . . . . . . . . . . . . . 258836 . . Label, Output Panel W/Parallel Airpak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 258685 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . C4, 5, 24, 25 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . 108940 . . Screw, 250−20x .75 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . 14
. . . 13 . . . . . S3 . . . . . 259356 . . Switch, Paralleling W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . . . . . 602208 . . Washer, Tooth.256idx0.510odx.028t Stl Pld Ext.250 A . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 189445 . . Screw, 250−20x .50 Pan Hd−Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 230339 . . Switch Handle W/Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-259 705 Page 126 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following
10
9
8
7
5 12
11
6

13

14

3
15

1 2

17

16

259 666
Figure 17-5. Panel, Auxiliary Power North America (Prior To ME260126E)

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-5. Panel, Auxiliary Power North America (Figure 17-1, Item 2)

... 1 .............. 209056 .. Cover,Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

... 2 .............. 197203 .. Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . RC5 . . . . 182954 .. Rcpt,Str 3p4w 50a 125/250v Flush Mtg *14-50 . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 259528 .. Label, Auxillary Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 248894 .. Panel,Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . GFCI1, 2 . . 246865 .. Rcpt, str dx grd 2P3W 20A 125V *5−20r GFI . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 025248 .. Stand-off,Insul .250-20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 214927 .. Boot,Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . C1−C2 . . . 217054 .. Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . CB1 . . . . 214926 .. Supplementary Protector,Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . . 1
... 11 . . RC1, RC2 . . 147632 .. Receptacle, Tw Lk Grd 2p3w 30a 250v L6-30r . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . RC4 . . . . 254094 .. Rcpt,Str 3p4w 50a 250v Flush Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . CB7, CB8 . . 093996 .. Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 14 .............. 190861 .. Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
... 15 .............. 201553 .. Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CB6 . . . . 201083 .. Supplementary Protector,Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . 1
... 17 .............. 190323 .. Boot,Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 800 Duo Air Pak TM-259 705 Page 127
 Eff w/MD360063E And Following

7
17
11
14

4 10
5
3

16
12

8
15 6

13

1
9

18
264 277

Figure 17-6. Panel, Auxiliary Power North America (Eff w/ME260126E)

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-6. Panel, Auxiliary Power North America (Figure 17-1, Item 2)

... 1 .............. 264275 .. Panel, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 264773 .. Label, Aux Power W/In Use Cover (Bw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 GFCI1−GFCI2 246614 .. Receptacle, Gfci 15/20a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . RC4 . . . . 254094 .. Rcpt, Str 3p4w 50a 250v Flush Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . RC1−RC2 . . 147632 .. Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . RC5 . . . . 182954 .. Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CB1 . . . . 214926 .. Supplementary Protector, Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . 1
... 8 . . CB7−CB8 . . 093996 .. Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 9 . . . . CB6 . . . . 201083 .. Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . 1
... 10 . . . C1−C2 . . . 217054 .. Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 11 .............. 214927 .. Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 201553 .. Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 209056 .. Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 14 .............. 207560 .. Insulator, Stand−Off With Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 197203 .. Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 190861 .. Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
... 17 .............. 263778 .. Guard, Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 .............. 263905 .. Cover, Receptacle Weatherproof Duplex Dual . . . . . . . . . . . . . . . . . . . . . . . 1

TM-259 705 Page 128 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following

 Hardware is common and 13 14

not available unless listed.
12

9 11
10

8
6
7
5 15

3 16
2 17
1
18

19

20
24 21
22
26 25
27 23 255 861

Figure 17-7. Generator

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-7. Generator (Figure 17-1, Item 36)

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−Pln Gr5 Pld Blk . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 264057 . . Endbell W/Exciter Stator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257974 . . . . Kit, Endbell w/O−ring (Includes)
. . . . . . . . . . . . . . . . . . . . 203635 . . . . . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 143220 . . . . . . O−Ring, 2.859 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 264060 . . . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 604538 . . . . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 172684 . . . . Nut, 312−18 .50hex .27h Stl Pld Sem Cone Wshr.76d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 604537 . . Nut, 312-18 .50hex .28h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 604538 . . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 261463 . . Screw, 312-18x4.50 Hex Hd-pln Stl Gr5 Pld Full . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . +260669 . . Stator, Weld/Power Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−Pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . . . . . . . . . . . 024617 . . Ring,Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 053390 . . Bearing,Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 251855 . . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 080389 . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . 8
. . . 11 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 8
. . . 12 . . . . . . . . . . . . . . 206242 . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 10
. . . 14 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 15 . . . . . . . . . . . . . . 210332 . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 800 Duo Air Pak TM-259 705 Page 129
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-7. Generator (Continued)

. . . 16 . . . . . . . . . . . . . . 191577 . . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 17 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199849 . . Screw, 625-11x4.00 Hex Hd-pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 602159 . . Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 189142 . . Brushholder, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 208469 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 25 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld Blk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . 604534 . . Screw, 312−18x1.25 Hex Hd−Pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-259 705 Page 130 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following

 Hardware is common and 22 23

not available unless listed. 21
20

24
19
18 25
26
27
28
29

16 17

15 30
32
31 70
14 82 80
68
81
13 33 69 79
67 78 77
34 66
12 71 72
35
73
36 61
10 62
37
11 38 40 39 63
74 76
9
64
42 65 75
8 43 44
7 41
45
5 6
60
46
47
4
48 59
2
3
50 58
1 49
51 53 55
57
56
52
54

255 862
Figure 17-8. Air Compressor

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-8. Air Compressor (Figure 17-1 Item 63)

... 1 .............. 233721 .. Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 206606 .. Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 210523 .. Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 209635 .. Hose, Tubing Oil Assy W/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 260299 .. Hose Assy, Air W/Fittings 3/4 X 37.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 071270 .. Ftg, Pipe Brs Tee St 1/4 Npt 071269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .............. 602887 .. Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 151662 .. Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 209621 .. Ftg, Stl Adapter 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 .............. 240354 .. Ftg, Stl Adapter 3/4 Sae-3/4 Jic 45 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 .............. 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 800 Duo Air Pak TM-259 705 Page 131
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-8. Air Compressor (Continued)

. . . 12 . . . . . . . . . . . . . . 260317 .. Hose, Nylon Blue 1/4 Id X 3/8 Od X 30-1/2 Lg . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . 210054 .. Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210040 .. Orifice/Muffler, Blowdown .120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 260318 .. Hose, Nylon Red 1/4 Id X 3/8 Od X 23-1/2 Lg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 249657 .. Air Cleaner, Intake 5.250 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 .. Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 254976 .. Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 253948 .. Bracket, Mtg Compressor (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 260374 .. Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 218305 .. Valve,Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 260374 .. Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 256685 .. Clutch, Electro Magnetic 12vdc W/8 Groove Pulley . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 210001 .. Airend, Gear-driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 206742 .. Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 209853 .. Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 209852 .. Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 260369 .. Ftg, Pipe Brs Elbow/Adapter M 1/8 Npt X 3/8 Od Line . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 253946 .. Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 253951 .. Bracket, Mtg Compressor (Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 210051 .. Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 206615 .. Sender, Pressure Oil 0- 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 209767 .. Ftg, Pipe Stl Connector M 3/4 Sae-npt Adapter . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 602965 .. Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 206746 .. Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 073655 .. Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 206937 .. Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 084999 .. Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 210053 .. Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 209787 .. Ftg, Pipe Stl Nipple Close 3/4 Npt Schedual 80 . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 206939 .. Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 127854 .. Clamp, Stl Cush 1.312 Dia X .343 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 260442 .. Stand-off, M12-1.75 Male X1/4-20 Fem .75 Hex 1.5 Lg . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 260323 .. Ftg, Stl Elbow M 90deg 3/4 X (Npt-jic 90deg) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 210058 .. Gauge, Oil Level (Modified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 247624 .. Pointer Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 209457 .. Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 209766 .. Ftg, Pipe Stl Tee Street 3/4 Npt M-f-f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 209457 .. Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 209638 .. Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 209639 .. Hose, Oil W/Fittings 23.320 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 210248 .. Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 260324 .. Ftg, Stl Elbow 45d 3/4-bspp(M) O-ring X 3/4 Jic M . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 214686 .. Ftg, Pipe Stl Elbow 90dg 3/4bspp O-ring X 3/4 Jic M . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . *206747 .. Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 210023 .. Filter, Seperator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 255515 .. Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 259231 .. Tubing, Sst .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 206743 .. Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 209754 .. Ftg, Stl Elbow 45 Deg 3/4 Npt (M) X 3/4 Jic (M) . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 209755 .. Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 209856 .. Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 214685 .. Hose Assy, Air W/Fittings 3/4 X 20.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 210027 .. Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 263516 .. Hose, Nylon White 1/4 Id X 3/8 Od X 33 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-259 705 Page 132 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-8. Air Compressor (Continued)

. . . 69 . . . . . . . . . . . . . . 258630 . . Hose, Tubing Oil Assy W/Fittings 42.500lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae-jic- . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 256486 . . Bracket, Mtg Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 209756 . . Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . *206745 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 206744 . . Thermostat, 170f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 210052 . . Valve, Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 260477 . . Ftg, Pipe Stl Tee Branch Sae-12 X Jic-12 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 256393 . . Ftg, Stl Elbow 90 Deg Ns 3/4 F Jic X 3/4 M Orfs . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 209851 . . Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
*Recommended Spare Parts.

Big Blue 800 Duo Air Pak TM-259 705 Page 133
 Eff w/MD360063E And Following

 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part

No. Mkgs. No. Description Quantity

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . . 258579 .. Harness, Engine Deutz (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 258583 .. Lead List, Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258962 .. Lead Assy, Elect W/Resistor & Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258958 .. Lead Assy, Twisted Pair W/Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 262762 .. Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258113 .. Cable, Interconnecting 3 Ft 6.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG12 . . . 215261 .. Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 238028 .. Conn, Deutsch 6p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG409 . . 177859 .. Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG13−PLG16 148850 .. Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . PLG400 . . 258798 .. Conn, Rect Quadlok Rcpt 94 Pos R Ang . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG400_1 . 258809 .. Conn, Rect Quadlok Cover 94 Posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG400_2 . 258807 .. Conn, Rect Quadlok Retainer Large 94 Posn . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG400_3 . 258808 .. Conn, Rect Quadlok Retainer Small 94 Posn . . . . . . . . . . . . . . . . . . . . . . . 1
PLG400_4,PLG401_5 258803 .. Plug, Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 .
PLG400_5,PLG401_4 258804 .. Plug, Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . PLG400_6 . 258811 .. Seal, Plug Single Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG401 . . 258794 .. Conn, Rect Quadlok Rcpt 60 Pos R Ang . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG401_1 . 258802 .. Conn, Rect Quadlok Cover 60 Posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG401_2 . 258805 .. Conn, Rect Quadlok Lever 60/94 Posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG401_3 . 258806 .. Conn, Rect Quadlok Retainer 60 Posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG402 . . 258716 .. Conn, Rect Mcp 62 Pos 1.5k/2.8mm Ra . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG402_1 . 258721 .. Conn, Rect Mcp Cover 62 Posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG402_3 . 240071 .. Plug, Cavity 2.5mm Din72585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PLG402_2,PLG403_2,
PLG405_2,PLG408_3 258720 .. Plug, Cavity 3.6mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . PLG402_4 . 240074 .. Seal, Plug Single Wire (5mm Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . PLG402_5 . 258719 .. Seal, Plug Single Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PLG403,PLG405 . . . . 258701 .. Conn, Circ Cpc 4skt Plug Cable Pushin Din72585 . . . . . . . . . . . . . . . . . . . 2
PLG403_1,PLG405_1 258708 .. Seal, Plug Single Wire (2.5mm Hole) Din72585 . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG404 . . 240077 .. Connector, Housing 2p Junior−Timer Geh . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG406 . . 240098 .. Connector, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG406_1 . 240099 .. Cap, Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG406_2 . 240100 .. Clamp, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG407 . . 258709 .. Conn, Rect Ng1 2pos Plug Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG407_1 . 258715 .. Seal, Plug Single Wire (8mm Hole) Ng1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG408 . . 258722 .. Conn, Circ Cpc 4pin Rcpt Panel Pushin Din72585 . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG408_1 . 258724 .. Seal, Plug Single Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 215265 .. Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 238029 .. Conn, Deutsch Wedge Lock 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG410 . . 212116 .. Conn, Deutsch 2P 1Row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212117 .. Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 259189 .. Harness, Air Compressor Air Pak (Includes) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S10 . . . . 206624 .. Switch, Tgl Sptt 6a 125vac (On)−On−(On)Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . C10/D10 . . 189701 .. Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB15 . . . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR10 . . . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . Mid . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 1
. . . . . . . . . Clutch . . . 212116 .. Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-259 705 Page 134 Big Blue 800 Duo Air Pak
 Eff w/MD360063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . . 258581 . . Harness, Weld Air Pak (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . PLG6,PLG26 193184 . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG7,PLG11,
. . . . . PLG27,PLG211 193183 . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . PLG5,PLG10,PLG20,
. . . . . PLG25,PLG210,
. . . . . . . . . PLG220 . . 113751 . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . PLG2,PLG9,PLG22,
. . . . . . . . . PLG29 . . . 150316 .. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . RC3,RC23 . 155129 .. Conn, Rect Univ 039 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 2
. . . . . . PLG8,PLG28 231708 .. Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 2
. . . . . . . . . . RC99 . . . . 158466 .. Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . RC98 . . . . 135133 .. Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC30 . . . . 229933 .. Conn, Rect Univ 039 10p/S 2row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259207 .. Cable, Lem 7 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 196602 .. Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 214933 .. Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . 214934 .. Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Big Blue 800 Duo Air Pak TM-259 705 Page 135
 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2014 Miller Electric Mfg. Co. 2014−01