Professional Documents
Culture Documents
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
) )
Big Blue 600 Air Pak
) )
Big Blue 800 Duo Pro
) )
Big Blue 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
21
17
19 20
16
18
15
14 22
6 7 13
74
10 72
5
9
23
11
19
12
24
11
87 101 103
102
116
118 104
108 107
117
109 105
111
112 106
3 110
114
2
4
115
1 119
120 113
126
125
121
124 122
123
PM-279640 Page 2 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
62
61 65
63
64
54
60
57
58
41 55
36 42
40 44
53 58
35
59 66
34 45 46 68
43
33
32 39
31 52 67
47 56
30 38 50
29 51
28 49
48 73
27
26 79 82 75
11 37 69
91 70 81
92 90
76 19
100 77
11
99 88 89
93 71 78
98 80
83
25 11
97
94
96 95
84
85
86
907752
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 3
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
. . . . . . . . . . . . . . . . . . . . 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
. . . 39 . . . . . . . . . . . . . . 254730 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 259354 . . Hose, Air Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 255768 . . Air Cleaner, Intake (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 254977 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 260285 . . Hose, Rbr .875 Id (Water Pump To Expansion Tank) . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 255770 . . Bracket, Mtg Alternator To Compressor Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . . 253942 . . Pulley, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 253963 . . Pulley, Idler 76mm Od 17mm Id 33mm W . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 253941 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 258014 . . Bracket, Mtg Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 253958 . . Tensioner, Auto Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 253940 . . Pulley, Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . *253944 . . Belt, Micro-v 8 Rib (Air Pak Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *265120 . . Belt, V 1/2 X 5/16 X 52 (Big Blue 800 Duo Pro) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 8 Blade Suction . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . Figure 1-11 . . Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 255666 . . Hose, Radiator Upper Deutz (2013 2.9 Liter) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 255667 . . Hose, Radiator Lower Deutz (2013 2.9 Liter) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . +259649 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 272498 . . Label, Notice Compressor Oil Fill (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 259648 . . Radiator/Oil Cooler 3 Row Core 1.500 In/Outlet (US) . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 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
. . . 62 . . . . . . . . . . . . . . 254275 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 260226 . . Extrusion, Rubber W/Adhesive .750 X .750 X 27.000 . . . . . . . . . . . . . . . . . 2
. . . 63 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 272341 . . Label, Warning Battery Explosion (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 255756 . . Guard, Fan Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 209612 . . Lever, Switch Lockout Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 209611 . . Switch, Disc Battery 2p 6-36 Volts (Prior to MK300718R) . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 285589 . . Switch, Battery Disconnect 2p 6-36V (Eff w/MK300718R) . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . *255765 . . Filter, Fuel Secondary (D2013 2.9l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . +259335 . . Bracket, Mtg Fuel Filters/Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 272555 . . . . Label, Notice Drain Water From Fuel Filter (En/Fr) . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 209093 . . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 206604 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 209092 . . Bracket, Mtg Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 209090 . . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 77 . . . . . . . . . . . . . +259532 . . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 260658 . . Label, Maintenance Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 278415 . . Label, Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 278439 . . Label, Fuel/Hour/Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 209059 . . Schematic, Air System (Big Blue Air Pak) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 260007 . . Label, Maintenance Deutz D2.9l4/Td2.9l4 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 209667 . . Latch, Paddle W/Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 210681 . . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 5
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
PM-279640 Page 6 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
20
21
19
17
27 23
12
18
28 25
1
30 16
29 8
24
2 22
15
31
7
13
4
10
5 3
11
9 26
Ref. 907752
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 7
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
PM-279640 Page 8 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
3
5
4
6
29
1
30
2
9 23
8
10
7
13
21
16 28
22
17
27 11
26
14
19
25
15 18
20 12
277068
24
Figure 1-3. Panel, Front Engine & Weld Controls, 800 Models
Figure 1-3. Panel, Front Engine & Weld Controls, 800 Models (Figure 1-1, Item 3)
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 9
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 1-3. Panel, Front Engine & Weld Controls, 800 Models (Continued)
1
10 5
6
9 26
2 7
13
27
29
16 24 11
17 25 20
21
15
14
18 22
19
277063
28 12
Figure 1-4. Panel, Front Engine & Weld Controls, Big Blue 600 Air Pak
PM-279640 Page 10 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 1-4. Panel, Front Engine & Weld Controls, Big Blue 600 Air Pak (Figure 1-1, Item 3)
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 11
Eff w/Serial No. MH260921R And Following
8 11
9
7 8
4
3 13
2
12 18
17
14
1
15
16 279623
PM-279640 Page 12 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
11
4
3
8
Ref. 279324
Figure 1-6. Panel, Weld Output, 600 Models
Figure 1-6. Panel, Weld Output, 600 Models (Figure 1-1, Item 1)
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 13
Eff w/Serial No. MH260921R And Following
6
4
5
7
17 3
14
11 10
12
16
13
9
1
2
15 9
18
271860-E
Figure 1-7. Panel, Auxiliary Power North America (Figure 1-1, Item 2)
PM-279640 Page 14 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
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
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 15
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
PM-279640 Page 16 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
18
13 14
1 9 9
19 10 10
24
4
3
22
2
15
8
21
15
6
7
23 6 11
20
8
16
7 5
12
17 Included With
Item 6
278908
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 17
Eff w/Serial No. MH260921R And Following
19 13 14
1 9 9
20 10 10
4
21
3
15
23
8
15
22 6
7
6 11
8
16
7 5
12
17 Included With
Item 6
24 279495
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 1-11. Air Compressor
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 19
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 21
Eff w/Serial No. MH260921R And Following
3 4
7
8
6 2
803 328
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.
PM-279640 Page 22 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R 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.
Wiring Harnesses
.................... 259189 .. Harness, Air Compressor Air Pak (Includes) (Prior to NA230715R) . . . 1
.................... 288377 .. Harness, Air Compressor Air Pak (Includes) (Eff w/NA230715R) . . . . . 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
. . . . . . . . . . CR11 . . . . 173069 .. Relay, Encl 12VDC Spdt 50A/30A 5pin Flange Mtg (Eff w/NA230715R) . 1
.................... 148850 .. Socket, Relay 5 Pin (Eff w/NA230715R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 23
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Wiring Harnesses
PM-279640 Page 24 Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak
Eff w/Serial No. MH260921R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Optional Components For Work Truck Configurations (907750001, 907750002, 907752001, 907752002)
Big Blue 600 Air Pak, 800 Duo Pro, And 800 Duo Air Pak PM-279640 Page 25
Miller Electric Mfg. LLC
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
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ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2020−01