TM-282374B 2019−01

Eff w/Serial No. MJ200857R

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 X Duo Air Pak

Deutz

For product information,

File: Engine Drive
Owner’s Manual translations,
and more, visit
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

 See the Miller Extranet for service memos that may aid in the repair of this product.
 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 Welder/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. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-17. Connecting To Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-18. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 − OPERATING WELDER/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-5. Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5-6. Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-7. Dynamic Dig Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-8. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-9. Lift-Arc TIG With Auto-Stop And Auto-Crater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-10. Voltage/Amperage Control With 14-Pin Remote Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-11. Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5-12. Summary File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5-13. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-14. Associating ArcReach Devices (ArcReach Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5-15. Operating Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5-16. Optional Air Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6-1. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
 TABLE OF CONTENTS

6-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7-3. Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7-5. Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7-6. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7-7. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7-8. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7-10. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7-11. Voltmeter/Ammeter Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7-12. Removing Optional Air Dryer For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9-2. Measuring/Discharging Input Capacitor Voltage Before Working On Unit . . . . . . . . . . . . . . . . . . . . . . . 57
9-3. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9-4. Troubleshooting Circuit Diagram For Welder/Generator (Use With Section 9-5) . . . . . . . . . . . . . . . . . 62
9-5. Troubleshooting Values For Circuit Diagram (Use With Section 9-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-6. Waveforms For Section 9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-7. Main Control Board PC1/PC21 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9-8. Main Control Board PC1/PC21 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-9. Filter Module PC4/24 Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9-10. Filter Module PC4/24 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9-11. IGBT Module LED Troubleshooting Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9-12. Engine Display Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9-13. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9-14. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SECTION 10 − SERVICING AND TROUBLESHOOTING AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 74
10-1. Component Location And System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10-2. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-3. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10-4. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10-5. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-6. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10-7. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10-8. Troubleshooting Air Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 11 − SERVICING AND TROUBLESHOOTING OPTIONAL AIR DRYER . . . . . . . . . . . . . . . . . . . . 84
11-1. Component Location For JP Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11-2. Air Dryer Operation And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11-3. Replacing Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11-4. Troubleshooting Optional Air Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SECTION 12 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12-1. Disassembly For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12-3. Replacing IGBT Modules/Heat Sink Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12-4. Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SECTION 13 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
SECTION 14 − ENGINE INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
SECTION 15 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
15-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
15-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
SECTION 16 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
 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

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
OM-282374C - 2018-11, safety_rtm 2018-01
 Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
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 install, operate, maintain, and wires together during testing and servicing.
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train-
ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog-
STATIC (ESD) can damage PC boards.
nize and avoid the hazards involved.  Put on grounded wrist strap BEFORE handling
boards or parts.
During servicing, keep everybody, especially children, away.
 Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ELECTRIC SHOCK can kill.
 Do not touch live electrical parts.
 Stop engine and remove input power plug from
receptacle (if applicable) before testing or re-
Using a generator indoors CAN KILL
pairing unit unless the procedure specifically YOU IN MINUTES.
requires an energized unit.
 Do not work on equipment unless it has been verified that the  Generator exhaust contains carbon monoxide.
machine case is not energized. This is a poison you cannot see or smell.
 Insulate yourself from ground by standing or working on dry insu-  NEVER use inside a home or garage, EVEN IF
lating mats big enough to prevent contact with the ground. doors and windows are open.
 Do not leave live unit unattended.  Only use OUTSIDE and far away from windows, doors, and
vents.
 If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
 When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
HIGH PRESSURE FLUIDS can injure or kill.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.  Engine fuel system components can be under
 Stop engine on inverter and discharge input capacitors according high pressure.
to instructions in Manual before touching any parts.  Before working on fuel system, turn off engine
to release pressure.
 If ANY fluid is injected in the skin seek medical help immediately.
MOVING PARTS can injure.
 Keep away from moving parts such as fans,
belts, and rotors.
 Keep away from pinch points such as drive
FUEL can cause fire or explosion.
rolls.
 Have only qualified people remove doors,  Stop engine and let it cool off before checking or
panels, covers, or guards for maintenance adding fuel.
and troubleshooting as necessary.  Do not add fuel while smoking or if unit is near
 Keep hands, hair, loose clothing, and tools any sparks or open flames.
away from moving parts.  Do not overfill tank; clean up any spilled fuel.
 Before working on generator, remove spark plugs or injectors
to keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on genera- FIRE OR EXPLOSION hazard.
tor components.
 Reinstall doors, panels, covers, or guards when servicing is  Do not place unit on, over, or near combustible surfaces.
finished and before starting engine.  Do not service unit near flammables.
Big Blue 800 X Duo Air Pak TM-282374 Page 1
 BATTERY EXPLOSION can BLIND.
 Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
 Stop engine before disconnecting or connect-
ing battery cables.
 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles.
 Observe correct polarity (+ and −) on batteries.
 Disconnect negative (−) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.
STEAM AND HOT COOLANT can burn.
 If possible, check coolant level when engine is
cold to avoid scalding.
 Always check coolant level at overflow tank, if
present on unit, instead of radiator.
 If the engine is warm, checking is needed, and there is no overflow
tank, follow the next two statements.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before completely
removing cap.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
 Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
FALLING EQUIPMENT can injure.
 Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
 Use correct procedures and equipment of adequate capacity to
lift and support unit.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
 Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
HOT PARTS can burn.
 Do not touch hot engine parts bare-handed.
 Allow cooling period before working on
equipment.
 To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
TILTING OR TIPPING can injure.
 Do not put any body part under unit while lifting.
 Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
 Be careful when working on stator and rotor assemblies.
TM-282374 Page 2
EXPLODING PARTS can injure.
 Failed parts can explode or cause other parts to
explode when power is applied to inverters.
 Always wear a face shield and long sleeves
when servicing inverters.
H.F. RADIATION can cause interference.
 High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with elec-
tronic equipment perform this installation.
 The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equipment
at once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OVERUSE can cause OVERHEATING.
 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit.
SHOCK HAZARD from testing.
 Stop engine or turn Off welding power source (if
applicable) before making or changing meter
lead connections.
 Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
 Read instructions for test equipment.
READ INSTRUCTIONS.
 Use Testing Booklet (Part No. 150 853) when
servicing this unit.
 Consult the Owner’s Manual for welding safety
precautions.
 Use only genuine replacement parts from the manufacturer.
 Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
formation at the beginning of the manual and in each section.
 Perform installation, maintenance, and service according to the
Technical Manual, industry standards, and national, state, and
local codes.
 Reinstall injectors and bleed air from fuel system according to
engine manual.
HYDRAULIC EQUIPMENT can injure
or kill.
 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
qualified person and following the manufacturer’s instructions.
 Do not modify or alter hydraulic pump or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
 Keep away from potential pinch points or crush points created by
equipment connected to the hydraulic system.
 Do not work under or around any equipment that is supported only
by hydraulic pressure. Properly support equipment by mechanical
means.
Big Blue 800 X Duo Air Pak
 HYDRAULIC FLUID can injure or kill.
 Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
 Relieve pressure before disconnecting or con-
necting hydraulic lines.
 Check hydraulic system components and all con-
nections and hoses for damage, leaks, and wear
before operating unit.
 Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
 Use a piece of paper or cardboard to search for
leaks−−never use bare hands. Do not use equip-
ment if leaks are found.
 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
 If ANY fluid is injected into the skin seek medical help immediately.
COMPRESSED AIR EQUIPMENT can
injure or kill.
 Before working on compressed air system, turn
off and lockout/tagout unit, release pressure,
and be sure air pressure cannot be accidentally
applied.
 Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
structions.
 Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
 Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
1-3. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals in-
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
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:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
Big Blue 800 X Duo Air Pak
COMPRESSED AIR can injure or kill.
 Before working on compressed air system,
turn off and lockout/tagout unit, release pres-
sure, and be sure air pressure cannot be acci-
dentally applied.
 Relieve pressure before disconnecting or con-
necting air lines.
 Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
 Do not direct air stream toward self or others.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and a
cap when working on compressed air system.
 Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
 If ANY air is injected into the skin or body seek medical help imme-
diately.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
 Release air pressure from tools and system be-
fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
For Diesel Engines:
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
 Always start and operate the engine in a well−ventilated
area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
TM-282374 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 2017−04

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

Safe3 2017−04

Keep your head out of the fumes.

Safe6 2017−04

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 2017−04

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

Safe20 2017−04

TM-282374 Page 4 Big Blue 800 X Duo Air Pak

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

Safe21 2017−04

Do not smoke while fueling or if near fuel.

Safe22 2017−04

Stop engine before fueling.

Safe23 2017−04

Do not fuel a hot engine.

Safe24 2017−04

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

Do not spray water on electrical parts, including Engine Control Unit (ECU).

Safe 118 2014−10

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2017−04

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2017−04

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

Safe91 2017−04

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

Big Blue 800 X Duo Air Pak TM-282374 Page 5

 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

<12.4 V
Read Owner’s Manual for battery maintenance information.

/ + − + −
Safe117 2014−06

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 2017−04

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

2-2. Miscellaneous Symbols And Definitions

 Some symbols are found only on CE products.

A Amperage Seconds Positive

V Voltage
Read Operator’s
Manual
Direct Current
(DC)

Hz Hertz Negative
Alternating
Current (AC)

TM-282374 Page 6 Big Blue 800 X Duo Air Pak

 Protective Earth Rated Load
(Ground)
Engine
n Speed

Engine Start Rated No−Load

Single Phase (Engine RPM)
n0 Speed

Engine Off
Three Phase (Engine Stop)
n1 Rated Idle Speed

Suitable For
Welding In An
Environment With
Increased Risk Of
Idle (Slow)
X Duty Cycle

Electric Shock

Off
Run (Fast)
h Hours

Maximum Power

On
Engine Belt
P1max Consumption

Engine−Driven
Air Compressor 3−Phase
Alternator with
Remote Rectifier
Air Compressor Circuit Breaker
Do Not Switch Supplementary
While Welding Protector
Air Filter
Output
Welding (General)
Call for
Maintenance
Shielded Metal
Arc Welding Previous
(SMAW) Check
Injectors/Pump
Flux Cored Arc
Welding (FCAW)
Check Valve
Clearance Next
Gas Metal Arc
Welding (GMAW)
Certified/Trained
Mechanic
Gas Tungsten Arc Menu
Welding (GTAW) /
Tungsten Inert
Gas (TIG) Spark Arrestor Cancel Function
Welding

Lift Arc TIG Air Cleaner View

Engine Oil Temperature

Enter

Fuel Filter Diagnostics

Engine Coolant Increase Arc Control

Battery (Engine)
U0 Rated No−Load
Voltage (OCV)
USB

Engine
U2 Conventional
Load Voltage
Push Button

Engine I2 Rated Welding

Current
Rotating Knob
And Push Button

Big Blue 800 X Duo Air Pak TM-282374 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

 This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Maximum Open-
Rated Output Dual Rated Output Single
Welding Mode Weld Output Range Circuit Voltage
Operator (Each Side) Operator
(Nominal)

20−400A Stick: 400A, 36 VDC, Stick: 800A, 38 VDC,

Dual Operator 100% Duty Cycle 100% Duty Cycle
CC/DC 95
40−800A TIG: 400A, 26 VDC, 100% TIG: 800A, 38 VDC, 100%
Single Operator Duty Cycle Duty Cycle

400A, 34 VDC, 100% Duty 800A, 38 VDC, 100% Duty

CV/DC 13−50V 95
Cycle Cycle

Generator Power Rating Engine Fuel Tank Capacity

Independent of Weld Output

Single-Phase, 4 kVA/kW, 34/17 A,
120/240 V AC, 50/60 Hz
Deutz TD2011L04w Oil-cooled, Four-cylinder,
3-Phase Generator (In addition to standard 25 gal (95 L)
Turbo-charged 63.4 HP Diesel Engine
4 kVA/kW Generator Power) Single-Phase/
Three-Phase, 12/20 kVA/kW, 50/48 A,
120/240 V AC, 50/60 Hz

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

A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06

B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range

−40 to 104°F (−40 to 40°C) −4 to 131°F (−20 to 55°C)

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07

TM-282374 Page 8 Big Blue 800 X Duo Air Pak

3-5. Dimensions, Weights, And Operating Angles
Dimensions
53.75 in. (1365 mm)
Height
(to top of exhaust)

28.5 in. (724 mm) G

(mtg. brackets turned in)
Width
30.75 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 27.5 in. (699 mm)
F 1 in. (25 mm)
30°
G 29.8125 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 907763

No fuel: 2020 lb ( kg) 802 161-A

W/fuel: 2195 lb ( 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.

Big Blue 800 X Duo Air Pak TM-282374 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 welder/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

100

80
DC VOLTS

60
Parallel Mode

40
Dual Operator
20 Minimum Settings

0
0 100 200 300 400 500 600 700 800 900

DC AMPERES

259 678-B

TM-282374 Page 10 Big Blue 800 X 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 X Duo Air Pak TM-282374 Page 11

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

4.00
3.75
3.50
No Air Output
3.25
3.00
2.75 With Air Output
2.50
2.25
US Gal./Hr.

2.00
Dual Weld Mode
1.75
1.50
1.25
1.00
0.75
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

268 071-A

Notes

TM-282374 Page 12 Big Blue 800 X Duo Air Pak

 SECTION 4 − INSTALLATION
4-1. Installing Welder/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

Tools Needed: 1 1

9/16 in. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

 Go to MillerWelds.com for more ! Do not weld on base. Welding on

information on truck installations.
Movement
! Do not move or operate unit where
it could tip.
 See Section 3-5 for lifting eye rating.
Airflow Clearance
NOTICE − Do not install unit where air flow
is restricted or engine may overheat.
Location/Mounting
! Always securely fasten welder/gen-
erator onto transport vehicle or
trailer and comply with all DOT and
other applicable codes.
base can cause fuel tank fire or ex-
To Bolt Unit In Place:
Remove hardware securing the four
plosion. Weld only on the four
mounting brackets to the base. Reverse
mounting brackets or bolt unit
brackets and reattach to base with original
down.
hardware.
NOTICE − Do not mount unit by supporting
the base only at the four mounting bracket- Mount unit to truck or trailer with 1/2 in. (12
s. Use cross-supports to adequately sup- mm) or larger hardware (not supplied).
port unit and prevent damage to base. To Weld Unit In Place:
1 Cross-Supports
Weld unit to truck or trailer only at the four
2 Mounting Brackets (Supplied) mounting brackets.
Mount unit on flat surface or use cross-sup-
ports to support base. Secure unit with
mounting brackets.
3 1/2 in Bolt And Washer (Minimum −
Not Supplied)
4 3/8-16 x 1 in. Screws (Supplied)

Big Blue 800 X Duo Air Pak TM-282374 Page 13

4-2. Grounding Generator To Truck Or Trailer Frame
! Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
! Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
! Use GFCI protection when operat-
And Vehicle Mounted Welding Gen-
erators.
! Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
4-3. Installing Exhaust Pipe
Tools Needed:
1/2 in.
TM-282374 Page 14
1 2
GND/PE
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
ing auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
rot_grnd2 2018−01 − 800652-D
1 Equipment Grounding Terminal (On
Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
 Electrically bond generator frame to ve-
hicle frame by metal-to-metal contact.
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Ref. 907 535-1 / 907 535−3 / Exhaust3
Big Blue 800 X Duo Air Pak
4-4. Connecting The Battery
Tools Needed:
1/2 in.
NOTICE − Lead acid batteries discharge
when stored in any temperature. Units that
are stored should have the battery
recharged every three months and before
being put into service. To preserve opti-
mum battery performance and life,
recharge battery in storage when the
open−circuit voltage drops to 12.4 volts
DC when measured across the battery
terminals.
! Connect negative (−) cable last.
NOTICE − Wait two minutes after engine
shutdown before disconnecting battery or
engine controller may be damaged.
4-5. Using The Battery Disconnect Switch
Big Blue 800 X Duo Air Pak
Battery is most easily accessed through
the rear panel. Remove battery access
panel from rear panel. Connect battery,
negative cable last. Reinstall battery ac-
cess panel.
 Do not allow the battery cables to
touch opposing terminals. When con-
necting the battery cables attach the
positive (+) cable to the positive (+)
battery terminal first, followed by neg-
ative (−) cable to negative (−) battery
terminal.
Conn_batt1 2014−11 802 168-E / S-0756-C
 Never start the engine when the
cables are loose or poorly connected
to the battery terminals.
 Never disconnect the battery while
the engine is running.
 Never use a quick battery charger to
start the engine.
 Do not charge battery with Engine
Control switch On.
 Always disconnect the negative (−)
battery cable before charging battery.
! 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.
907 634−2
TM-282374 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 15.

Full

Diesel

Full

907763 / 907 634−2

 Check all engine fluids daily.
 Automatic warning and shutdown indi-
cators are displayed on the Engine Dis-
play. See Section 14 for engine display
information.
Engine must be cold and on a level surface.
Automatic shutdown system stops engine if
oil pressure is too low or engine tempera-
ture is too high.
 This unit has a low oil pressure shut-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
NOTICE − Diesel engines in Miller equip-
ment are meant to operate optimally at mod-
erate to rated load. Using light or no load for
extended periods of time may cause wet-
stacking or engine damage.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe, see Section 15.
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Add fresh diesel fuel before starting (see
engine maintenance label for fuel specifica-
tions). Leave filler neck empty to allow room
for expansion.
Engine stops if fuel level is low.
Oil
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
add oil (see engine maintenance label).
 To improve cold weather starting:
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel in-
formation.
Use correct grade oil for cold weather
(see engine maintenance label or en-
gine manual).

TM-282374 Page 16 Big Blue 800 X 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 X Duo Air Pak TM-282374 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.
NOTICE − Do not exceed machine duty
cycle.
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
See Section 4-15 for proper cable size.
1 Electrode Holder Cables
2 Work Cables
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
trode holder cables to Positive (+) ter-
minals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
Positive (+) terminals and electrode holder
cables to Negative (−) terminals.
 Be sure Process Selector switches
are set correctly. See Section 5-4.

TM-282374 Page 18 Big Blue 800 X Duo Air Pak

4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
 Direct Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
1
! Stop engine.
! Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connec-
tions must be of the same polarity.
NOTICE − For common work connection,
Big Blue 800 X Duo Air Pak
Welder B (Right) Side
2
work cable must be able to carry combined
weld output of both modules (see Section
4-15 for proper cable size).
NOTICE − Do not exceed machine duty
cycle.
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
1 Electrode Holder Cables
2 Work Jumper Cable
3 Common Work Cable
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect common
work cable and work jumper cable to
Welder B (right) Negative (−) terminal. Con-
Tools Needed:
3/4 in.
1
258 836
nect other end of work jumper cable to
Welder A (left) Negative (−) terminal.
Connect electrode holder cables to Positive
(+) terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect common work
cable and work jumper cable to Welder B
(right) Positive (+) terminal. Connect other
end of work jumper cable to Welder A (left)
Positive (+) terminal.
Connect electrode holder cables to Nega-
tive (−) terminals.
 Be sure Process Selector switches are
set correctly. See Section 5-4.
TM-282374 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.
NOTICE − Do not exceed machine duty
cycle.
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
See Section 4-15 for proper cable size.
1 Wire Feeder Cables
2 Work Cables
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire
feeder cables to Positive (+) terminals.
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
cables to Positive (+) terminals and wire
feeder cables to Negative (−) terminals.
 Be sure Process Selector switches are
set correctly. See Section 5-4.

TM-282374 Page 20 Big Blue 800 X Duo Air Pak

4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
 Direct Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
! Stop engine.
! Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connec-
tions must be of the same polarity.
NOTICE − For common work connection,
work cable must be able to carry combined
Big Blue 800 X Duo Air Pak
Welder B (Right) Side
weld output of both modules (see Section
4-15 for proper cable size).
NOTICE − Do not exceed machine duty
cycle.
 For common work connection, work
cable must be able to carry combined
weld output of both CC weld output ter-
minals (see Section 4-15 for proper
cable size).
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
1 Wire Feeder Cables
2 Work Jumper Cable
3 Common Work Cable
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect com-
Tools Needed:
3/4 in.
258 836
mon work cable and work jumper cable to
Welder B (right) Negative (−) terminal.
Connect other end of work jumper cable to
Welder A (left) Negative (−) terminal.
Connect wire feeder cables to Positive (+)
terminals.
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect common
work cable and work jumper cable to Weld-
er B (right) Positive (+) terminal. Connect
other end of work jumper cable to Welder
A (left) Positive (+) terminal.
Connect wire feeder cables to Negative (−)
terminals.
 Be sure Process Selector switches
are set correctly. See Section 5-4.
TM-282374 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.
NOTICE − Do not exceed machine duty
cycle.
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
See Section 4-15 for proper cable size.
1 Electrode Holder Cable
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work
cable to Negative (−) terminal and elec-
trode holder cable to Positive (+) terminal.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cable to
Positive (+) terminal and electrode holder
cable to Negative (−) terminal.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and wire
feeder cable to Positive (+) terminal.
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
cable to Positive (+) terminal and wire feed-
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-282374 Page 22 Big Blue 800 X Duo Air Pak

4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
 Direct Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
2
! Stop engine.
! Failure to properly size and connect
weld cables may cause excessive
heat and start a fire, or damage your
machine.
NOTICE − When making weld connections
with a common work cable, connect weld
cable of adequate size between Negative
(−) weld output terminals, and connect a
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the
workpiece.
NOTICE − When using these connections
as a common work terminal, all connec-
tions must be of the same polarity.
NOTICE − For common work connection,
work cable must be able to carry combined
weld output of both modules (see Section
Big Blue 800 X Duo Air Pak
Welder B (Right) Side
3
4-15 for proper cable size).
NOTICE − Do not exceed machine duty
cycle.
 Use Dual Operator mode for CC and
CV welding (see Section 5-2).
1 Electrode Holder Cable
2 Wire Feeder Cable
3 Work Jumper Cable
4 Common Work Cable
For Direct Current Electrode Positive
(DCEP), connect common work cable and
work jumper cable to Welder B (right) Neg-
ative (−) terminal. Connect other end of
work jumper cable to Welder A (left) Nega-
tive (−) terminal.
Tools Needed:
3/4 in.
Ref. 251 340-A / Ref. 802 292-A
Connect electrode holder cable to one Pos-
itive (+) terminal.
Connect wire feeder cable to remaining
Positive(+) terminal.
 Be sure Process Selector switches are
set correctly. See Section 5-4.
For Direct Current Electrode Negative
(DCEN), connect common work cable and
work jumper cable to Welder B (right) Posit-
ive (+) terminal. Connect other end of work
jumper cable to Welder A (left) Positive (+)
terminal.
Connect electrode holder cable to one
Negative (−) terminal, and wire feeder
cable to remaining Negative (−) terminal.
 Be sure Process Selector switches are
set correctly. See Section 5-4.
TM-282374 Page 23
4-14. Making Single Operator CC Weld Connections
 Direct Current Electrode Positive
(DCEP) connections are shown.
Welder A (Left) Side
2
! Stop engine.
NOTICE − Do not exceed machine duty
cycle.
 Welder B (right) weld output terminals
are disabled in Single Operator mode.
Connect only to Welder A (left) termi-
nals for Single Operator mode opera-
tion.
TM-282374 Page 24
Welder B (right) Terminals
Inactive In Single Operator Mode
1
 Use Single Operator mode for CC weld-
ing only. Welder B weld output terminals
are disabled in Single Operator mode.
(see Section 5-2).
 See Section 4-15 for proper cable size.
1 Electrode Holder Cable
2 Work Cable
Tools Needed:
3/4 in.
258 836
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
to Negative (−) terminal and electrode hold-
er cable to Positive (+) terminal.
For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to Posit-
ive (+) terminal and electrode holder cable
to Negative (−) receptacle.
 Be sure Process Selector switch is set
correctly. See Section 5-4.
Big Blue 800 X 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 10 − 100% Duty Cycle
Duty Cycle Duty Cycle
Amperes 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)
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)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
700 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120)
800 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120) 4x4/0 (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, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08

4-16. Weld Output Terminals

! Turn off power before connecting
to weld output terminals.
! Do not use worn, damaged, un-
dersized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

1
2

output term1 2015−02

Big Blue 800 X Duo Air Pak TM-282374 Page 25

4-17. 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-282374 Page 26 Big Blue 800 X Duo Air Pak

4-18. Connecting To The Air Compressor
Open Position
Closed Position
! Air pressure is present at air shutoff
valve whenever Engine Display on
front panel indicates air pressure.
1 3/4 in. NPT Air Pressure
Fitting
2 Air Shutoff Valve
Connect air hose with 3/4 in. NPT fitting (not
supplied) to air shutoff valve.
Big Blue 800 X Duo Air Pak
1
Be sure valve is in open position when us-
ing air compressor.
The compressor runs and air pressure is
available whenever the engine is running
and the front panel Compressor switch is
moved to the On position (see Section 5-2).
Run engine at weld/power speed for maxi-
mum air compressor output. Compressor
output is reduced when engine is running at
idle speed.
! Stop engine and release air pres-
sure before servicing compressor.
907763
The air compressor will not start if still under
pressure. If air compressor is turned off,
wait for air pressure to bleed off (about 20
seconds) before turning air compressor on
again.
 Using the air compressor does not sig-
nificantly affect weld or generator pow-
er output.
TM-282374 Page 27
 SECTION 5 − OPERATING WELDER/GENERATOR
5-1. Front Panel Controls (See Section 5-2)

10 6 11 7 12 8

4 5 3 14 1

13

15

907763 / 277078

TM-282374 Page 28 Big Blue 800 X Duo Air Pak

5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls
1 Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed with no generator power or weld
load, and weld/power speed with load ap-
plied.
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 en-
gine damage.
2 Engine Display
See Section 14 for engine display informa-
tion.
Weld Controls
3 Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
When a remote control is connected to the
Remote receptacle, the Auto Remote Sense
(ARS) feature automatically switches volt-
age/amperage control to the remote control
(see Section 5-10).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage set-
tings.
If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am-
perage control adjusts voltage and amper-
age.
 If a remote device connected to Remote
Receptacle is faulty or is disconnected
during operation, the meters display
CHEK REMT (see Section 7-11). Clear
fault by stopping and restarting the unit or
by turning Process/Contactor switch to
another position.
4 Process/Contactor Switch
See Section 5-4 for Process/Contactor
switch information.
5 Adjust Control/Select Button
Adjust Control
With Process/Contactor Switch in any SMAW
or GTAW process, turn Adjust control to ad-
just preset amperage. With Process/Contac-
tor switch in any FCAW or GMAW process,
turn Adjust control to adjust preset voltage.
Select Button
Push the control to use as Select button.
Big Blue 800 X Duo Air Pak
 To access Arc Control setting, push and
hold Adjust control for 1 second, then re-
lease. Rotate counterclockwise to set
softer arc control. Rotate clockwise to set
stiffer arc control. Push Adjust control in
and release to save Arc Control setting.
Arc Control setting will time out after 5
seconds of inactivity.
 To access Service Menu, push and hold
Adjust control for 5 seconds, then re-
lease. See Section 5-5 for Service Menu
operation. Service Menu will time out af-
ter 5 seconds of inactivity.
Weld Meters
 Weld meters also work in combination to
display troubleshooting error codes (see
Section 7-11).
6 DC Voltmeter
Voltmeter displays preset voltage (GMAW/
FCAW welding) with contactor off, and actual
output voltage with the contactor on. Voltme-
ter displays voltage at the weld output termi-
nals, but not necessarily the welding arc due
to resistance of cable and connections.
To set voltage, turn Process/Contactor switch
to GMAW or FCAW position. Turn V/A control
until desired voltage is displayed on Volt-
meter. When welding is finished, voltmeter
displays average weld voltage and then de-
faults to preset voltage.
7 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A con-
trol until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays average weld amperage and then
defaults to preset amperage.
8 Arc Control Meter
Displays current Arc Control setting. Default
value for all processes is 0. Arc Control set-
tings adjust: DIG for SMAW processes, Auto
Stop for GTAW processes, and inductance
for FCAW and GMAW processes. For softer
settings, the LEDs to the left of the star illumi-
nate. For stiffer settings, the LEDs to the right
of the star illuminate. No Arc Control settings
are accessible for GTAW Remote and CAC-A
processes. See Section 5-6.
Other Receptacles
9 USB Receptacle
Allows software updates from a USB drive
(see Section 5-11). A summary file of record-
ed data from the unit will be saved to a USB
drive that is inserted (see Section 5-12).
Indicator Lights
10 Setup Light
Illuminates when in the Service Menu.
11 In Use Light
Illuminates when connected to an ArcReach
accessory.
12 Arc Control Light
Illuminates when in the Arc Control settings.
13 Welder Selector Switch
NOTICE − Do not switch under load.
Use switch to select Dual Operator or Single
Operator welding mode.
Place switch in Welder A/Welder B (dual op-
erator) position for CC and CV output from
Welder A (left) and Welder B (right) weld out-
put terminals. Control the weld output from the
terminals on each side using the weld con-
trols on that same side.
Place switch in Welder A (single operator)
position for weld output from Welder A (left)
weld output terminals only.
 Welder B (right) weld output terminals are
disabled in Single Operator mode. Con-
nect only to Welder A (left) terminals for
Single Operator operation.
Compressor Controls
14 Air Compressor Switch
Use switch to turn air compressor on and off.
Air pressure is present at the compressor air
shutoff valve whenever the compressor is
running. The compressor shuts off when the
engine stops. To use air, the compressor must
be turned on each time the engine is started.
The air compressor will not start if still under
pressure. If air compressor is turned off, wait
for air pressure to bleed off (about 20 sec-
onds) before turning air compressor on again.
15 Air Shutoff Valve
! Air pressure is present at valve when-
ever Air Pressure display (part of en-
gine display, see Section 14) indicates
air pressure.
Close valve to stop air flow when connecting
or changing tools or air hoses (see Section
4-18).
TM-282374 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 or other start-
ing fluids.
 If engine does not start, let engine
come to a complete stop before at-
tempting restart.
To Start:
1 Wait to Start/Preheating Display
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.
or Run/Idle position. Glow plugs function
automatically according to ambient tem-
Turn Engine Control switch to Start. Re-
lease Engine Control switch when engine
perature. The operator needs to pause at
starts.
either switch position while the engine con-
To Stop: turn Engine Control switch to Off
troller goes through the preheat sequence.
position.

Notes

TM-282374 Page 30 Big Blue 800 X Duo Air Pak

5-4. Process/Contactor Switch
1 Process/Contactor Switch
! Weld output terminals are
energized when Process/
Contactor switch is in an
Electrode Hot position and
the engine is running.
Use switch to select weld process
and weld output on/off control
(see table below).
Place switch in Remote On/Off
Switch Required positions to turn
weld output on and off with a de-
1
vice connected to the Remote re-
ceptacle.
Place switch in Electrode Hot
positions for weld output to be on
whenever the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Sec-
tion 5-9).

Ref. 277070-A

Process/Contactor Switch Setting Typical Process Applications (DC Only)

MIG solid wire and dual shield flux core use a voltage sensing (VS) feeder that does not
Output On – GMAW/FCAW (MIG)
require a control cable back to the welder/generator.

Output On – FCAW-S (Electrode FCAW (Flux Cored Arc Welding − self shielded) uses a voltage sensing (VS) feeder that
Negative) does not require a control cable back to the welder/generator.
OUTPUT ON

Output On − SMAW (STICK XX18

Stick welding with or without a remote amperage control. Strike an arc to start welding.
and STICK XX10)
Lift-Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
Output On – GTAW (Lift-Arc TIG) welder/generator to aid arc start. Can be used with or without a remote control. Auto
Crater option can be enabled/disabled using the Service Menu (see Section 5-5).
Output On – CAC-A (Air Carbon Arc
Gouging with or without a remote amperage control. Strike an arc to start gouging.
Gouging)
REMOTE ON/OFF REQUIRED

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

Remote ON/OFF Required - SMAW Stick welding with RHC-14 control allows remote On/Off and Amperage control. This can
(Remote Stick) help eliminate accidental arc strikes.

Remote ON/OFF Required - GMAW/ MIG solid wire and dual shield flux core using a constant speed feeder. Use feeders with
FCAW (Remote MIG) 14-pin remote voltage control, or use a Spoolmatic 30A with WC24 control.

Big Blue 800 X Duo Air Pak TM-282374 Page 31

5-5. Service Menu
1 Adjust Control/Select Button
Press and hold control for 5 seconds,
then release to access the Service
Menu. Rotate the knob to scroll
through the menu items. Press and
release the control to access the op-
1 tions and information within each
menu item.
Rotate the control counterclockwise
to decrease the value or select NO/
OFF. Rotate the control clockwise to
increase the value or select YES/
ON.
Press and release control to save se-
lection. After 5 seconds of inactivity,
the menu will time out and the selec-
tion will not be saved.

277078

Menu Item Selectable Item Description

Option(s)
HOT STRT LIMT OFF Disables Hot Start option.
(Only accessible in SMAW LIMT 1.25 Sets Hot Start current limit, selectable between 1.25 and 2.0 (0.25 increments) in
processes) SMAW XX10 and SMAW Remote.

LIMT 1.50 Sets Hot Start current limit, selectable between 1.5 and 3.0 (0.5 increments) in
SMAW XX18.
DIG RNGE 50 - 150 Sets current limit above preset amperage between 50 and 150 amps.
AUTO CRTR ATCR ON Enables Auto Crater option.
(Only accessible in GTAW
processes) ATCR OFF Disables Auto Crater option.

VRD* VRD ON Enables VRD (Voltage Reducing Device) option, lowering open-circuit voltage.
VRD OFF Disables VRD (Voltage Reducing Device) option.
SOFT WARE −− Displays the current revision of firmware installed.
FACT RSET* RSET YES Resets all settings to factory defaults.
RSET NO All settings remain at previous settings.
*On Side A, user must first select whether to apply settings to Side A only or to both sides.

TM-282374 Page 32 Big Blue 800 X Duo Air Pak

5-6. Arc Control Settings
 Arc Control is not active when the Process/Contactor switch is in the following positions:
Electrode Hot − CAC-A (Air Carbon Arc Gouging)
Remote ON/OFF GTAW (Remote TIG)

 Miller recommends Hobart filler metals.

Process/Contactor Switch Arc Control
SOFT Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT -12

 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance)

(1 to 25)
STIF 12
Voltage sensing feeder

SOFT Flat or horizontal welds with XX18 electrode with short weld cables
(−25 to −1)

 (0) Starting point for XX18, XX13, XX14, XX24, and XX22 electrodes

STIFF Minimizes stickiness with XX18, XX14, XX22, XX24, and XX13
(1 to 25) electrodes.

STOP Auto-Crater off (see Section 5-5). More sensitive Auto-Stop

(−5 to −1)

 (0) Starting point.

STOP Less sensitive Auto-Stop

(1 to 5)

Lift-Arc start. No Auto Crater allows full control on pipe welds with
short or long arc length. Auto Stop feature allows arc to be broken
without loss of shielding gas.

STOP Auto Crater on (see Section 5-5). More sensitive Auto-Crater

(−5 to −1) initiation

 (0) Starting point

STOP Less sensitive Auto-Crater initiation

(1 to 5)

SOFT
(−25 to −1)

 (0) Starting point

STIFF
(1 to 25)

Big Blue 800 X Duo Air Pak TM-282374 Page 33

Process/Contactor Switch Arc Control
SOFT Starting point for stainless steel wire (high inductance)
(−25 to −1)
SOFT -12
 (0) Starting point for mild steel wire

STIFF Starting point for aluminum wire (low inductance).

(1 to 25)
STIF 12
Starting point for dual shield flux core, vertical overhead
Wire feeder connects to
Remote receptacle STIF 25

5-7. Dynamic Dig Settings

Process/Contactor Switch Arc Control
SOFT Starting point for 3/32 rod
(−25 to −1)
SOFT -15
 (0) Starting point for XX10 electrode/open root vertical down joint

STIFF Stiffer, more rapidly responding arc

(1 to 25)

Dig Range
DIG Starting point for 3/32 rod
(50)
DIG RNGE 65
(100) Starting point for downhill pipe (factory default)

DIG RNGE 115

(150)

Arc Control
SOFT Flat or horizontal welds with XX18 electrode or 3/32 rod with short
(−25 to −1) weld cables

SOFT -15
 (0) Starting point for XX10, XX11, XX13, XX14, XX24, and XX22
electrodes

STIFF
(1 to 25)

Dig Range
DIG Starting point for 3/32 rod
(50)
DIG RNGE 65
Starting point for XX18 electrode

DIG RNGE 75
(100) Starting point for downhill pipe (factory default)

DIG RNGE 115

(150)

TM-282374 Page 34 Big Blue 800 X Duo Air Pak

5-8. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
1
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted too
high. If electrode sticks to
2 workpiece, use a quick twist to free
it.

5-9. Lift-Arct TIG With Auto-Stopt And Auto-Cratert

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 at Process/Contac-
tor 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-
Arc End With Auto-Stop piece contamination by using
Auto-Crater or Auto-Stop to end
1 2 3 the arc.

 See Section 5-5 to adjust

Auto-Stop and Auto-Crater.
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.
Arc End With Auto-Crater:
OR
 Remote control is not needed
when using Auto-Crater.
Arc End With Auto-Crater 1 While welding.
2 Lift torch slightly to start
1 2 3 4 Auto-Crater end (current is
reduced).
3 Lower torch. Weld current
ramps down.
4 Shielding gas continues until
shut off.
 Miller recommends Hobart
filler metals.

WM Marketing

Big Blue 800 X Duo Air Pak TM-282374 Page 35

5-10. Voltage/Amperage Control With 14-Pin Remote Accessory
1 Remote Receptacle
Connect optional remote control to
receptacle.
2 3  When a remote control is con-
nected to the Remote recep-
tacle, the Auto Remote Sense
feature automatically switches
voltage/amperage control to
the remote control. When a de-
vice is connected to the Re-
mote receptacle, remote volt-
age/amperage control is al-
ways available regardless of
the position of the Process/
Contactor switch.
2 Voltmeter
3 Ammeter
1

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 just Optional Remote Meters
Set TIG or STICK Process Control to 100%

CV Welding Max (205 A DC)

Output On: Voltmeter toggles

between preset and actual
output when not welding, ac-
tual 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 weld output

Set WIRE Process

0774 / Ref.272 446-B / Ref. 907 695

TM-282374 Page 36 Big Blue 800 X Duo Air Pak

5-11. Updating Software
Obtain the latest firmware to be loaded
from MillerWelds.com.
Copy the desired firmware to an approved
USB flash drive.
With the machine turned off, insert the
flash drive into the USB receptacle on the
front of the machine. Turn the Engine Con-
trol switch to the Run or Run/Idle position.
 Do not start the engine.
Big Blue 800 X Duo Air Pak
When the machine has powered up, if valid
files exist on the flash drive, the user is
prompted to confirm the start of the down-
load. The Voltmeter/Ammeter display
reads: AL? NO.
Confirm by rotating the Adjust Control/Se-
lect button clockwise to select YES. Then
press the Select button.
 After the update has started, do not
power down or remove the flash drive
until the update is complete.
During the download, the left meter display
indicates the active download with ALLC,
ALLW, AL C, or AL W. The right meter dis-
play indicates the percentage of the down-
load completed with a number from 0 to
100.
When the update has completed success-
fully, the machine restarts.
Failures are indicated on the meter display.
Correction of failed updates depends on
what type of failure occurred.
TM-282374 Page 37
5-12. Summary File
1 Summary File
Each time a USB stick is inserted
1 in the USB receptacle, a summa-
ry file is saved to the USB stick as
SummaryFile.txt.
“USB ACC” will display as the file
is written. File is complete when
display no longer shows “USB
ACC.”
The summary file provides diag-
nostic and weld information.

TM-282374 Page 38 Big Blue 800 X Duo Air Pak

5-13. Fuel/Hour Gauge Descriptions

Big Blue 800 X Duo Air Pak TM-282374 Page 39

5-14. Associating ArcReach Devices (ArcReach Models Only)

! Stop engine.
NOTICE − Do not exceed machine duty cycle.
Associating ArcReach Device To Engine Driven Welder/Generator
Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection
diagrams.
The welder/generator has the ability to associate automatically with an ArcReach device at power up. The Process/Contactor switch must
be set to an Output ON mode to associate with an ArcReach device.
See the ArcReach device Owner’s Manual to associate the device to the welder/generator.
When the association process is complete, the In Use light will be illuminated. Depending on the capabilities of the ArcReach device, the
Process/Contactor switch, Adjust Control/Select button, and Arc Control adjustment may be overridden.

The following ArcReach accessories are compatible with this welder/generator:

ArcReach Stick/TIG Remote ArcReach SuitCase Feeders ArcReach Smart Feeder

For Stick Or TIG Welding For MIG Or FCAW Welding For Advanced Wire Processes

When welder/generator is associated When welder/generator is associated When welder/generator is associated

with Stick/TIG Remote: with Suitcase X-TREME ArcReach with Smart Feeder, all controls switch
SMAW processes: Amperage, feeder, voltage and wire feed settings to the feeder, and the display reads
Electrode Type, and Arc Control are adjusted on the feeder. SMRT ACC.
settings are adjusted on the remote.  When using an ArcReach device,
GTAW and CAC-A processes: engine speed is always
Amperage settings are adjusted on the weld/power speed.
remote.

274460-A / 266206-D

TM-282374 Page 40 Big Blue 800 X Duo Air Pak

5-15. Operating Oil Pan Heater
1 Oil Pan Heater Plug
Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Heater rated at 300 watts.
! Do not run engine while oil
pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
power source when engine oil is
warm to eliminate possibility of oil
coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.
! The area near the oil pan
heater gets hot.
Disconnect plug to turn off heater.

Oil heater1 2018−01

Notes

Big Blue 800 X Duo Air Pak TM-282374 Page 41

5-16. 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 welder/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 7-12.
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.
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.

907763 / 803 228 / 803 229

TM-282374 Page 42 Big Blue 800 X Duo Air Pak

 SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. Export Auxiliary Power Receptacles
4
1 2
1 110 V 16 A AC Receptacle RC1
2 220 V 16 A AC Receptacle RC3
Receptacles supply 50/60 Hz single-phase
power.
3 Supplementary Protector CB7
CB7 protects GFCI1 and RC1 from over-
load. If supplementary protector opens, the
receptacles do not work. Press button to re-
set.
! Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
! Unplug power cord before attempt-
ing to service accessories or tools.
4 110 V 20 A AC Receptacle GFCI1
5 110 V 20 A AC Receptacle GFCI2
Big Blue 800 X Duo Air Pak
8 7
6
12
! Test GFCI monthly. See Section 6-2
for GFCI information and for reset-
ting and testing procedures.
6 Supplementary Protector CB1
CB1 protects RC5 from overload. If supple-
mentary protector opens, the receptacle
does not work. Place switch in On position
to reset.
7 400 V 30 A 3-Phase Receptacle RC5
Receptacle supplies 50/60 Hz three-phase
power
8 Supplementary Protector CB5
CB5 protects the auxiliary power winding
from over current. If CB5 opens, the 110 volt
receptacles and 220 volt receptacles do not
work. Place switch in up position to reset.
9 Earth Leakage Circuit Breaker ELCB1
ELCB1 protects receptacles RC3 and RC4
from overload and earth leakage fault. If cir-
cuit breaker opens, the receptacles do not
5
9
10
11
Ref. 264 998
work. Place switch in On position to reset
circuit breaker.
10 Supplementary Protector CB8
CB8 protects GFCI2 and RC2 from over-
load. If supplementary protector opens, the
receptacles do not work. Press button to re-
set.
11 220 V 16 A AC Receptacle RC4
12 110 V 16 A AC Receptacle RC2
Receptacles supply 50/60 Hz single-phase
power.
Maximum combined output of all standard
receptacles is 4 kVa/kW.
 At least once a month, run engine at
weld/power speed and press test but-
ton to verify ELCB1 is working properly.
 Generator power decreases as weld
output increases.
TM-282374 Page 43
6-2. GFCI Receptacle Information, Resetting, And Testing
 Alternate location for red
and green indicator LEDs.
5
 Orientation of receptacle may be different in other applications.
! Use GFCI protection when operat-
ing auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
! Unplug power cord before attempt-
ing to service accessories or tools.
1 120 V 20 A AC GFCI Receptacle
2 GFCI Receptacle Test Button
3 GFCI Receptacle Reset Button
4 Red GFCI Indicator Light (LED)
5 Green GFCI Indicator Light (LED)
 Red and Green indicator lights may be
combined in a single LED.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than fol-
low its intended safe path.
TM-282374 Page 44
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting/Testing GFCI Receptacle
! Test GFCI monthly.
! If Red LED blinks, stop using GFCI
receptacle and have it replaced.
! Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
2
RotGFCI1 2017-10
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and dis-
connect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place ignition switch in RUN
position, and press GFCI Reset button. Re-
connect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Testing GFCI Receptacles
Start engine and press the GFCI Test but-
ton. The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have GFCI replaced if any of the follow-
ing occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
Big Blue 800 X Duo Air Pak
Big Blue 800 X Duo Air Pak
7-1. Maintenance Label

NOTICE − The total initial oil fill requires approximately

18 qt (17 L). Service oil fill is 11 qt (10.4 L)
Check engine dipstick as filling. Do not overfill.
SECTION 7 − MAINTENANCE

TM-282374 Page 45
DEUTZ Service: http://www.deutzamericas.com
To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer. They are staffed with highly
qualified parts, service and engine specialists to handle your different needs.
The DEUTZ Service Desk enhances this support and can be contacted by completing and submitting the Service Support Form. 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.

7-2. 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 7-7
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 7-9,
500 oil and filter after initial 50 and Engine
Hours to 75 hours of use. Manual
See engine manual for oil
specifications.
 Oil  Oil Filter  Fuel Filters 
Weld Cables
Every Section 7-4,
FUEL
1000 OR 7-9, and
Hours 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

TM-282374 Page 46 Big Blue 800 X Duo Air Pak

7-3. Cleaning Unit
Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust.

NOTICE − Use of a power washer is acceptable; however, cover or avoid electrical parts and the Engine Control Unit (ECU) located on the upper
left side of the center upright.

7-4. Checking Generator Brushes

! Stop engine and let cool.
1 Generator Brush
Mark and disconnect leads at brushhold-
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 2018−01 / Ref 190823

7-5. Battery Replacement

! Stop engine.
1 Battery Locator Bracket
Mounting Holes
Access battery as shown in Section
4-4. Disconnect battery.
View From Top Of Unit
Remove J-bolts securing battery
Larger Battery and remove battery.
Smaller 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.

1
Tools Needed:

255 858

7-6. Battery Maintenance

Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.

Big Blue 800 X Duo Air Pak TM-282374 Page 47

7-7. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 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-
4 ing and the possibility of filter damage
makes cleaning a risk. Consider the
1 risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
2 ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
the safety element after servicing the pri-
Optional mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
customer supplied)
3 Service Indicator Window
4 Service Indicator Reset Button
5 6 7 8
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
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
cleanings.
Optional
5 Housing
9
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
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
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm) ! Do not clean housing with air
from element. 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-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
Blow Inspect (dust ejector down).

aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B

7-8. 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-282374 Page 48 Big Blue 800 X Duo Air Pak

7-9. Servicing Fuel And Lubrication Systems
Tools Needed:
! Stop engine and let cool.
! After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter
5 Secondary Fuel Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
maintenance label for oil/filter change in-
formation.
Big Blue 800 X Duo Air Pak
4 5
6
To replace fuel filters:
Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clock-
wise. For primary fuel filter, reconnect water
sensor. Bleed air from fuel system accord-
ing to engine manual.
Inspect fuel line, and replace if cracked or
worn.
Close doors.
To reset service reminder intervals shown
on the Engine Display, see Sections 14-12
and 14-13.
Ref. 907763 / Ref. 907 634−2
To drain sludge from fuel tank:
! Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
! Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while drain-
ing fuel tank.
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
TM-282374 Page 49
7-10. Engine/Generator Overload Protection
! Stop engine.
 When a supplementary protector, cir-
cuit breaker or fuse opens, it usually in-
dicates a more serious problem exists.
 See Section 10-5 for air compressor
overload protection.
See Section 5-16 for air dryer overload
protection.
1 Supplementary Protector CB9/CB29
CB9 and CB29 protect the 24 volt AC out-
put to remote receptacles. If CB opens,
weld output and 24 volt output to remote re-
ceptacle stops.
2 Supplementary Protector CB2
CB2 protects the engine control circuit. If
CB2 opens, the engine does not crank.
TM-282374 Page 50
3
4
6
5
7
3 Fuse F1
4 Fuse F2
F1 and F2 protect the stator exciter winding
from overload. If F1 opens, weld and gen-
erator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.
5 Supplementary Protector CB3
6 Supplementary Protector CB4
CB3 protects the engine weld control cir-
cuit. If CB3 opens, weld output stops,
meters will be blank; however, generator
power is still available.
CB4 protects the field flashing circuit. If
CB4 opens, the generator may not excite at
start-up and weld and generator power out-
put may not be available.
8
7
907763
7 Supplementary Protector CB14
Air dryer overload protection, see Section
5-16.
8 Supplementary Protector CB15
Compressor overload protection, see Sec-
tion 10-5.
9 Circuit Breaker CB10 (Not Shown)
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault is
corrected.
10 Circuit Breaker CB16 (Not Shown)
CB16 protects the glow plug circuit. If
CB16 opens, the glow plug will not operate.
CB16 automatically resets when the fault is
corrected.
Big Blue 800 X Duo Air Pak
7-11. Voltmeter/Ammeter Error Displays

IGBT TEMP
Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. Display Example

 When an error is displayed, normally weld output has stopped but generator power output may be okay.
 To reset error displays, stop unit and then restart. See below to reset CHEK REMT display.

Error Display Description

CHEK REMT Indicates a remote device connected to the Remote Receptacle may be faulty. CHEK REMT is also displayed whenever a
remote device has been connected to the Remote Receptacle and then disconnected. Clear fault by stopping and restarting
the unit, or by pressing and releasing the Adjust Control/Select button. If problem continues, check the remote device and main
control board PC1/PC21.

IGBT 1SHT Indicates the thermistor in IGBT module 1 has shorted. .

IGBT 1OPN Indicates the thermistor in IGBT module 1 is open.

IGBT 2SHT Indicates the thermistor in IGBT module 2 has shorted.

IGBT 2OPN Indicates the thermistor in IGBT module 2 is open.

IGBT TEMP Indicates an IGBT module has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle.
Keep engine access door closed when running unit to maintain proper cooling airflow past module. Allow unit to cool before
restarting.

MAX POWR Engine power limit exceeded, causing weld output to be temporarily reduced. Error clears after 5 seconds.

S/W ERR Software version mismatch occurred. Reload software update.

S/W BLD Software build mismatch occurred. Reload software update.

COMM LOSS Indicates a communication loss between control boards. Parallel mode will not function. Error can be cleared by pressing
and releasing the Adjust Control/Select button. Unit can operate in dual operator mode only after clearing error.

Big Blue 800 X Duo Air Pak TM-282374 Page 51

7-12. 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

TM-282374 Page 52 Big Blue 800 X Duo Air Pak

 Notes

Big Blue 800 X Duo Air Pak TM-282374 Page 53

 SECTION 8 − THEORY OF OPERATION
1 Engine
Engine supplies force to turn revolving 6
fields. 8 8
Control Relay CR5 Supplementary AC AC
Protector CB4 Receptacles Receptacles
Energizes at start-up to supply power to GFCI1, GFCI2, RC3, RC4
the exciter circuit and Control Board RC1, RC2
PC1. 5

2 Engine Control (ECU) 7 7

Fuses F1, F2
Components
1 Supplementary
Regulate engine speed in response to Protectors ELCB1
changes in weld or power load. Control CB5, CB7, CB8
interprets signal from engine sensors Control Relay
and maintains idle or weld/power speed. CR5
Current
Control relays CR4 and CR24 are pow- Feedback
ered by PC1 and PC21 to control the au- to PC1
tomatic idle function. The engine goes to
1 3 4
idle when both relays are energized. 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.
10
4 Stator Windings 26
Air Supplementary
Supply power to exciter, generator pow- Protector
er, and weld circuits. Compressor/
Clutch 7 CB9
5 Fuses F1 And F2
Supplementary
Protect exciter windings from overload. Protector 24 VAC
25 CB1
6 Supplementary Protector CB4
Protects the field flashing circuit. Control
Relay 8
7 Supplementary Protectors ELCB1, CR10
CB1, CB5, CB7, and CB8 AC
Receptacle
Protect AC receptacles from overload. RC5
8 AC Receptacles GFCI1, GFCI2 24
and RC1, RC2, RC3, RC4, RC5
Air Pressure Current Feedback
Provide connection points and power for Switch
auxiliary equipment. S11
9 Supplementary Protector CB3 9
Protects the power supply to control 23
boards PC1 and PC21. Supplementary
Protector
 The following descriptions use Side Air Compressor
Switch
CB3
A circuit diagram designators. Side S10
B has identical components with dif-
ferent designators. 2
See circuit diagram.
10 Supplementary Protector CB9 Engine
ECU
Provides overload protection for 24 volts
AC portion of Remote 14 receptacle.
11 Voltage/Amperage Control 15
Adjusts weld output amperage or volt- 2 2
age level.
Control
12 Process/Contactor Switch Glow Plug Relay CR8
Relay
Selects weld process and weld output CR4
Control
on/off control. Board
13 Arc Control PC1
Adjusts dig and hot start for Stick weld-
ing, inductance for MIG welding, and arc
stop parameters for Lift-Arc TIG weld-
ing.

TM-282374 Page 54 Big Blue 800 X Duo Air Pak

 14 Metering
Displays preset and actual (rectified
AC Or DC Control Circuits  Indicates Side A. Side B and filtered) values of the weld voltage
has identical components and amperage.
Weld Current Circuit with different designators. 15 Control Board PC1
See circuit diagram.
External Circuits or Controls weld output by changing the
Mechanical Coupling gate pulses to IGBT (power modules
PM1 and PM2) after comparing current
or voltage feedback to reference level
3φ Power set by voltage/amperage adjustment
control or remote control connected
through Remote receptacle.
Magnetic Coupling
When a remote control is connected to
the Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperage control to the remote
control.
16 Main Rectifier
Changes AC weld current to DC.
17 Burden Resistor R10
Provides a bleed path for a capacitor
18 27 22 bank C3.
Hall Device Filter Positive (+) 18 Hall Device HD1
Module Weld Output Provides current feedback signal to
HD1 PC4 Terminal PC1.
19 Stabilizer Z1
Smooths (filters) weld output current.
21 Electrode 20 Capacitor Bank C3
16 20 17 Filters the DC output voltage of main
IGBT rectifier.
Burden
Capacitor Power 21 IGBT Power Modules PM1 And
Main Resistor
Rectifier Bank C3 Modules PM2
R10
PM1 and
PM2 Power modules use pulse width modu-
lation to control the amount of output
from the welding generator.
22 Positive (+) And Work (−) Weld
Output Terminals
Provide weld output and allow manual
19 22 changing of output polarity.
Work (−) Weld 23 Air Compressor Switch S10
Stabilizer Output Turns air compressor on and off.
Z1 Terminal 24 Air Pressure Switch S11
Prevents control relay CR10 from ener-
gizing and compressor from running
Current
when system pressure is above 20 psi.
IGBT Feedback Work
Gating 25 Control Relay CR10
Signals Voltage CR10 energizes when air compressor
Feedback switch is closed to supply power to com-
15 pressor clutch.
26 Air Compressor/Clutch
Clutch engages when energized to op-
11 12 13 14 erate compressor. (See Section 11 for
additional air compressor information.)
Voltage/ Process/
Arc Control Metering 27 Filter Module PC4
Amperage Contactor
Control Switch Filters signals for ArcReach communi-
cation.

Big Blue 800 X Duo Air Pak TM-282374 Page 55

 SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting Flowchart

This flowchart is intended as a general guide only. Always read and follow the safety
information and specific instructions given elsewhere in this Technical Manual.

Note stock number and serial number of machine.

What does the operator say is wrong?
Gather Information What was the operator doing?
When and where does the problem occur?
Has any part of the system recently changed?

Check for signs of damage and for proper connections, gas

Visual Inspection supply, cable routing, consumables, and wire feed system.

For inverter power sources that have unknown problems or

Pre-Power Checks are not powering up.

Check for required input voltage, phases, and frequency.

Check Input Power Make sure power source and plugs are wired correctly. VAC
Make sure engine speed is set to correct RPM.

For important service memos and software updates.

Check Extranet It is possible the issue has already been identified and
addressed by Miller.

Check open-circuit voltage for each process and polarity.

Check OCV Check auxiliary power output if available.

Test machine under load with a load bank.

Load/Function Test Test all system functions.
Perform a weld test when possible.

Trouble1_2018-05

TM-282374 Page 56 Big Blue 800 X Duo Air Pak

9-2. Measuring/Discharging Input Capacitor Voltage Before Working On Unit
! 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 Resistor R 10
2 Side B Burden Resistor R210
Locate burden resistors.
3 Digital Multimeter
Check capacitor bank voltage
across burden resistors as shown.
Measure the DC voltage across
5 each burden resistor until voltage
4 drops to near 0 (zero) volts.
4 Side A Rectifier SR6
5 Side B Rectifier SR26
Proceed with job inside unit.
Reinstall cover and side panels, if
side panels are removed, when
finished.

 If the capacitor voltage does

not drop to near zero after sev-
eral minutes, use a bleeder re-
sistor of between 25 and 1000
ohms, at least 5 watts, #16
AWG 1000 volts DC insulating
rating wire to discharge the ca-
pacitor(s) .
6 Typical Bleeder Resistor
An example of a typical bleeder re-
sistor is shown on this page.

2
1

Typical Bleeder Resistor

25 to 1000 ohms,
5 watt resistor

Tools Needed: #16 AWG 1000 volts DC

insulation rating, approx
3/8 in. 3 in. (76 mm) leads

907763

Big Blue 800 X Duo AIr Pak TM-282374 Page 57

9-3. Troubleshooting Tables

 See Section 9-4 for test points and values and Section 16 and following for parts location.
 Use Testing Booklet (Miller Part No. 150853) when servicing this unit.
 See the Miller Extranet for service memos that may aid in the repair of this product.
 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 7-11). See Section 14 for engine display
information.

A. Welding

Trouble Remedy

No weld output; generator power output Check Voltmeter/Ammeter help displays (see Section 7-11) 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 receptacle (see Section 4-17).

Reset supplementary protector CB3 (see Section 7-10).

Reset supplementary protector CB9 and/or CB29 (see Section 7-10). Check for faulty remote device
connected to Remote 14 receptacle.

Check and secure connections to Remote receptacle (see Section 4-17).

Check continuity of resistor R8 and connections.

Check fuse F2, and replace if open (see Section 7-10). Check brushes and slip rings, weld excitation cir-
cuit, and the rotor.

Check connections between Process Switch and main control board PC1 or PC21.

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 9-4 and 9-5).

Check main control board PC1 and/or PC21 and connections, and replace PC1 and/or PC21 if necessary
(see Section 9-7).

Check voltage feedback wiring and main control board PC1 and/or PC21. Repair or replace as neces-
sary.

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

Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check integrated rectifier SR2, ca-
pacitor C6, and the rotor and brushes.

Check continuity of resistor R3 and connections.

Check integrated rectifiers SR1, SR2, and SR4, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-13).

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

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.

TM-282374 Page 58 Big Blue 800 X Duo Air Pak

 Trouble Remedy

Erratic weld output (continued). Remove excessive coils from weld cables.

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 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 9-4 and 9-5).

Check main control board PC1 and/or PC21 and connections, and replace PC1 and/or PC21 if
necessary.

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

Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check capacitor C6, integrated
rectifier SR2, and the rotor and brushes.

Increase Voltage/Amperage Adjust control setting.

Repair or replace remote control device.

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

Check main control board PC1 and/or PC21 and connections, and replace PC1 and/or PC21 if
necessary.

Low open-circuit voltage. Check position of Process/Contactor switch.

Check main control board PC1 and/or PC21 and connections, and replace PC1 and/or PC21 if necessary
(see Section 9-7).

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 4-17).

No 24 volt AC output at Remote recep- Reset supplementary protector CB9 and/or CB29 (24 volt) (see Section 7-10). If CB9 and/or CB29 contin-
tacle RC14. ues to open check devices connected to RC14.

B. Generator Power

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

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

Check fuse F1, and replace if open (see Section 7-10). 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.

Big Blue 800 X Duo AIr Pak TM-282374 Page 59

 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 7-10). If F1 is open, check condition of brushes and slip
rings and check rotor windings and insulation to chassis ground.

Check Voltmeter/Ammeter help displays if available (see Section 7-11).

Clean slip rings, and install new brushes if necessary (see Section 9-13).
Check integrated rectifier SR2, and replace if necessary.

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

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 (see Section 9-14).

Low output at generator power AC Check fuse F1 and replace if open (see Section 7-10). If F1 is open, check capacitor C6, integrated recti-
receptacles. fier 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 Reset receptacle supplementary protector CB1 (see Section 6-1). If it continues to open, check devices
receptacles; weld output okay. connected to receptacles.

Check wiring at receptacle RC5. Check receptacle and replace if necessary.

No generator power or weld output. Check fuse F2, and replace if open (see Section 7-10). 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
necessary.

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 9-14).

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. CB10 will automatically reset after several minutes if the cause of
over-current is corrected. (see Section 7-10). Check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 7-10). 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.

TM-282374 Page 60 Big Blue 800 X Duo Air Pak

 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 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).

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 14).

Check engine display for diagnostic codes (see Section 14). 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
7-10). Check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 7-10). 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 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 7-7 and 7-9).

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.

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 15).
wetstacking occurs.

Big Blue 800 X Duo AIr Pak TM-282374 Page 61

 9-4. Troubleshooting Circuit Diagram For Welder/Generator (Use With Section 9-5)

! Measure capacitor bank C3 voltage according to Section 9-2, and

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

V10 V10
V5, R3

V2, R2
V7

V6, R4 V10, R8
V4, R5

V3, R6
V1, R1 I2 V9 V8
I1
V9

V8, R7
Engine
Flashing control
V16 relay CR5
Diode

R14*
V19
R13* V14

R10

R11*
V21

V14 V18

V14

V20
R12*

V19

I3 V17
Air compressor clutch

 *See Section 9-5 to measure R11−R14.

TM-282374 Page 62 Big Blue 800 X Duo Air Pak
 V11 V22

V15

V13

V12, R9

V13 See Section 9-7

for PC1 and PC21
Information

281933-C

Big Blue 800 X Duo AIr Pak TM-282374 Page 63

9-5. Troubleshooting Values For Circuit Diagram (Use With Section 9-4)

a) Condition − 70F (21C); cold machine (no warm-up); no load; weld/power RPM unless noted.
b) Process/Contactor switch in Electrode Hot − Stick position unless noted.
c) Tolerance +10% unless specified.
d) Reference − single arrow references to circuit common (lead 42), double arrow reference to points indicated.
e) Wiring Connections − see Table 13-1
f) Stop engine before checking resistance

Voltage Readings

Designator Description Value Notes

V1 Rotor 96 volts DC
V2 Rotor 97 volts DC
V3 Exciter winding 109 volts AC
V4 Exciter winding 132 volts AC
V5 Exciter winding 132 volts AC
V6 Exciter winding 132 volts AC
V7 Exciter winding 264 volts AC
V8 Stator winding 264 volts AC
V9 Stator winding 132 volts AC
V10 Stator winding 64 volts AC
V11 Burden resistor R10 95 volts DC
V12 Power supply for 14-pin receptacle 24 volts AC
V13 Idle control relay CR4. CR24 12 volts DC at idle RPM
V14 Hot battery bus 12 volts DC
V15 Open Circuit Voltage VRD On:
Stick Hot: 29 volts DC; TIG Hot: 29 volts DC;
FCAW/MIG: 95 volts DC
VRD Off:
Stick Hot: 95 volts DC; TIG Hot: 29 volts DC;
FCAW/MIG: 95 volts DC
V16 Fuel pump 12 volts DC battery voltage with ignition switch S1 On
V17 Glow plugs when energized 12 volts DC with respect to chassis ground
V18 Engine control relay CR5 when energized 12 volts DC
V19 Glow plug relay CR8 12 volts DC when glow plugs are energized
V20 Air compressor clutch 12 volts DC with compressor running
V21 Oil 1.8 volts DC at idle RPM; 2.0 volts DC at high
speed
V22 Current Feedback 1 volt DC per 100 A of output
Resistance Readings

R1 Revolving field 22 ohms

R2 Revolving field 14 ohms
R3 thru R9 Various Less than 1 ohm
R10 Fuel level sender 30 ohms = full fuel tank
240 ohms = empty fuel tank
For R11-R14, unplug connectors and measure resistance down leads to component.
R11 Speed 304 ohms (leads 202, 203)
R12 Air Compressor Clutch 2.8 ohms (two leads of clutch connector)
R13 Temp 2.35k ohms (leads 200, 201)

TM-282374 Page 64 Big Blue 800 X Duo Air Pak

Designator Description Value Notes
R14 Actuator 2.3 ohms (leads 207, 208)
Amperage Readings

I1 Revolving field 4.4 amps ±5%

I2 Revolving field 7.0 amps ±5%
I3 Glow plug 50 amps inrush, 30 amps hot ±5%

9-6. Waveforms For Section 9-4

 The waveforms represent the output of the welder/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/ B. CV/DC Open-Circuit Voltage, Process/

Contactor Switch In Electrode Hot − Stick Contactor Switch In Electrode Hot − Wire
Position, Voltage/Amperage Control At Max Position, Voltage/Amperage Control At Max

20 ms 20 V
20 ms 20 V

gnd gnd

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

Test Equipment Needed:

Oscilloscope
Load Bank

Big Blue 800 X Duo AIr Pak TM-282374 Page 65

9-7. Main Control Board PC1/PC21 Testing Information
! Stop engine.
Test Equipment Needed: See Section 9-8 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Control Board PC1, PC21
Shown From Back
2 Receptacle RC9
3 Receptacle RC10
4 Receptacle RC11
5 Receptacle RC3
6 Receptacle RC4
7 Receptacle RC5
8 Receptacle RC6
9 Receptacle RC8
10 Receptacle RC2

Back of PC1

RC10 RC9
RC2 RC8 RC6 RC5 RC4 RC3 RC11

3 10 2 9 8 7 6 5 4

2
 Typical receptacle configura- PC Board Surface
tion. Pin 1 is denoted by dimple. 3 4

Ref. 273653-G

TM-282374 Page 66 Big Blue 800 X Duo Air Pak

9-8. Main Control Board PC1/PC21 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 in Stick position

e) Pins not listed are not used on this model

Receptacle Pin Description Value

RC11/RC211 1 USB Data + 0.0 to 3.3 volts DC

2 +5 volts DC +5 volts DC

3 USB Data − 0.0 to 3.3 volts DC

4 Ground Return 0 volts

5 Ground Return 0 volts

6 Ground Return 0 volts

7 Ground Return 0 volts

8 Ground Return 0 volts

RC3/RC23 1 Auxiliary Power Current Transformer + 0.0 to 3.3 volts AC

6 Auxiliary Power Current Transformer − 0.0 to 3.3 volts AC

RC5/RC25 1 Ground Return 0 volts

2 Engine Run/Idle 12 volts DC when active

3 Engine Crank 12 volts DC when active

8 Idle Speed Relay 0 volts when relay is active

10 Battery + + 12 volts DC

RC4/RC24 4 Engine Speed Feedback 24 volts AC

RC6/RC26 3 J1939 CAN High Ch1 Bus

4 J1939 CAN Low Ch1 Bus

5 J1939 CAN High Ch2 Bus

6 J1939 CAN Low Ch2 Bus

7 Parallel Mode 0 volts when active

RC8/RC28 1 +15 volts DC +15 volts DC

2 Current Feedback 0 to 15 volts DC

3 −15 volts DC −15 volts DC

4 Ground Return 0 volts

RC9/RC29 1 24 volts AC 24 volts AC

2 Ground 0 volts

Big Blue 800 X Duo AIr Pak TM-282374 Page 67

 Receptacle Pin Description Value
RC2/RC22 1 +15 volts isolated +15 volts DC

2 −10 volts isolated −10 volts DC

3 Isolated Ground 0 volts

4 PWM Signal −10 to +15 volts DC

7 IGBT 1 Temperature 0 to 2.5 volts DC

8 Ground Return 0 volts

9 +15 volts isolated +15 volts DC

10 −10 volts isolated −10 volts DC

11 Isolated Ground 0 volts

12 PWM Signal −10 to +15 volts DC

15 IGBT 2 Temperature 0 to 2.5 volts DC

16 Ground Return 0 volts

RC10/RC210 1 Weld Voltage Feedback + 0 to 100 volts DC (reference RC10−3)

2 Weld Voltage Feedback + 0 to 100 volts DC (reference RC10−4)

3 Weld Voltage Feedback − 0 to −100 volts DC (reference RC10−1)

4 Weld Voltage Feedback − 0 to −100 volts DC (reference RC10−2)

TM-282374 Page 68 Big Blue 800 X Duo Air Pak

9-9. Filter Module PC4/24 Troubleshooting Information
 All signals come from PC1.
1 LED1 (Red)
LED1 lights when contactor is on
and while welding. Indicates that fil-
ter is connected correctly.
2 LED2 (Red)
LED2 lights when contactor is on
and while welding. Indicates that fil-
ter is connected correctly.
3 RC1
4 RC2
5 RC3

Ref. 269 559-C / Ref 907763

9-10. Filter Module PC4/24 Test Point Values

PC4 Information
PC4 Receptacle/Pin Value
RC2 1 Side A Negative Stud, Z1 output to stud

RC1 1 Saturable core input voltage

RC3 1 Saturable core center tap voltage

PC24 Information
PC24 Receptacle/Pin Value
RC2 1 Z2 output to Parallel Switch S3

RC1 1 Local saturable core input voltage

RC3 1 Local saturable core center tap voltage

Big Blue 800 X Duo AIr Pak TM-282374 Page 69

9-11. IGBT Module LED Troubleshooting Indicators
 Voltage signals come from
PC1 for PM1 and PM2 on side
A IGBT assembly and from
PC21 for PM21 and PM22 on
1 side B IGBT assembly.
3 4 2 1 IGBT Assembly
2 LED1 (Green)
Lit when +15 volts DC supply is
present.
3 LED2 (Green)
Lit when −10 volts DC supply is
present.
4 LED3 (Yellow)
Lit when PWM signal is present in-
dicating that weld contactor is on
driving IGBTs.

907763 / 273649-B

IGBT MOD 1/21 Information

Plug/Socket PC1 PC1 Reference Value
Receptacle/Pin
PLG20 1 RC2 1 RC2 3 Power Supply: +15 volts DC from PC1, LED1 lights when supply is present

PLG20 2 RC2 2 RC2 3 Power Supply: −10 volts DC from PC1, LED2 lights when supply is present

PLG20 3 RC2 3 -- Isolated ground

PLG20 4 RC2 4 RC2 3 PWM signal from PC1, LED3 lights when signal is present

PLG20 5 RC2 7 RC2 8 +1.9 volts DC to PLG20−6 at room temperature

PLG20 6 RC2 8 -- Circuit common

IGBT MOD 2/22 Information

Plug/Socket PC1 PC1 Reference Value
Receptacle/Pin
PLG10 1 RC2 9 RC2 11 Power Supply: +15 volts DC from PC1, LED1 lights when supply is present

PLG10 2 RC2 10 RC2 11 Power Supply: −10 volts DC from PC1, LED2 lights when supply is present

PLG10 3 RC2 11 -- Isolated ground

PLG10 4 RC2 12 RC2 11 PWM signal from PC1, LED3 lights when signal is present

PLG10 5 RC2 15 RC2 16 +1.9 volts DC to PLG10−6 at room temperature

PLG10 6 RC2 16 -- Circuit common

TM-282374 Page 70 Big Blue 800 X Duo Air Pak

9-12. Engine Display Testing Information
1 Rear of Engine Display
See Section 14 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 at
Off/shutdown
5 Not Used
6 Ground Plug PLG12
Pin Description
8 31 ohms = full fuel tank
237 ohms = empty fuel tank

Test Equipment Needed:

Ref. 907763 / 256 689

Big Blue 800 X Duo AIr Pak TM-282374 Page 71

9-13. Replacing Brushes And Cleaning Slip Rings

Tools Needed:

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

907763 / 255 861 / Ref: 190 823

1
Replace
Damaged Brushes

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

TM-282374 Page 72 Big Blue 800 X Duo Air Pak

9-14. Checking Unit Output After Servicing
Check engine speeds. Engine speed ad-
justment must be done by the engine’s
factory authorized service agent.
1 AC Receptacles GFCI1, GFCI2
And RC1, RC2
1 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 RC3, RC4.
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 9-3).
3 Resistor R8
Place Process Selector switch in the
Stick position.
Check open-circuit voltage across weld
output terminals. There should be 87 − 92
volts DC present. If correct voltage is not
present, stop engine and reconnect lead
112 and/or lead 103 to different taps on
R8.

 Connect R8 leads so at least half of

! Stop engine before adjusting resistor length is in circuit.
resistors R3 and R8. 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.

2  Perform a load bank test to ensure

welder/generator operates properly
after servicing. Be sure load bank is
capable of handling the rated output
of the welder/generator being tested
3 (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,
repeat troubleshooting procedures.
! Stop engine and let cool.
Complete pre-operational checks in
table. Reinstall cover and side panels.
Test Equipment Needed:
Pre-Operational Checks

Wipe engine surfaces clean.

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 / 907763

Big Blue 800 X Duo AIr Pak TM-282374 Page 73

 SECTION 10 − SERVICING AND TROUBLESHOOTING
AIR COMPRESSOR
10-1. Component Location And System Operation
Theory Of Operation
 See illustration on adjacent page and
the sections referenced below to lo-
cate components.
1 Inlet Air Filter (Compressor Air Filter)
Removes contaminants from air entering
compressor (see Section 10-4 for loca-
tion).
2 Inlet Valve Assembly
Controls amount of air entering compres-
sor after receiving signal from pressure
regulator.
3 Compressor (Oil-Cooled Rotary
Screw)
Produces 125 psi (862 kPa) compressed
air when Air Compressor switch S10 is On.
4 Primary Oil Separator (Tank)
Separates most of the oil from the air leav-
ing compressor.
5 Oil Level Gauge
Indicates oil level in primary oil separator.
Read gauge only when compressor is Off
(see Section 10-6 for location).
6 Pressure Relief Valve (Safety Valve)
Automatically releases air when system air
pressure exceeds 150 psi (1034 kPa).
7 Air Pressure Switch S11
TM-282374 Page 74
Prevents air compressor from starting if
system air pressure is above 20 psi (138
kPa).
8 Pressure Gauge Sender
Provides system air pressure information
to front panel air pressure gauge.
9 Secondary Oil Separator
Removes remaining oil from air supply.
10 Separator Scavenge Check Valve/
Filter Orifice
One way valve and filter controls flow of oil
from secondary oil separator back to com-
pressor.
11 Minimum Pressure Check Valve
Maintains 50 psi (345 kPa) at compressor
outlet to keep oil circulating through sys-
tem.
12 Shutoff Valve
Controls air flow. Stops air flow when
closed (see Section 4-18 for location).
13 Pressure Regulator
Monitors system air pressure and sends
signal to inlet valve assembly to control air
flow into compressor.
14 Blow Down Valve
Relieves system air pressure when com-
pressor stops.
209 059-A
15 High Air Temperature Switch S12
Stops compressor if compressor air/oil
mixture temperature exceeds 248°F
(120°C).
16 Thermostatic Control Valve
Allows compressor oil to bypass oil cooler
(item 19) when oil temperature is cool; di-
rects oil through cooler when oil tempera-
ture exceeds 170°F (77°C).
17 Oil Filter
Removes contaminants from compressor
oil.
18 Oil Drain
Provides convenient location to drain oil
when servicing compressor (see Section
10-6 for location).
19 Oil Cooler (Radiator)
Cools compressor oil to help maintain cor-
rect system operating temperature.
20 Oil Fill
Provides convenient location to add oil to
compressor (see Section 10-6 for loca-
tion).
21 Air Dryers (Optional) − Not Shown
Remove excess moisture from com-
pressed air to prevent damage to tools and
other equipment.
Big Blue 800 X 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 X Duo Air Pak TM-282374 Page 75

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-282374 Page 76 Big Blue 800 X 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 X Duo Air Pak TM-282374 Page 77

10-4. Servicing Compressor Air Cleaner

1 ! Stop engine.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
damaged element is not covered by the
warranty.

 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.
NOTICE − If you decide to clean the pri-
mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
the safety element after servicing the pri-
mary element three times.
1 Compressor Air Cleaner
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
2 3 4 5 indicator.
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
cleanings.
2 Housing
3 Safety Element (Optional)
Optional 4 Primary Element
6 5 Cover
6 Dust Ejector
To clean air filter
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.
! Do not clean housing with air
hose.
Keep nozzle Clean primary element with compressed
2 in (51 mm) air only.
from element.
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 5/15*−907 634-2 / ST-153 929-B / ST-153 585 / Ref. S-0698-B

TM-282374 Page 78 Big Blue 800 X 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.

 See Section 7-10 for engine/gener-

ator 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.

907763

Big Blue 800 X Duo Air Pak TM-282374 Page 79

10-6. Servicing Air Compressor
3
! Stop engine and let cool. Wait 60 sec-
onds for system pressure to drop be-
fore changing oil.
1 Air Compressor Oil Filter
2 Secondary Air Compressor Air/Oil
Separator
3 Air Compressor Oil Drain Hose
w/Removable Cap
4 Air Compressor Oil Fill Cap
5 Air Compressor Oil Level Indicator
6 Air Compressor Primary Air/Oil
Separator Tank
7 Oil Scavenge Tube
TM-282374 Page 80
Air Compressor Assembly Right Side
7
2
1
To change compressor oil and filter:
 The engine oil drain and compressor oil
drain hoses are located together in the
base. Be sure to select the correct hose
when draining compressor oil.
 Be sure o-rings at oil drain and oil fill fit-
tings are in place before reinstalling caps.
Drain compressor oil while compressor is still
warm.
Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Re-
move cap from oil drain hose and drain oil into
a suitable container. Reinstall oil drain hose
cap. Tighten cap with wrench.
Remove filter by turning filter counterclock-
wise. Remove filter. Apply thin coat of oil to
gasket on new filter. Install new filter and turn
clockwise until tight.
Tools Needed: 7/8, 15/16 in.
5
Too
High
Full Full
Too
Low
907763 / 255 862-A
Add recommended oil until oil level indicator
shows system is full (see compressor mainte-
nance label for oil specifications). Reinstall oil
fill cap. Tighten cap with wrench.
To replace secondary air/oil separator:
Loosen nut securing oil scavenge tube on
separator base. Lift oil scavenge tube from
separator. Turn filter counterclockwise. Re-
move filter.
Apply thin coat of oil to gasket on new filter.
Install filter and turn clockwise. Reinstall oil
scavenge tube.
Start engine, run air compressor, and check
for oil leaks.
! Stop engine.
Big Blue 800 X 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

907763 / 255 862-A / Ref: 803 228

Big Blue 800 X Duo Air Pak TM-282374 Page 81

10-8. Troubleshooting Air Compressor System
 See Sections 10-1 thru 10-7 for normal air
compressor maintenance procedures See
Section 16 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. Re-
place 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 150 psi (1034 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 air 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. 195117).
moisture in compressed air.

TM-282374 Page 82 Big Blue 800 X Duo Air Pak

 Trouble
Oil in air from compressor.
Oil in compressor air cleaner.
Notes
Big Blue 800 X Duo Air Pak
Remedy
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.
 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.
TM-282374 Page 83
 SECTION 11 − SERVICING AND TROUBLESHOOTING
OPTIONAL AIR DRYER

! 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.
Dryer1_2018-01

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-282374 Page 84 Big Blue 800 X 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 welder/genera-
tor is running.
The timer control regulates the drying
and regeneration cycles of the air dry-
JP Models 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 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
CB14.
2 Timer Control LED
Verify dryer solenoid is functioning by
listening for dryer canisters to purge, or
2 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.

803 229 / 236 974 / 907763

Big Blue 800 X Duo Air Pak TM-282374 Page 85

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-
pressor may require service.
1
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 CB14 (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−systems.com.

TM-282374 Page 86 Big Blue 800 X Duo Air Pak

Notes

Big Blue 800 X Duo Air Pak TM-282374 Page 87

 SECTION 12 − DISASSEMBLY AND REASSEMBLY

12-1. Disassembly For Service

Lift Here

907763

TM-282374 Page 88 Big Blue 800 X Duo Air Pak

 ! Stop engine and let cool. Disconnect
battery negative (−) cable.
Use Section 9-3 to determine if trouble is in
stator, rotor, engine or combination of these
components.
These instructions will remove components
surrounding the engine/generator assembly;
thereby allowing the engine/generator as-
sembly to remain on the unit base.
When the front panel assembly and compo-
nents up to the center upright are removed,
the center upright needs to be supported.
Prepare proper supporting blocks.
Should it be necessary to remove the stator
or engine, prepare proper supporting blocks
to shim under the engine adapter
Remove exhaust pipe and fuel tank cap. Re-
move top cover, left side panels, and right
side panels. Replace fuel tank cap.
Big Blue 800 X Duo Air Pak
1 Auxiliary Power Panel
Remove hardware securing auxiliary power
panel. Tilt panel forward. Disconnect wires
from generator to CB1.
 To aid in reassembly, mark leads before
disconnecting. See lead list summary in
Table 13-1 for connection information.
Disconnect leads 11, 12, 13, 21, 22 and 23
from main rectifiers SR6 and SR26.
Disconnect remaining leads coming from the
stator.
2 Control Box
3 Resistors R3 and R8
4 Stabilizer Z1 and Z21
5 Valve Ball Box
Disconnect wires from fuel sender and dis-
connect wiring harness from engine and
wires from air compressor.
Disconnect resistors R3 and R8 and discon-
nect stabilizers Z1 and Z21.
Disconnect ground leads attached to base.
Disconnect plug at control box. Remove
screws securing control box to base.
Remove engine air intake hose. Remove
hardware from valve ball box located in lower
front panel. Remove steel air line clamp from
front to center upright brace. Remove steel oil
cooler line clamp from center upright.
Remove hardware securing front panel and
center upright to base and pull assembly up
and out of unit.
Go to Section 12-2.
Proceed with engine service/repair. When
service/repair is complete, reverse proced-
ure to reinstall upright. Tighten center upright
assembly hardware to 30 ft lb (41 N.m).
TM-282374 Page 89
12-2. Disassembly Of Generator
3
C
1
D B
NOTICE − Do not damage stator or rotor win-
dings during this procedure.
1 Brushes
Remove brushes from brushholder assembly
before disassembling generator.
2 Stator
With engine properly supported, remove
hardware securing stator to engine. Remove
the following parts as needed:
TM-282374 Page 90
Torques:
A 30 ft lb (41 N.m)
18 ft lb (24 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
255 861
3 Endbell with Exciter Stator Reassembly Instructions:
Exciter stator comes off with endbell. Reinstall engine and generator parts as
needed using torque values in table.
4 Rotor
Reinstall upright assembly. Reconnect fuel
If engine must also be removed, remove en-
line.
gine from base mounts.
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative (−) battery cable. Rein-
stall panels, doors, and exhaust pipe.
Big Blue 800 X Duo Air Pak
12-3. Replacing IGBT Modules/Heat Sink Assembly
A. Removing IBGT Assembly

! Stop engine and let cool. Discon-

nect battery negative (−) cable.
Remove top cover, left side panels, and
right side panels.
1 Mounting Bracket
2 Capacitor Pan
Remove hardware securing bracket to
pan. Remove bracket.
Disconnect plugs and output leads at
IGBT assembly.
Remove hardware securing IGBT/Ca-
pacitor assembly to the pan and remove
assembly from unit.

907763 / 907752

Big Blue 800 X Duo Air Pak TM-282374 Page 91

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-282374 Page 92 Big Blue 800 X Duo Air Pak

12-4. Torque Specifications
 All tolerances +10% unless specified.
282372-A

Part No. Description Qty. Where Used Torque Req.

601948 Screw, 312−18x1.00 Hex Hd−Pln Gr5 Pld 2 Base, Fuel Filter Assy To Bkt 15 ft lb
604534 Screw, 312−18x1.25 Hex Hd−Pln Gr5 Pld 2 Brushholder To Endbell 12 ft lb
004454 Screw, 625−11x1.00 Hex Hd−Pln Gr5 Pld 4 Center Upright To Base 140 ft lb
199849 Screw, 625−11x4.00 Hex Hd−Pln Gr5 Pld 2 Engine Mounts To Base (Left & Right) 100 ft lb
199849 Screw, 625−11x4.00 Hex Hd−Pln Gr5 Pld 2 Generator Mounts To Base 100 ft lb
223287 Screw, M 6−1.0x 16 Pan Hd−Torx Slffmg 1 Mag Pickup To Bkt 69 in. lb
208424 Screw, M 6−1.0x 90 Soc Hd−Hex Pln 12.9 Din 912 2 Comp Rear Bkt To Comp 10 ft lb1
605579 Screw, M 8−1.2x 20 Hex Hd−Pln 8.8 Pld 1 Alternator Tension Bkt To Fan/Alt Bkt 20 ft lb
605579 Screw, M 8−1.2x 20 Hex Hd−Pln 8.8 Pld 4 Fan Blade To Water Pump Pulley 20 ft lb
605579 Screw, M 8−1.2x 20 Hex Hd−Pln 8.8 Pld 1 Comp Rear Bkt To Engine 20 ft lb
192686 Screw, M 8−1.25x 25 Hex Hd−Pln 8.8 Pld Din933 1 Fuel/Comp Brkt To Engine 20 ft lb2
192686 Screw, M 8−1.25x 25 Hex Hd−Pln 8.8 Pld Din933 4 Inlet Valve To Comp 20 ft lb
218558 Screw, M 8−1.2x 50 Hex Hd−Pln 8.8 Pld 4 Manifold To Comp 20 ft lb
208422 Screw, M 8−1.25x 90 Hex Hd−Pln 8.8 Full Thd Din933 1 Fan/Alt Bkt To Engine 20 ft lb
208422 Screw, M 8−1.25x 90 Hex Hd−Pln 8.8 Full Thd Din933 2 Compressor/Muffler Bracket To Engine 20 ft lb
208423 Screw, M 8−1.25x 100 Hex Hd−Pln 8.8 Full Thd Din933 1 Fan/Alt Bkt To Engine 20 ft lb
208423 Screw, M 8−1.25x 100 Hex Hd−Pln 8.8 Full Thd Din933 1 Muffler To Compressor/Muffler Bracket 20 ft lb
198447 Screw, M10−1.5x 20 Hex Hd−Pln 8.8 Pln 1 Idler Pulley To Engine 30 ft lb
049026 Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln 4 Rotor To Engine 30 ft lb
172555 Screw, M10−1.5x 50 Hex Hd−Pln 8.8 Pld 4 Crankshaft Pulley To Engine 30 ft lb
172555 Screw, M10−1.5x 50 Hex Hd−Pln 8.8 Pld 6 Barrel To Engine Adapter 30 ft lb
210821 Screw, M10−1.5x 60 Soc Hd−Pln 8.8 Pld 1 Belt Tensioner 35 ft lb
183915 Screw, M10−1.5x100 Hex Hd−Pln 8.8 Pld 1 Fan/Alt Bkt To Engine 30 ft lb
044772 Screw, M12−1.75x 30 Hex Hd−Pln 8.8 Pln 1 Compressor To Compressor Bkt 80 ft lb
044772 Screw, M12−1.75x 30 Hex Hd−Pln 8.8 Pln 4 Plate, Mtg Compressor To Alternator Bkt 80 ft lb
208426 Screw, M12−1.75x 45 12pt Flange Screw 12.9 1 Muffler Bkt To Comp Bkt 60 ft lb
270730 Screw, M14−2.0x 30 Hex Hd−Pln 8.8 Pln 4 Engine Mounts To Engine 100 ft lb
208421 Screw, M20−2.5x110 Soc Hd Cap Din 912 12.9 Pln 1 Fan Pulley To Bkt 100 ft lb
220439 Stud, Stl 12mm−1.75 X 80mm Pld Full Thrd 2 Compressor To Compressor Bkt 60 ft lb
208497 Nut, M08−1.2 13mmhex 8.3mm T Stl Pld Sem Con Washer 3 Muffler To Turbo 20 ft lb
Rectifier Rectifier Nuts 6 Rectifiers To Brkt 10 ft lb3
Deutz Long Alternator Bolt (Reuse) 1 Alternator 20 ft lb
Deutz Short Alternator Bolt (Reuse) 1 Alternator 20 ft lb
173336 Ftg, Adapter Oil Drain 1 Engine Oil Drain Connection To Oil Pan 50 ft lb
267180 Clamp, Hose .500 − .906 Clp Dia W/Sst Screw 2 Fuel Line Clamps (1/2” Line) 40 in. lb4
209635 Hose, Tubing Oil Assy W/Fittings 42.360lg 1 Tube To Valve Box Only 80 ft lb
239507 Hose, Tubing Oil Assy W/Fittings 22.380lg 1 Connection To Engine Only 80 ft lb
209762 Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−Jic− 1 Connect To Engine Cooler 80 ft lb
209623 Ftg, Stl Adapter Long 3/4 Sae−3/4 Jic 1 Connect To Engine Cooler 80 ft lb
209764 Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 1 Connect To Engine Cooler 80 ft lb
209756 Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae 1 Connect To Engine Cooler 80 ft lb
210251 Ftg, Stl Swivel Straight Thread Conn 3/4 O−Ring 2 Connect To Engine Cooler 80 ft lb
209825 Ftg, Stl Adapter Swivel 12m X Jic−12 F 1 Connect To Engine Cooler 80 ft lb
210250 Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg 1 Connect To Engine Cooler 80 ft lb
209633 Hose, Tubing Oil Assy W/Fittings 20.000lg 1 To Radiator Assembly 80 ft lb5
1 Replace 2 comp screws
2 Replaces screw already in engine
3 Nuts come with rectifiers
4 Leave clamp loose at filter
5 Both ends

Big Blue 800 X Duo Air Pak TM-282374 Page 93

Notes

TM-282374 Page 94 Big Blue 800 X 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 X Duo Air Pak MJ200857R and following 281933-C See Table 13-1

Big Blue 800 X Duo Air Pak TM-282374 Page 95

 Figure 13-1. Circuit Diagram For Welder/Generator
TM-282374 Page 96 Big Blue 800 X Duo Air Pak
 281933-C

Big Blue 800 X Duo Air Pak TM-282374 Page 97

 Table 13-1. Lead List Summary For Big Blue 800 X Duo Air Pak Eff w/Serial No. MJ200857R 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. 146557) 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 BUS PLATE (−) TO R3 42Q BRUSH (FRONT) TO R3
POSC BUS PLATE (+) TO R3 42R R3 TO PLG98 (9)
−−−− 42T PLG25 (1) TO TE2 (A/B)
11A WELD STATOR TO SR6 42TT CR1 (85) TO GND STRIP (BOTT)
12A WELD STATOR TO SR6 42W COMPRESSOR CLUTCH TO GROUND TERMINAL
13A WELD STATOR TO SR6 42X GND STRIP (BOTT) TO CR10 (B)
15A BUS PLATE (−) TO SR6 (−)(MASTER) 42Z GND TO TE2 (A/B)
16A Z1 TO MOD1/MOD2 BUS BAR (MASTER) 42ZZ PLG101 (1) TO GND STRIP (BOTT)
18A BUS PLATE (+) TO SR6 (+)(MASTER) 43A CR1 (30) TO STARTER
18C S3 (1) TO POS OUTPUT STUD (A+) 44B CB10 (SIL) TO CR10 (4)
18D PLG10 (2) TO RC30 (4) 44C CR14 TO CB10 (SIL)
18D POS OUTPUT STUD (A) TO POS BUS PLATE (LOOSE) 44D CB10 TO CR5 (1)
18E POS FILTER MODULE (A) TO POS BUS PLATE (A+) 44E CB2 TO CR5 (1)
18F S3 (1) TO PLG30 (4) 45A CB16 (SIL) TO CR8 (87)
20A Z21 TO MOD21/MOD22 BUS BAR 46A PLG101 (18) TO CR4 (30)
21A WELD STATOR TO SR26 46B CR4 (30) TO CR24 (30)
22A WELD STATOR TO SR26 48A SPLICE (WIRE 48B) TO S1 (PLG409)
23A WELD STATOR TO SR26 48B PLG5 (2) TO LEAD 48A
24A BUS PLATE (+) TO SR26 (+)(SLAVE) 49A PLG4 (1) TO CR5 (5)
24B S3 (2) TO POS BUS PLATE (B+)(LOOSE) 49B S1 (1) TO CR5 (5)
24C PLG210 (2) TO RC30 (2) 51A PLG4 (4) TO CR5 (6)
24E POS FILTER MODULE (B) TO POS BUS PLATE (B+) 52A CB2 TO S1 (B)
24E S3 (2) TO PLG30 (2) 52B CB2 TO CR5 (3)
25A BUS PLATE (−) TO SR26 (−)(SLAVE) 54B FUEL PUMP (+) TO RC409 (1)
26A PLG210 (3) TO RC30 (3) 56A CR1 (86) TO S1 (S)
26B S3 (5) TO Z2 (LOOSE) 56C TE2 (D) TO PLG5 (3)
26C S3 (5) TO PLG30 (3) 56D TE2 (D) TO PLG25 (3)
26H FILTER MODULE (SLAVE) TO S3 (5) 57A PLG100 (3) TO CR8 (85)
27A S3 (3) TO POS OUTPUT STUD (B+) 60A D12 (CATH) TO ALT (D+)
28A S3 (6) TO NEG OUTPUT STUD (B−) 61A CR14 (86) DRYER OPTION TO TE3
30B PLG10 (3) TO RC30 (8) 61B CR1 (87A) TO CR5 (4)
30C S3 (4) TO PLG30 (8) 61C D12 (ANODE) TO TE3
30D S3 (4) TO NEG OUTPUT STUD (A−) 61E S10 (6) TO TE3
30E NEG OUTPUT STUD (A) TO Z1 (LOOSE) 61P CR5 (4) TO TE3
30H FILTER MODULE (MASTER) TO NEG OUTPUT STUD 61Q PLG101 (14) TO TE3
(MASTER) 61R PLG102 (A) TO TE3
40A CB3 TO TE2 (C) 61T TE3 TO CR8 (86)
40B CR24 (85) TO TE2 (C) 61U TE3 TO TE3
40C PLG5 (10) TO TE2 (C) 66A PLG3 (1) TO CT LEAD
40E PLG25 (10) TO TE2 (C) 67A PLG3 (6) TO CT LEAD
40G TE2 (C) TO CR4 (85) 71C PLG12 (8) TO FUEL SENDER
41A PLG101 (17) TO CR4 (87A) 72A AIR PRES SENDER (2) TO PLG12 (7)
41B CR4 (87A) TO CR24 (87A) 73A CB8 (30) TO GLOW PLUGS
42AA GND STUD TO RC3 (PE) 74A PLG5 (8) TO PLG15 (86)(CR4)
42AB RC1 (PE) TO RC3 (PE) 75A PLG101 (11) TO PLG102 (K)
42AC RC4 (PE) TO RC3 (PE) 76A PLG101 (10) TO PLG102 (L)
42AD RC4 (PE) TO RC2 (PE) 77A PLG101 (2) TO PLG102 (B)
42AE RC4 (PE) TO GFCI 2 (GREEN) 80A EXCITER STATOR TO TE1 (E−LEFT)
42AE D10 (ANODE) TO GND STRIP (BOTT) 80B TE1 (F) TO PLG9 (2)
42AF RC1 (PE) TO GFCI 1 (GREEN) 80C TE1 (F) TO PLG29 (2)
42AG GND STUD TO NEUTRAL STUD 81A EXCITER STATOR TO TE1 (F−LEFT)
42AG CR14 (85) DRYER OPTION TO GND STRIP (BOTT) 81B TE1 (E) TO CB9
42AH GROUND STUD TO RC5 (PE) 81C PLG4 (4) TO CB9
42BA CHASSIS GND TO GND (BOTTOM) 81D CB9 TO CB29
42BA CHASSIS GND TO GND (BOTTOM) 81E PLG24 (4) TO CB29
42BB CHASSIS GND TO GND STUD (AUX POWER PANEL) 84A GFCI 1 (LINE−HOT) TO CB7
42BC CHASSIS GND TO TE1 (F−LEFT) 85A GFCI 2 (LINE−HOT) TO CB8
42BC CHASSIS GND TO TE1 (F−LEFT) 89A STATOR TO EXIT
42C PLG4 (6) TO GND STRIP (BOTT) 89B NEUTRAL STUD TO RC5 (N)
42D AIR PRESSURE SENDER (1) TO BASE RAIL 90A EXCITER STATOR TO TE1 (C−LEFT)
42EA 90B TE1 (C−RIGHT) TO ELCB 1 (LINE)
42EA 91A EXCITER STATOR TO TE1 (B−LEFT)
42EJ FUEL PUMP (−) TO RC409 (2) 91B TE1 (B−RIGHT) TO CB5 (LINE RIGHT)
42F BASE RAIL TO ENGINE GND STRAP 92A EXCITER STATOR TO TE1 (A−LEFT)
42G FUEL SENDER TO GND STRIP (BOTT) 92B TE1 (A−RIGHT) TO CB5 (LINE LEFT)
42H S3 (7) TO PLG30 (1) 93A STATOR TO EXIT
42I GND (TOP) TO GND (BOT) 94A NEUTRAL STUD TO CB5 (LOAD LEFT)
42J PLG5 (1) TO TE2 (A/B) 94B NEUTRAL STUD TO ELCB1 (LINE)
42K RC30 (1) TO TE2 (A/B) 94C GFCI 2 (LINE−WHITE) TO CB5 (LOAD LEFT)
42M GND STRIP (BOTT) TO BASE RAIL 94D GFCI1 (LINE WHITE) TO CB5 (LOAD LEFT)
TM-267603 Page 98 Big Blue 800X/800CA Duo Air Pak
Lead Connections Lead Connections
96A ELCB1 (LEFT−LOAD) TO RC4 (N) 190A PLG6 (3) TO PLG26 (3)
96B ELCB1 (LEFT−LOAD) TO RC3 (N) 191A PLG6 (4) TO PLG26 (4)
97A ELCB1 (RIGHT−LOAD) TO RC4 (L) 200A SPLICE TO PLG100 (9)
97B ELCB1 (RIGHT−LOAD) TO RC3 (L) 200B SPLICE TO PLG105 (1)
98A STATOR TO EXIT 201A SPLICE TO PLG100 (8)
99A STATOR TO EXIT 201B SPLICE TO PLG105 (2)
100A EXCITER STATOR TO PLG98 (1) 202A PLG104 (1) TO PLG100 (12)
100B F1 TO RC98 (1) 203A PLG104 (2) TO PLG100 (13)
101A EXCITER STATOR TO RC98 (2) 204A PLG103 (5) TO PLG100 (18)
101B RC98 (2) TO SR2 (AC) 205A PLG103 (4) TO PLG100 (19)
102A R3 TO PLG98 (3) 206A PLG103 (3) TO PLG100 (17)
102B RC98 (3) TO C6 (−) 207A PLG103 (2) TO PLG100 (15) (TWISTED PAIR WITH 208A)
102C SR2 (−) TO C6 (−) 208A PLG103 (1) TO PLG100 (14) (TWISTED PAIR WITH 207A)
103A EXCITER STATOR TO R5 209A PLG106 (1) TO PLG100 (22)
104A EXCITER STATOR TO PLG98 (5) 210A PLG106 (2) TO PLG100 (21)
104B F2 TO RC98 (5) 211A PLG106 (3) TO PLG100 (20)
105A BRUSH (CENTER) TO PLG98 (6) 212A CB10 (BATT) TO STARTER
105B RC98 (6) TO C6 (+) 212B CB10 TO CB16
105C SR2 (+) TO C6 (+) 212C STARTER TO ALT
105D SR1 (+) TO SR2 (+) 220A PLG2 (1) TO PLG20 (1)
105E SR4 (+) TO SR1 (+) 221A PLG2 (2) TO PLG20 (2)
106A F1 TO SR2 (AC) 222A PLG2 (3) TO PLG20 (3)
107A SR4 (AC) TO F2 223A PLG2 (4) TO PLG20 (4)
108A BRUSH (REAR) TO PLG98 (7) 224A PLG2 (7) TO PLG20 (5)
108B RC98 (7) TO SR4 (−) 225A PLG2 (8) TO PLG20 (6)
110A CB4 TO SR1 (AC) 226A PLG2 (9) TO PLG10 (1)
111A CB4 TO CB3 227A PLG2 (10) TO PLG10 (2)
111B CB3 TO CR5 (2) 228A PLG2 (11) TO PLG10 (3)
112A R8 TO PLG98 (4)
229A PLG2 (12) TO PLG10 (4)
112B SR4 (AC) TO RC98 (4)
120A PLG2 (1) TO PLG20 (1) 230A PLG2 (15) TO PLG10 (5)
121A PLG2 (2) TO PLG20 (2) 231A PLG2 (16) TO PLG10 (6)
122A PLG2 (3) TO PLG20 (3) 232A CB29 TO PLG29 (1)
123A PLG2 (4) TO PLG20 (4) 274A PLG25 (8) TO PLG16 (CR24)(86)
124A PLG2 (7) TO PLG20 (5) 300A CB1 (TOP−LEFT) TO RC5 (L1)
125A PLG2 (8) TO PLG20 (6) 301A CB1 (TOP−CENTER) TO RC5 (L2)
126A PLG2 (9) TO PLG10 (1) 302A CB1 (TOP−RIGHT) TO RC5 (L3)
127A PLG2 (10) TO PLG10 (2) 303A RC1 (L) TO GFCI 1 (LOAD−HOT)
128A PLG2 (11) TO PLG10 (3) 304A RC1 (N) TO GFCI 1 (LOAD−WHITE)
129A PLG2 (12) TO PLG10 (4) 305A RC2 (L) TO GFCI 2 (LOAD−HOT)
130A PLG2 (15) TO PLG10 (5) 306A RC2 (N) TO GFCI 2 (LOAD−WHITE)
131A PLG2 (16) TO PLG10 (6) 307A CB5 (LOAD RIGHT) TO CB8
132A CB9 TO PLG9 (1) 307B CB5 (LOAD RIGHT) TO CB7
163A TE3 TO HAT SWITCH (S12) 311A CB14 TO CR14 (30)
163B TE3 TO CR10 (A) 311B CR14 (30) TO CR15 (4)
163D TE3 TO CR15 (2) 435A PLG101 (12) TO R6 (TWISTED PAIR WITH 436A)
164A S10 (5) TO S10 (2) 435B R6 TO PLG4 (2) (TWISTED PAIR WITH 436B)
164B CR10 (9) TO S10 (5) 435C R6 TO PLG102 (H) (TWISTED PAIR WITH 436C)
165A D10 (CATHODE) TO COMPRESSOR (CLUTCH) 435D SPLICE TO R6
165B CB15 TO D10 (CATHODE) 435E SPLICE TO R6
168A S11 AIR PRESSURE LOCKOUT TO S12 (SWITCH) 435F PLG6 (5) TO LEAD 435D (TWISTED PAIR 435F/436F)
168B S12 (SWITCH) TO CR10 (6) 435G PLG26 (5) TO LEAD 435E (TWISTED PAIR 435G/436G)
169A S11 AIR PRESSURE LOCKOUT TO S10 (3) 436A PLG101 (13) TO R6 (TWISTED PAIR WITH 435A)
172A TIMER (BLACK) TO CR15 (6) 436B R6 TO PLG4 (3) (TWISTED PAIR WITH 435B)
175A CB15 TO CR10 (7) 436C R6 TO PLG102 (G) (TWISTED PAIR WITH 435C)
183A PLG6 (7) TO RC30 (6) 436D SPLICE TO R6
183B PLG26 (7) TO RC30 (7) 436E SPLICE TO R6
183C S3 (8) TO PLG30 (6) 436F PLG6 (6) TO LEAD 436D (TWISTED PAIR 436F/435F)
183D S3 (8) TO PLG30 (7) 436G PLG26 (6) TO LEAD 436E (TWISTED PAIR 436G/435G)

Big Blue 800X/800CA Duo Air Pak TM-267603 Page 99

 SECTION 14 − 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.

14-1. 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 14-4).
Function buttons are used to navi-
gate through menus, increase/de-
crease, and select (see Section
14-2).
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.
There are two display types: 6-Up
and 1-Up. The default 6-Up display
shows six values at once. The 1-Up
display shows one value on the
screen. See Sections 14-5 and
14-6.

MurphyDisplay 2018−01 / 258 833-D

14-2. 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

TM-282374 Page 100 Big Blue 800 X Duo Air Pak

14-3. RPM Signal Failed Display
1 pears. Place Engine Control switch
RPM SIGNAL FAILED
14-4. Service Reminder Screen
Wait to Start/Preheating
1
Service Reminder
Engine Oil
Compressor Oil
 Glow plugs turn on automatically as de-
termined by ambient temperature.
Compressor oil information appears
only on models with air compressor.
1 Wait to Start/Preheating Display
The Wait to Start display appears when the
Engine Control switch is in the Run or Run/
Idle position and glow plugs are functioning.
The operator needs to pause at either
Big Blue 800 X Duo Air Pak
Hide
Remaining Service Reminder
0 Engine Oil
0 Compressor Oil
switch position while the engine controller
goes through the preheat sequence. Once
this message clears, the engine can be
started.
2 Service Reminder Display
The Service Reminder display shows ser-
vicing intervals in hours counting down
from engine manufacturer recommended
service intervals. This display appears for
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 30 minutes or longer,
the RPM signal failed message ap-
in Off position to reset.
2
Remaining
480
495
a few seconds. It can also be found as a
1-up screen (see Section 14-7).
The 6-Up Display then appears as the de-
fault. The engine can be started when the
6-Up Display appears.
If the Enter/Diagnostic function button is
pressed while in this display, the DM2 dia-
gnostic screen appears. (see Section
14-11).
TM-282374 Page 101
14-5. 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 14-6). 3 Engine Oil Pressure 9 Engine Hourmeter

14-6. 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 go to the next display, press the
Next function button. To return to
30 75 the 6-Up Display, press the View
32 F 0%
15 90 function button.

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

TM-282374 Page 102 Big Blue 800 X Duo Air Pak

14-7. 1-Up Displays
1 1-Up Machine Hours Display
To go to the next display, press the
Next function button. To return to
previous display, press the Previ-
1 ous 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

Big Blue 800 X Duo Air Pak TM-282374 Page 103

14-8. 1-Up Compressor Displays
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

TM-282374 Page 104 Big Blue 800 X Duo Air Pak

14-9. 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
14-10 and 14-11).
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

Big Blue 800 X Duo Air Pak TM-282374 Page 105

14-10. 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
13-1.
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
(Ack)
10 To acknowledge the fault and ad-
OC: 0 vance the display to the 1-up or
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
11 14 remedied before operation can
continue.

12 13

1 of 1 Warning

SPN: 100 FMI 1

Low oil pressure warning threshold
exceeded

OC: 1

Prev Next Hide Ack

TM-282374 Page 106 Big Blue 800 X Duo Air Pak

 Table 14-1. 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

14-11. 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 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

Big Blue 800 X Duo Air Pak TM-282374 Page 107

14-12. 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

14-13. 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 500 490

Modify Reset Cancel

6

TM-282374 Page 108 Big Blue 800 X Duo Air Pak

14-14. 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

Big Blue 800 X Duo Air Pak TM-282374 Page 109

14-15. 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 500 490 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

TM-282374 Page 110 Big Blue 800 X Duo Air Pak

14-16. 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
14-4 and 14-11).
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 

Big Blue 800 X Duo Air Pak TM-282374 Page 111

Notes

TM-282374 Page 112 Big Blue 800 X Duo Air Pak

 SECTION 15 − RUN-IN PROCEDURE
run_in2 2014−10

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.

15-1. Wetstacking
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 Welder/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.
NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
2
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.
1

Big Blue 800 X Duo Air Pak TM-282374 Page 113

15-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
! Stop engine.
! Do not touch hot exhaust pipe, en-
gine parts, or load bank/grid.
! Keep exhaust and pipe away from
flammables.
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 Load Bank
Turn all load bank switches Off. If needed,
connect load bank to 115 volts ac wall
receptacle or generator auxiliary power
receptacle.
2 Welder/Generator
Place Welder Selector switch in the A
position (Single Operator) and rotate A/V
control to minimum. Place Process Select-
or switch in Stick position.
3 Weld Cables
TM-283374 Page 114
1
+
3 6
Connect load bank or resistor grid to
generator Side A weld output terminals
using proper size weld cables with correct
connectors. Observe correct polarity.
4 Resistance Grid
Use grid sized for generator rated output.
Turn Off grid.
5 Voltmeter
6 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several minutes.
For Load Bank
Set load bank switches and then adjust
generator A/V control so load equals
rated voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manual).
S-0683 / S-0684
For Resistance Grid
Set grid switches and then adjust gen-
erator A/V control so load equals rated
voltage and current of the generator
(see nameplate, rating label, or the
specifications section in this manual).
Check generator and meters after first five
minutes then every fifteen minutes to be
sure generator is loaded properly.
NOTICE − Check oil level frequently during
run-in; add oil if needed.
It is recommended to run the welder/gener-
ator for two hours minimum and up to four
hours under load. Place A/V control in
minimum position, then shut down load
bank or grid to remove load. Run engine
several minutes at no load.
! Stop engine and let cool.
7 Engine Exhaust Pipe
Repeat procedure if wetstacking is pres-
ent.
Big Blue 800 X Duo Air Pak
 TM-282374B 2019−01

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 X )

Duo Air Pak

Eff w/Serial No. MJ200857R And Following

For product information,

File: Engine Drive
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 SECTION 16 − PARTS LIST
 Hardware is common and not
available unless listed.

38
37
36

35
34
33

39

32 40

41

31

21 28
19
42
20 27
29
26
30
43
12 18
17
23 25
14 44
11 16
132 22
133
134 24
116
117

135 15
13
136
10
9 119
122
118
125
137 123 120
121
7 8
124
6
3 128
4
2
129
1
130
127
131 126
5

Figure 16-1. Main Assembly

TM-282374 Page 116 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following

71 72

70
69 73
66
68
54 67

65

64 75 74
55

56
53 63
57 62 76
61
77
50
59 60
51 58
82 78
52 79
83
84 80
85 81
86
87
49
88
48 100
45 46 101 89
47 99
90
91
115
114 113 104 97
112
103
102
98

92
105
93
106
94
107

95
108
96
109

110

111

907763

Big Blue 800 X Duo Air Pak TM-282374 Page 117

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly

. . . 1 . . . . . . . . . . Figure 16-4 . . Weld Output Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 16-5
. . . 3 . . . . . . . . . . Figure 16-3
. . . 4 . . . . TE1 . . . . 255682
. . . 5 . . . . CT1 . . . . 105370
. . . 6 . . . . . . . . . . . . . . 277521
. . . 7 . . . . . . . . . . . . . . 276357
. . . 8 . . . . . . . . . . . . . . 254117
. . . . . . . . . . . . . . . . . . . . 209683
. . . 9 . . . . . . . . . . . . . . 191448
. . . 10 . . . . . . . . . . . . . . 206352
. . . 11 . . . . . . . . . . . . . . 260581
. . . 12 . . . . . . . . . . . . . . 259533
. . . 13 . . . . . . . . . . . . . . 256487
. . . 14 . HD1, HD21 . 168829
. . . 15 . SR6, SR26 . 279872
. . . 16 . . . . . . . . . . . . . . 259039
. . . 17 . . R10, R210 . 188067
. . . 18 . . . . . . . . . . . . . . 256489
. . . 19 . . . . . . . . . . Figure 16-8
. . . 20 . . . . . . . . . . . . . . 279485
. . . 21 . . . . PC3 . . . . 269559
. . . 22 . . . . . . . . . . . . . +269943
. . . 23 . . . . . . . . . . . . . . 218086
. . . 24 . . . . . . . . . . . . . . 260961
. . . 25 . . . . . . . . . . . . . . 209094
. . . 26 . . . . . . . . . . . . . . 227731
. . . 27 . . . . . . . . . . . . . . 210151
. . . 28 . . . . . . . . . . . . . +255669
. . . 29 . . . . . . . . . . . . . . 272334
. . . 30 . . . . . . . . . . . . . . 272333
. . . 31 . . . . . . . . . . . . . . 189464
. . . 32 . . . . . . . . . . . . . . 282178
. . . 33 . . . . . . . . . . . . . +266513
. . . 34 . . . . . . . . . . . . . . 272340
. . . 35 . . . . . . . . . . . . . . 189052
. . . 36 . . . . . . . . . . . . . . 227728
. . . 37 . . . . . . . . . . . . . . 272339
. . . 38 . . . . . . . . . . . . . . 272333
. . . 39 . . . . . . . . . . . . . . 191354
. . . 40 . . . . . . . . . . . . . . 206604
. . . 41 . . . . . . . . . . . . . . 190992
. . . 42 . . . . . . . . . . . . . . 254678
. . . 43 . . . . . . . . . . . . . . 196220
. . . 44 . . . . . . . . . . . . . . 268932
. . . . . . . . . . . . . . . . . . . . 124253
. . . . . . . . . . . . . . . . . . . . 189912
. . . . . . . . . . . . . . . . . . . . 189913
. . . . . . . . . . . . . . . . . . . . 181572
. . . . . . . . . . . . . . . . . . . . 259499
. . . . . . . . . . . . . . . . . . . . 084173
. . . . . . . . . . . . . . . . . . . . 264196
. . . . . . . . . . . . . . . . . . . . 189910
. . . . . . . . . . . . . . . . . . . . 181572
. . . . . . . . . . . . . . . . . . . . 189908
. . . . . . . . . . . . . . . . . . . . 254678
. . . . . . . . . . . . . . . . . . . . 228054
. . . 45 . . . . . . . . . . Figure 16-7
. . . 46 . . . . . . . . . . . . . . 010862
. . . 47 . . . . . . . . . . . . . . 266520
. . . 48 . . . . . . . . . . . . . . 023313
. . . 49 . . . . . . . . . . . . . . 265397
TM-282374 Page 118
. . Auxiliary Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Engine & Weld Control Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Block, Term Assy Standard W/Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Xfmr. Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Enclosure Opening D 13.688 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cover, Control Board (Dual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Safety Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Panel, Generator Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Engine Extension Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pan, Vault & Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . 2
. . Rectifier, Si 3ph 300 Amp 600 Piv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Resistor, Ww Fxd 100 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Mtg Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Weld Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Mtg Wcc Filter Network Potted Assy . . . . . . . . . . . . . . . . . . . . . . . 2
. . Circuit Card Assy, Wcc Filter Network Potted . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Caution Do Not Use Ether (Trilingual) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Air Cleaner Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Hot Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Breathing Diesel Engine Exhaust . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Danger Using A Generator Indoor (En/Fr/Sp−Sym) . . . . . . . . . . . . 1
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Use Diesel Fuel Only (Trilingual) . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Falling Equipment (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Hot Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Tank Screw-on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . . 1
. . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . . Fitting, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe Hose .500 X 9.265 Lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . Clamp, Hose .460 - .545 Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Sender, Fuel Gauge Reed Switch 9in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Fitting, Stand Pipe Hose .3125 X 9.260 Lg 90deg Zinc . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Valve, Drain Fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Cap, Tank Screw−On 3.500 In W/Vent W/Lanyard 8in . . . . . . . . . . . . . . 1
. . . . Gasket, Fuel Sender/Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Hose 1.562 - 2.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Hose 1.312 - 3.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 800 X Duo Air Pak
 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly (Continued)

. . . 50 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 255768 . . Air Cleaner, Intake (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine Lh Hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 267435 . . Engine, Deutz Dsl Elec Td2011l04 (T4i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . Figure 16-9 . . Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 266515 . . Muffler, Exhaust W/Manifold Deutz 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 206613 . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 208040 . . Tensioner, Belt W/Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 218609 . . Belt, Micro V 21mm X 1485mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 207808 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 208024 . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 208042 . . Spacer, Stl .800 Id X 1.188 Od X .090 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 239507 . . Hose, Tubing Oil Assy W/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 240354 . . Ftg, Stl Adapter 3/4 Sae-3/4 Jic 45 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 267977 . . Guard, Fan Lh W/Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . +239503 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 239501 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 265398 . . Plate, Cover Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 260226 . . Extrusion, Rubber W/Adhesive .750 X .750 X 27.000 . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . . . . . . . 254275 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 272335 . . Label, Notice Do Not Disconnect Batt (En/Fr/Sp-Sym) . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 272341 . . Label, Warning Battery Explosion (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 272498 . . Label, Notice Compressor Oil Fill (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . +239505 . . Guard, Fan Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 209623 . . Ftg, Stl Adapter Long 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 209633 . . Hose, Tubing Oil Assy W/Fittings 20.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 239515 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 8 Blade Suction . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley (available from engine manufacturer) . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 206800 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 209611 . . Switch, Disc Battery 2p 6-36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 209612 . . Lever, Switch Lockout Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (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
. . . 88 . . . . . . . . . . . . . . 209093 . . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 209092 . . Bracket, Mtg Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 209090 . . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 91 . . . . . . . . . . . . . +259532 . . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 209667 . . Latch, Paddle w/ Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 210681 . . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . . 259402 . . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 191626 . . Bumper, Door Access Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 96 . . . . . . . . . . . . . . 259406 . . Panel, Generator Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . . 260658 . . Label, Maintenance Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 278415 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 278439 . . Label, Fuel/Hour/Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 209059 . . Schematic, Air System (Big Blue Air Pak) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 206464 . . Label, Maintenance Big Blue Air Pak Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257139 . . Fuel Line Assy, W/Clamps 11.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 800 X Duo Air Pak TM-282374 Page 119

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly (Continued)

. . 102 . . . . . . . . . . . . *192744 . . Filter, Fuel Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *255764 . . Filter, Fuel Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 267764 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 239542 . . Bracket, Fuel Filter Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 106 . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 2
. . 107 . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 109 . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 110 . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 2
. . 111 . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 2
. . 112 . . . . . . . . . . . . . 207847 . . Heater, Oil Pan 120V 300W 22mm X 1.5 Metric Thd . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . . 176528 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . . 173336 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . . 066298 . . Washer, Seal Oil Cu .722 Id X .937 Od X .056 T . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42.000 No 1 Awg W/Clamp & .400 Rng . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . . 260236 . . Cable, Bat Pos 24.000 No 1 Awg W/Clamp & .400 Rng . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 266385 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 120 . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12V 925 Crk 195 Rsv Gp 31 Maint Free . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . . 264924 . . Bracket, Battery Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 123 . . . . . . . . . . . . . 272342 . . Label, Warning Do Not Weld On Base (En/Fr−Sym) . . . . . . . . . . . . . . . . . . 2
. . 124 . . . . . . . . . . . . . . . . . . . . . . . Label, Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . . . . . . . . . 272343 . . Label, Warning General Precautionary (En/Fr−Sym) . . . . . . . . . . . . . . . . . 1
. . 126 . . . . . . . . . . . . . 258582 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . Figure 16-2 . . Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 128 . . R3, R8 . . . 189699 . . Resistor, Ww Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 129 . . Z1, Z21 . . . 249772 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 130 . . . . . . . . . . . . . 248940 . . Bracket, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 131 . . . . . . . . . . . . . 207096 . . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 132 . . . . . . . . . . . . . 265249 . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 133 . . . . . . . . . . . . . 259265 . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 134 . . . . . . . . . . . . . 259268 . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 135 . . . . . . . . . . . . . 259266 . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 136 . . . . . . . . . . . . . 265250 . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 137 . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
*Recommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-282374 Page 120 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and not available unless listed.

12

13

8
16
15
3
14
2

1 5 6
4 9

7 19
18

23

17

20

8
10
2 22
2 11
21 Ref. 268617 / Ref. 907752

Figure 16-2. Control Box Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-2. Control Box Assembly (Figure 16-1 Item 127)

. . . 1 . . . . . . . . . . . . . . 258577 . . Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . . 083432 . . Supplementary Pro, Man Reset 1p 10A 250 VAC Frict . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 090104 . . Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 113247 . . Relay, Encl 12VDC Dpdt 20A/120VAC 8pin Flange Mtg . . . . . . . . . . . . . . . 1
. . . 7 SR1−SR2,SR4 035704 . . Rectifier, Integ Bridge 40. Amp 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . TE2, TE3 . . 190210 . . Block, Term 5−3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . CR4,CR24 . 173069 . . Relay, Encl 12VDC Spdt 50A/30A 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2
. . . 10 . . CB3−CB4 . . 139266 . . Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 2
. . . 11 . . . . CB14 . . . . 139266 . . Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB15 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10A 250VAC Frict . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 129524 . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR8 . . . . 197325 . . Relay, Encl 12VDC Spst 70A 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR5 . . . . 252053 . . Relay, Encl 12VDC Spst 35A/14VDC 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 C10/D10, C12/D12 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . R6 . . . . . 262019 . . Resistor Board, 120 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . CB10, CB16 . 190374 . . Circuit Breaker, Auto Reset 12VDC 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 268474 . . Relay, Delay Fix 12VDC Spst (N.O.) 10A 30Sec . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . C6 . . . . . 087110 . . Capacitor, Elctlt 240 uF 200 VDC Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . F1−F2 . . *256852 . . Holder, Fuse Mintr W/10a Slo−Blo Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*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.
Big Blue 800 X Duo Air Pak TM-282374 Page 121
 Eff w/Serial No. MJ200857R And Following

 Hardware is common and

not available unless listed.

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 16-3. Panel, Front Engine & Weld Controls

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front Engine & Weld Controls (Figure 16-1, Item 3)

. . . 1 . . . . . . . . . . . . . . 275689 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ........................
. . . 3 . . . . . . . . . . . . . . 277517 . .
. . . 4 . . . . . . . . . . . . . . 276583 . .
. . . 5 . . . . PC1 . . . . 280612 . .
. . . 6 . . . . PC21 . . . . 280613 . .
. . . 7 . . . . . . . . . . . . . . 277524 . .
. . . 8 . . . . . . . . . . . . . . 278559 . .
. . . 9 . . . . . . . . . . . . . . 279297 . .
. . . 10 . . . . . . . . . . . . . . 278485 . .
. . . 11 . . . . . . . . . . . . . . 217680 . .
. . . . . . . . . . . . . . . . . . . . 201244 . .
. . . 12 . . . . . . . . . . . . . . 207073 . .
. . . 13 . . CB9,CB29 . 083432 . .
. . . 14 . . . . . . . . . . . . . . 190323 . .
. . . 15 . . . . . . . . . . . . . . 170391 . .
. . . 16 . . . . . . . . . . . . . . 245663 . .
. . . 17 . . . . . . . . . . . . . . 276230 . .
. . . 18 . . . . . . . . . . . . . . 276484 . .
. . . 19 . . . . . . . . . . . . . . 256689 . .
. . . . . . . . . . . . . . . . . . . . 242579 . .
. . . 20 . . . . . . . . . . . . . . 270453 . .
. . . . . . . . . . . . . . . . . . . . 215000 . .
. . . 21 . . . . . . . . . . . . . . 231468 . .
. . . 22 . . . . . . . . . . . . . . 231469 . .
Label, Nameplate (Order by Model and Serial No.) . . . . . . . . . . . . . . . . . . . 1
Gasket, Control Board Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Seal, Control Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit, Service Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, Service Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gasket, 14 Pin Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Foam, LED Process Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Baffle, Lead Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Assy, Encoder Nut W/O−Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Supplementary Pro, Man Reset 1p 10A 250VAC Frict . . . . . . . . . . . . . . . . 2
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . . 2
Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . 2
Knob, Encod 1.67 D. X 6mm Id Push On W/Spring/Print . . . . . . . . . . . . . . 2
Harness, Front Panel USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Display, LCD Alphanumeric Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Screw, K40x 10 Pan Hd−Phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . 8
Label, Warning Read Owner’s Manual Wordless . . . . . . . . . . . . . . . . . . . . . 1
Screw, 006−32x .18 Hex Hd−Slt Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Nut, 375−32 .56hex .22h Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nut, 500−28 .69hex .28h Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . 2

TM-282374 Page 122 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front Engine & Weld Controls (Continued)

. . . 23 . . . . . . . . . . . . . . 190512 . . Stand−Off, No 6−32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 12

. . . 24 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 086288 . . Tubing, Gl Acryl .750− .786 Id Spool Yel Fa1 . . . . . . . . . . . . . . . . . . . . . . . .75
. . . 26 . . . . . . . . . . . . . . 279479 . . Strap, Grounding 15.12 In Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 206624 . . Switch, Tgl Sptt 6A 125VAC (On)−On−(On) Spd Term . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 278563 . . Foam, LED Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . 278564 . . Foam, LED Fuel And Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 280214 . . Spring, Wave (Stainless Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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 X Duo Air Pak TM-282374 Page 123

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and

not available unless listed. 9
10

8 11
9
7 8

4
3 13
2

12 18

17

14
1
15
16 279623

Figure 16-4. Panel, Weld Output

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-4. Panel, Weld Output (Figure 16-1, 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 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 108940 . . Screw, 250−20x .75 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . . 14
. . . 12 . . . . . S3 . . . . . 259356 . . Switch, Paralleling W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . 602208 . . Washer, Tooth.256idx0.510odx.028t Stl Pld Ext.250 A . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 189445 . . Screw, 250−20x .50 Pan Hd−Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 230339 . . Switch Handle W/Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 269892 . . Guard, Polarity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 127854 . . Clamp, Stl Cush 1.312 Dia X .343 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . 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-282374 Page 124 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following
3
15 12
6

1 13
7

2
14

10 8
9

16
11
5
4

264 996

Figure 16-5. Panel, Auxiliary Power Export Deluxe Prior to Serial No. MJ420704R

Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 16-5. Panel, Auxiliary Power Export Deluxe Prior to Serial No. MJ420704R

. . . 1 . . . . . . . . . . . . . . 264997 . . Panel, Aux Power (Ex) Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ........................
. . . 3 GFCI1−GFCI2 280236 . .
. . . . . . . . . C1−C2 . . . 217054 . .
. . . 4 . . RC1−RC2 . . 173555 . .
. . . 5 . . RC3−RC4 . . 176355 . .
. . . 6 . . CB7−CB8 . . 093996 . .
. . . 7 . . . . CB5 . . . . 266567 . .
. . . 8 . . . ELCB1 . . . 222991 . .
. . . 9 . . . . . . . . . . . . . . 144844 . .
. . . 10 . . . . . . . . . . . . . . 209056 . .
. . . 11 . . . . RC5 . . . . 251972 . .
. . . 12 . . . . CB1 . . . . 254884 . .
. . . 13 . . . . . . . . . . . . . . 214927 . .
. . . 14 . . . . . . . . . . . . . . 203016 . .
. . . 15 . . . . . . . . . . . . . . 207560 . .
. . . 16 . . . . . . . . . . . . . . 197203 . .
Label, Aux Power (Ex) Deluxe (Order by Model and Serial No.) . . . . . . . . 1
Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Capacitor, Cer Disc .0047 uF 3000 VDC W/Terms . . . . . . . . . . . . . . . . . . . 2
Rcpt, Str 2p3w 16A 130V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rcpt, Str 2p3w 16A 220V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Supplementary Pro, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . . . 2
Supplementary Protector, Man Reset 2p 40A 240VAC . . . . . . . . . . . . . . . . 1
Circuit Breaker, Elcb 16A 220V 0.030A Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stand−Off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rcpt, Str 4p5w 32A 400V 3ph Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Supplementary Protector, Man Reset 3p 30A 480VAC . . . . . . . . . . . . . . . . 1
Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Insulator, Stand−Off With Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 X Duo Air Pak TM-282374 Page 125

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and 11

not available unless listed. 16 12
10
9
11
8

14

13
8
15

7 1

4
3
4 5
5

282758-A

Figure 16-6. Panel, Auxiliary Power Export Deluxe Eff w/Serial No. MJ420704R

Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 16-6. Panel, Auxiliary Power Export Deluxe Eff w/Serial No. MJ420704R

. . . 1 . . . . . . . . . . . . . . 282759 . . Panel, Aux Power (Ex) Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Label, Aux Power (Ex) Deluxe (Order by Model and Serial Number) . . . . 1
. . . 3 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . RC1−RC2 . . 173555 . . Rcpt, Str 2p3w 16A 130V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . RC3−RC4 . . 176355 . . Rcpt, Str 2p3w 16A 220V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . RC5 . . . . 251972 . . Rcpt, Str 4p5w 32A 400V 3ph Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . CB7−CB8 . . 093996 . . Supplementary Pro, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB5 . . . . 266567 . . Supplementary Protector, Man Reset 2p 40A 240VAC . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 203016 . . Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 207560 . . Insulator, Stand-Off With Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 GFCI1−GFCI2 280236 . . Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . C1−C2 . . . 217054 . . Capacitor, Cer Disc .0047 uF 3000 VDC W/Terms . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . CB1 . . . . 254884 . . Supplementary Protector, Man Reset 3p 30A 480VAC . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 214927 . . Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . ELCB1 . . . 282446 . . Circuit Breaker, Rccb 16A 240V 0.030A Trip . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 282731 . . Bracket, Rccb Single Din Rail Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 272330 . . Label, Warning Electric Shock/Moving Parts (Sym) . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 263778 . . Guard, Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-282374 Page 126 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and 13 14

not available unless listed.
12

9 11
10

8
6
7
5 15

4 28

3 16
2 17
1
18

19

20
24 21
22
26 25
27 23 255 861 / Ref. 907 634−3

Figure 16-7. Generator

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

Figure 16-7. Generator (Figure 16-1, Item 45)

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

. . . 2 . . . . . . . . . . . . . . 183387
. . . 3 . . . . . . . . . . . . . . 278733
. . . . . . . . . . . . . . . . . . . . 257974
. . . . . . . . . . . . . . . . . . . . 203635
. . . . . . . . . . . . . . . . . . . . 143220
. . . . . . . . . . . . . . . . . . . . 278735
. . . . . . . . . . . . . . . . . . . . 604538
. . . . . . . . . . . . . . . . . . . . 172684
. . . . . . . . . . . . . . . . . . . . 604537
. . . . . . . . . . . . . . . . . . . . 604538
. . . . . . . . . . . . . . . . . . . . 261463
. . . 4 . . . . . . . . . . . . . +273541
. . . . . . . . . . . . . . . . . . . . 273484
. . . . . . . . . . . . . . . . . . . . 258654
. . . 5 . . . . . . . . . . . . . . 190197
. . . . . . . . . . . . . . . . . . . . 172674
. . . 6 . . . . . . . . . . . . . . 039207
. . . . . . . . . . . . . . . . . . . . 172555
. . . 7 . . . . . . . . . . . . . . 024617
. . . 8 . . . . . . . . . . . . . . 053390
. . . 9 . . . . . . . . . . . . . . 251855
. . . 10 . . . . . . . . . . . . . . 080389
. . . 11 . . . . . . . . . . . . . . 083883
. . . 12 . . . . . . . . . . . . . . 206242
. . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . . 6
. . Endbell, W/Exciter Stator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Kit, Endbell w/O−ring (Includes)
. . . . . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . O−Ring, 2.859 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . 4
. . . . Nut, 312−18 .50hex .27h Stl Pld Sem Cone Wshr.76d . . . . . . . . . . . . . . 4
. . Nut, 312-18 .50hex .28h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . . . 4
. . Screw, 312-18x4.50 Hex Hd-pln Stl Gr5 Pld Full . . . . . . . . . . . . . . . . . . . . . 4
. . Stator, Weld/Power Assy Complete (Includes) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Stator, Weld/Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Barrel, Stator (CH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, M10−1.5x 50 Hex Hd−Pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . . . 1
. . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . 8
. . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 8
. . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Big Blue 800 X Duo Air Pak TM-282374 Page 127

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-7. Generator (Continued)

. . . 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
. . . 16 . . . . . . . . . . . . . . 259483 .. Bracket, Mtg Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 191579 .. Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 199849 .. Screw, 625-11x4.00 Hex Hd-pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 071731 .. Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 071890 .. Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 071730 .. Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 083476 .. Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 135205 .. Nut, 625-11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 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
. . . 28 . . . . . . . . . . . . . . 191577 .. Guard, Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ 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-282374 Page 128 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following

13 14
9
9
10
1 10

15

15
6
7

6 11

8
16

7 5
Included With 12
17 Item 6
252 915-D

Figure 16-8. Weld Output Module

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-8. Weld Output Module (Figure 16-1, Item 19)

... 1 .............. 278884 .. Heat Sink Assy, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 250350 .. Bus Bar, Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 250323 .. Insulator, Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 250348 .. Bus Bar, Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 245378 .. Bus Bar, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . C3 . . . . . 246841 .. Capacitor, Elctlt 35000 uF 100 VDC Can 3.00 Dia . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 239547 .. Washer, Flat Nylon .516 Id X 1.250 Od X .062 Thk . . . . . . . . . . . . . . . . . . . 2
... 8 .............. 202853 .. Screw, M 6−1.0x 14 Hex Hd−Phl Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . . 8
... 9 .............. 602207 .. Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . . . . 4
... 10 .............. 227186 .. Washer, Flat .254idx0.468odx.090t Stl Zc Cl . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 .............. 217283 .. Bolt, Crg Stl .250−20 X .750 Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 152461 .. Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . . 1
... 13 .............. 223039 .. Screw, 250−28x .75 Hex Hd−Pln Stl Gr5 Pld Zinc Blk . . . . . . . . . . . . . . . . 2
... 14 .............. 223040 .. Screw, 250−28x .87 Hex Hd−Pln Stl Gr5 Pld Zinc Clr . . . . . . . . . . . . . . . . . 2
... 15 .............. 247093 .. Stand−Off, Conductive Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 16 .............. 250346 .. Bracket, Mtg Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 .............. 602154 .. Screw, 250−20x .50 Hexwhd.50d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . . 2

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 X Duo Air Pak TM-282374 Page 129

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and 75

not available unless listed. 76
77

79 82

78
80 74
81
72 72
73

70 71
45

69

68
66
65 67
27 28

26
12
25
24
23 29
13 22
11 21
20
10
14
9
15
19
8 16 18
17

7 49
45
36
45

30
6
31 35
5
34

4
33

32

267 588
Figure 16-9. Air Compressor

TM-282374 Page 130 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following

64

56
63
57
62
61 58

55

54
59
53

52
33 60

50 51

37
39 38
40

41
49
42

43 48

47

46
44

45

Big Blue 800 X Duo Air Pak TM-282374 Page 131

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-9. Air Compressor (Figure 16-1 Item 54)

... 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 . . . . . . . . . . . . . . 087318 .. Clamp, Stl Cush 1.000 Dia X .406 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 209621 .. Ftg, Stl Adapter 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . 210054 .. Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 210040 .. Orifice/Muffler, Blowdown .120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . 218601 .. Hose, Nylon Red 1/4 Id X 3/8 Od X 36 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 218602 .. Hose, Nylon Blue 1/4 Id X 3/8 Od X 44 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 071270 .. Ftg, Pipe Brs Tee St 1/4 Npt 071269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . 210053 .. Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 16 . . . . . . . . . . . . . . 084999 .. Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 151662 .. Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 206937 .. Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 209787 .. Ftg, Pipe Stl Nipple Close 3/4 Npt Schedual 80 . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 209754 .. Ftg, Stl Elbow 45 Deg 3/4 Npt (M) X 3/4 Jic (M) . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . 206743 .. Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . . . . 209767 .. Ftg, Pipe Stl Connector M 3/4 Sae-npt Adapter . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 210051 .. Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 210040 .. Orifice/Muffler, Blowdown .120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 25 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . . . . 206746 .. Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . . . . . . . . . . 602965 .. Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . . . . . . . . . . . . 272762 .. Sender, Pressure Oil 0−200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 073655 .. Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 . . . . . . . . . . . . . . 206939 .. Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 209457 .. Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 209638 .. Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . . 209639 .. Hose, Oil W/Fittings 22.5 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . . 209766 .. Ftg, Pipe Stl Tee Street 3/4 Npt M-f-f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 . . . . . . . . . . . . . . 247624 .. Pointer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 210058 .. Gauge, Oil Level (Modified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 37 . . . . . . . . . . . . . . 209641 .. Hose, Nylon White 1/4 Id X 3/8 Od X 36 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 38 . . . . . . . . . . . . . . 209646 .. Tubing, Sst .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 39 . . . . . . . . . . . . . . 209856 .. Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
... 40 . . . . . . . . . . . . . . 210027 .. Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 41 . . . . . . . . . . . . . . 209755 .. Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 42 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 43 . . . . . . . . . . . . . . 208029 .. Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 44 . . . . . . . . . . . . . . 214686 .. Ftg, Pipe Stl Elbow 90dg 3/4bspp O-ring X 3/4 Jic M . . . . . . . . . . . . . . . . . 1
... 45 . . . . . . . . . . . . . . 210248 .. Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 46 . . . . . . . . . . . . . *206747 .. Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 47 . . . . . . . . . . . . . . 220326 .. Head, Spin On Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 48 . . . . . . . . . . . . . . 214687 .. Ftg, Pipe Stl 3/4bspp X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 49 . . . . . . . . . . . . . . 214685 .. Hose Assy, Air W/Fittings 3/4 X 20.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 50 . . . . . . . . . . . . . . 209756 .. Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
... 51 . . . . . . . . . . . . . *206745 .. Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 52 . . . . . . . . . . . . . . 210052 .. Valve, Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 53 . . . . . . . . . . . . . . 206744 .. Thermostat, 170f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 54 . . . . . . . . . . . . . . 209825 .. Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 55 . . . . . . . . . . . . . . 209764 .. Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 56 . . . . . . . . . . . . . . 209851 .. Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-282374 Page 132 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-9. Air Compressor (Continued)

. . . 57 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . 267651 . . Ftg, Pipe Stl Swivel 3/4 Jic (M) X 3/4 Jic (F) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 243794 . . Hose, Tubing Oil Assy W/Fittings 19.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 267531 . . Bracket, Mtg Ftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae-jic- . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 265396 . . Bracket, Mtg Compressor (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 260369 . . Ftg, Pipe Brs Elbow/Adapter M 1/8 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 211904 . . Manifold, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 209853 . . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 602887 . . Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 73 . . . . . . . . . . . . . . 225038 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 256685 . . Clutch, Electro Magnetic 12VDC W/8 Groove Pulley . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 260374 . . Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 210001 . . Airend, Gear-driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258419 . . Kit, Compressor Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . 78 . . . . . . . . . . . . . . 260374 . . Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 254976 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 010862 . . Clamp, Hose 1.562 − 2.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 249657 . . Air Cleaner, Intake 5.250 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210016 . . Gasket, Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 218305 . . Valve, Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *246991 . . Filter Kit, Ingersoll Rand (Ce55 G1)
*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.

Big Blue 800 X Duo Air Pak TM-282374 Page 133

 Eff w/Serial No. MJ200857R And Following

 Hardware is common and

not available unless listed.

3 4
6
7
5 2

803 328

Figure 16-10. Optional Air Dryer Assemblies

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-10. Optional Air Dryer Assemblies

... 1 .............. 193362 .. Cartridge, Desiccant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 2 .............. 193365 .. Heater Assembly,12 V 75 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 219491 .. Timer, Ctrl w/Cord & Plug (2 Min Cycle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 219492 .. Kit, Unloader Valve (Valve/Misc O−rings/Seals) . . . . . . . . . . . . . . . . . . . . . . 1
.................... 219493 .. Kit, Inlet Valve (Check Valve/Spring/Gasket/O−rings) (Not Shown) . . . . . 1
... 5 .............. 248678 .. Muffler, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 .............. 242536 .. Muffler, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 239786 .. Valve, Ctrl (Valve/Solenoid) 12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 264669 .. Harness, Air Dryer T2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-282374 Page 134 Big Blue 800 X Duo Air Pak

 Eff w/Serial No. MJ200857R 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

.................... 267288 .. Harness, Engine Deutz (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 267290 .. Lead Assy, Elect #41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 267292 .. Lead Assy, Elect #46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG101 . . 240075 .. Conn, Rect Jpt Rcpt 25 Pos R Ang Left Key . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG100 . . 240442 .. Conn, Rect Jpt Rcpt 25 Pos R Ang Right Key . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240076 .. Conn, Rect Jpt Cover 25 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 240074 .. Seal, Plug Single Wire (5mm Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
.................... 240071 .. Plug, Cavity 2.5mm Din72585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . PLG104 . . 240077 .. Conn, Rect Jpt 2 Pos 1 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG12 . . . 215261 .. Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 .. Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 238028 .. Conn, Deutsch 6p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 238029 .. Conn, Deutsch Wedge Lock 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG106 . . 266134 .. Conn, Rect 3 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CLUTCH . . 212116 .. Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212117 .. Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG103 . . 240081 .. Conn, Circ Cpc 7skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240082 .. Conn, Circ Cpc Clamp 90deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG102 . . 240098 .. Conn, Circ Cpc 12skt Size 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240099 .. Conn, Circ Cpc Cap Plg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240100 .. Conn, Circ Cpc Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG409 . . 177859 .. Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 .. Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB2 . . . . 139266 .. Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR1 . . . . 252053 .. Relay, Encl 12VDC Spst 35A/14VDC 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S10 . . . . 206624 .. Switch, Tgl Sptt 6A 125VAC (On)−On−(On)Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR5 . . . . 223710 .. Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR10 . . . . 113247 .. Relay, Encl 12VDC Dpdt 20A/120VAC 8pin Flange Mtg . . . . . . . . . . . . . . . 1
.................... 164617 .. Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 268472 .. Lead Assy, Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 279497 .. Harness, Weld Air Pak (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . . . PLG3 . . . . 114655 .. Conn, Rect Mini 045 6skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG4,PLG24 116513 .. Conn, Rect Mini 045 12skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG5,PLG25 113752 .. Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG6,PLG26 113751 .. Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG9,PLG29 117037 .. Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . PLG10,PLG210 113750 .. Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 2
.................... 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . . 1

Big Blue 800 X Duo Air Pak TM-282374 Page 135

 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
www.MillerWelds.com

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2019 Miller Electric Mfg. LLC 2019−01