TM-4409C March 2005

Eff w/LC251836 And Following

Processes
Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting

and Gouging

With Optional Equipment:

Battery Charging

Description

Engine Driven Welding Generator And

Air Compressor

Big Blue Air Pak

®

Visit our website at

www.MillerWelds.com
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-2. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Sound Level Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-5. Stick And MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-6. TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-8. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-9. Generator AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-10. Optional 3-Phase Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-11. Air Compressor Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-12. Optional Battery Charging Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-13. Manufacturing Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Installing Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. Using The Optional Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-7. Engine/Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-11. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-1. Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-2. Description Of Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-4. Using Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-2. Connecting To Optional AC Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-3. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 7 − OPERATING OPTIONAL BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-1. Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. Determining Battery Charging Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-3. Battery Charge Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-4. Battery Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-5. Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
 TABLE OF CONTENTS

SECTION 8 − ENGINE/GENERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8-1. Engine Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-2. Routine Engine/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-4. Servicing Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-5. Inspecting/Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-7. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-8. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 9 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 10 − WELDING GENERATOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . . . . . . . . . . 54
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-4. Waveforms For Section 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10-8. Using Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10-9. LED Board PC9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10-10. Diagnostic LED’s On LED Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-11. Idle Module PC7 Testing Information And Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . 64
10-12. Time Delay Relay TD1 Testing Information And Troubleshooting Flow Charts . . . . . . . . . . . . . . . . 66
10-13. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10-14. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SECTION 11 − SERVICING AND TROUBLESHOOTING
AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11-1. Component Location And System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11-2. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11-3. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11-4. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11-5. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11-6. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11-7. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11-8. Troubleshooting Air Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SECTION 12 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12-3. Air Compressor System Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12-4. Engine Component Assembly And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 13 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SECTION 14 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
SECTION 15 − AIR COMPRESSOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. . . 102
SECTION 16 − PARTS LIST FOR LC251836 THRU LC670816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SECTION 17 − PARTS LIST EFF W/LC670817 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-4409N - 10/04, safety_rtm 8/03

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.

1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see STATIC (ESD) can damage PC boards.
the symbol, watch out, and follow the related instructions to
D Put on grounded wrist strap BEFORE handling
avoid the hazard.
boards or parts.
Y Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
Y During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

ENGINE EXHAUST GASES can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un- D Do not breathe exhaust fumes.
less the procedure specifically requires an en- D Use in open, well-ventilated areas, or vent ex-
ergized unit. haust outside and away from any building air in-
D Insulate yourself from ground by standing or working on dry insu- takes.
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
FUEL can cause fire or explosion.
SIGNIFICANT DC VOLTAGE exists after stopping D Stop engine and let it cool off before checking or
engine on inverters. adding fuel.
D Stop engine on inverter and discharge input capacitors according D Do not add fuel while smoking or if unit is near
to instructions in Maintenance Section before touching any parts. any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.

MOVING PARTS can cause injury.

D Keep away from moving parts such as
fans, belts, and rotors.
D Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from mov-
ing parts.
D Before working on generator, remove spark plugs or injec-
tors to keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on gener-
ator components.
D Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connect-
ing battery cables.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and −) on batteries.
D Disconnect negative (−) cable first and connect it last.

FLYING METAL can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face
shield during servicing. D Do not tip battery.
D Be careful not to short metal tools, parts, or D Replace damaged battery.
wires together during testing and servicing. D Flush eyes and skin immediately with water.

Big Blue Air Pak TM-4409 Page 1

 STEAM AND HOT COOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
FALLING UNIT can cause injury.
D Use equipment of adequate capacity to lift and
support unit and components.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Securely attach components to lifting equip-
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
D Allow cooling period before servicing.
D Wear protective gloves and clothing when
working on a hot engine.
D Do not touch hot engine parts bare-handed.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
1-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-4409 Page 2
TILTING OR TIPPING can cause injury.
D Do not put any body part under unit while lifting.
D 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.
D Be careful when working on stator and rotor assemblies.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D 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.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Big Blue Air Pak
 SECTION 2 − DEFINITIONS

2-1. Symbols And Definitions

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Check engine belt Check Air Cleaner Starting Aid Engine

Jump start/Battery
Battery (Engine) Battery Charge Jump Start
Charge
OPT

Do Not Switch Read Operator’s Certified/Trained

Engine Oil
Under Load Manual Mechanic

Check Injectors/ Check Valve Engine Coolant

Fuel
Pump Clearance Temperature

Hourmeter (HM) Air Pressure Temperature Air Compressor

Positive Negative Wire Feed Welding Arc

A Amperes
V Volts Panel/Local Remote

Direct Current Alternating Gas Tungsten Arc

Output
(DC) Current (AC) Welding (TIG)

Stick (SMAW) Constant Current MIG (GMAW) Constant Voltage

Welding (CC) Welding (CV)

3
Air Carbon Arc Protective Earth
Three Phase
1 Single Phase
Cutting (CAC-A) (Ground)

DC Electrode DC Electrode Electrode

Work Connection
Positive Negative Connection

Circuit Breaker Time

h Hours
s Seconds

On Off

Big Blue Air Pak TM-4409 Page 3

 SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications

Maximum
Weld Rated Engine
Welding Open-Circuit Generator Power Fuel Tank
Output Welding Engine Oil
Mode Voltage Rating Capacity
Range Output Capacity
(Nominal)

500 A,
CC/DC 20 − 750 A 40 Volts 95
DC,
100% Duty Standard
Cycle Single-Phase,
CV/DC 14 − 40 V 56 DEUTZ
4 kVA/kW, 34/17 A,
600 A, 120/240 V AC,
44 Volts 50/60 Hz Deutz BF4M2011
CC/AC DC, Oil-Cooled,
20 - 575 64 3-Phase Generator 11 qt 25 gal
(Optional) 40% Duty Four-Cylinder,
Option* (10.4 L) (95 L)
Cycle Turbo-Charged
Single Phase/Three Phase,
Single-Phase/Three-Phase,
12/20 kVA/kW, 50/48A, 64 HP Diesel Engine
750 A,
120/240 VAC, 60 Hz
Battery 12 Volt
Charge/ Jump Start *In Addition To Standard
12/24 V 14/28 4 kVA/kW Generator Power
Jump 750 A,
Start 24 Volt
Jump Start

3-2. Air Compressor Specifications

Compressor Model Air Output At Effective Factory Pressure Safety Relief Air Compressor
And Type Working Pressure Setting Valve Rating Oil Capacity

60 scfm (1.7 m3 min−1),

Ingersoll Rand CE55 G
100 psi (690 kPa), 125 psi (862 kPa) 150 psi (1034 kPa) 4 qt (3.8 L)
Rotary Screw
100% Duty Cycle

3-3. Sound Level Table

Weld/Power Speed 40 Volts DC At 500 44 Volts DC At 600

Idle Speed (1235 rpm)
(1850 rpm) Amps Amps

96.6 Lwa sound power 102.8 Lwa sound power 103.9 Lwa sound power 106.0 Lwa sound power
Air Compressor On 71.7 dBa at 23 ft (7 m) 77.9 dBa at 23 ft (7 m) 79.0 dBa at 23 ft ( 7 m) 81.1 dBa at 23 ft (7 m)
77.2 dBA 3.3 ft (1 m) 83.0 dBA 3.3 ft (1 m) 89.8 dBA 3.3 ft (1 m) 93.3 dBA 3.3 ft (1 m)
from front panel from front panel from front panel from front panel

94.6 Lwa sound power 100.6 Lwa sound power 103.0 Lwa sound power 104.5 Lwa sound power
Air Compressor Off 69.7 dBa at 23 ft (7 m) 75.7dBa at 23 ft (7 m) 78.1dBa at 23 ft (7 m) 79.6 dBa at 23 ft (7 m)
74.5 dBA 3.3 ft (1 m) 78.8 dBA 3.3 ft (1 m) 86.0 dBA 3.3 ft (1 m) 91.8 dBA 3.3 ft (1 m)
from front panel from front panel from front panel from front panel

TM-4409 Page 4 Big Blue Air Pak

3-4. Dimensions, Weights, And Operating Angles
Dimensions
54-1/2 in (1384 mm) G
Height
(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)
Width
30-3/4 in (781 mm)
(mtg. brackets turned out)
Depth 69-1/2 in (1765 mm)
A 69-1/2 in (1765 mm)
B* 55-7/8 in (1419 mm) A
C* 46-3/8 in (1178)
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
Y Do not move or operate unit where it could
tip
tip.
B C

D* 11 in (279 mm)
E 27-1/2 in (699 mm)
F 1 in (25 mm) 30°
H
G 29-1/2 in (749 mm) 30°
20°
9/16 in (14 mm) Dia. D
H Front Panel End 20°
4 Holes

* With mounting brackets in center

position. Dimensions vary with loca- F
tion of mounting brackets. E

Weight
802 161-A
No fuel: 2010 lb (907 kg)
803 231
w/fuel: 2185 lb (993 kg)

Notes

Work like a Pro!

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

Big Blue Air Pak TM-4409 Page 5

3-5. Stick And MIG Volt-Ampere Curves
A. DC Stick Mode The volt-ampere curve shows the
minimum and maximum voltage
100 and amperage output capabilities of
Ranges the welding generator. Curves of all
300 − Max other settings fall between the
185 − 525 curves shown.
80 125 − 400
85 − 250
55 − 125
DC VOLTS

60

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES

B. AC Stick Mode (Optional)

100

80

60
AC VOLTS

40

20

0
0 100 200 300 400 500 600 700

AC AMPERES

C. MIG Mode

100

80
DC VOLTS

60 MAX

40

20 MIN

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES 208 135 / 203 415 / 208 956

TM-4409 Page 6 Big Blue Air Pak

3-6. TIG Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
A. DC TIG Mode curves shown.

100
Ranges
60−450
80 40−330
30−220
20−110
DC VOLTS

60

40

20

0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700
DC AMPERES

B. AC TIG Mode (Optional)

100

80
AC VOLTS

60

40

20

0
0 100 200 300 400 500 600 700

AC AMPERES

208 136 / 208 957

Big Blue Air Pak TM-4409 Page 7

3-7. Fuel Consumption
The curve shows typical fuel use
under weld or generator power
3.00 loads.
2.75
2.50
2.25 w/ Air Output

2.00
US Gal./Hr.

1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 100% DUTY CYCLE

208 211

3-8. Duty Cycle And Overheating

100% Duty Cycle At 500 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.

Continuous Welding

40% Duty Cycle At 600 Amperes

4 Minutes Welding 6 Minutes Resting

1000
800

600
500
WELD AMPERES

400

300
250
200

150

100
10 15 20 25 30 40 50 60 80 100
% DUTY CYCLE 202 356

TM-4409 Page 8 Big Blue Air Pak

3-9. Generator AC Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.

150 300

125 250

100 200
AC VOLTS

75 150

50 100

25 50

0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE

193 018

Notes

Work like a Pro!

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

Big Blue Air Pak TM-4409 Page 9

3-10. Optional 3-Phase Generator Power Curves
The ac power curves show the gen-
erator power available in amperes
at the single-phase 120/240 volt re-
ceptacle or three-phase 240 volt
A. 12 kVA/kW Single-Phase AC Output (No Weld Load) terminals.

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 20 40 60 80 100
AC AMPERES

B. 20 kVA/kW Three-Phase AC Output (No Weld Load)

280

260

240
AC VOLTS

220

200

180
0 10 20 30 40 50 60 70
AC AMPERES

197 472 / 197 473

TM-4409 Page 10 Big Blue Air Pak

3-11. Air Compressor Output Curve

The air output curve shows the vol-

ume and pressure of air available
from the air compressor.

140

120
POUNDS PER SQUARE INCH (PSI)

100

80
Idle
60

40

20

0
0 10 20 30 40 50 60 70 80 90 100

CUBIC FEET PER MINUTE (CFM)

208 955

3-12. Optional Battery Charging Output Curve

The battery charging curves show

the charging amperage and voltage
output of the welding generator.
As battery voltage nears the charg-
ing voltage, charging current de-
50 creases.

45
40
35
30
DC VOLTS

25
20
15
10
5
0
0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

210 269

Big Blue Air Pak TM-4409 Page 11

3-13. Manufacturing Rating Label

TM-4409 Page 12 Big Blue Air Pak

 SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Y Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
Movement ble codes.
Y Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Y If unit does not have GFCI re-
ceptacles, use GFCI-protected
OR OR extension cord.

. See Section 4-2 for mounting in-

formation.
Grounding:
1 Equipment Grounding Terminal
Location (On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
OR lated copper wire.

Grounding
1
GND/PE 2

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

3 Y Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.

Airflow Clearance

18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)

18 in
18 in (460 mm)
(460 mm)

install3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274

Big Blue Air Pak TM-4409 Page 13

4-2. Mounting Welding Generator
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
Y Do not mount unit by sup-
porting the base only at the
four mounting brackets.
Use cross-supports to ade-
2 quately support unit and pre-
vent damage to base.
Mounting Surface:
1 Cross-Supports
OR 2 Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1
3 1/2 in Bolt And Washer
Inadequate support. (Minimum − Not Supplied)
4 3/8-16 x 1 in Screws
(Supplied)
Y Do not use flexible mounts. To Bolt Unit In Place:
Remove hardware securing the
1 four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Using Mounting Brackets Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
2 the four mounting brackets.

Welding Unit In Place

Bolting Unit In Place
3
2

Tools Needed:
9/16 in
install3 6/04 803 274 / 190 250-A / 803 231

TM-4409 Page 14 Big Blue Air Pak

4-3. Installing Optional Spark Arrestor Muffler
Y Stop engine and let cool.
1 Spark Arrestor Muffler
2 Double-Flanged Elbow
3 Nut
4 Flat Washer
5 Mount
6 Bracket
7 Screw
8 Single-Flanged Elbow
2 9 Rain Cap
10 Clamp
Loosely assemble components as
10 1 shown.

9 . Mount the muffler with the clean-

out plug to the outside.
After assembly, final-tighten all
clamps and hardware.

. Be sure to tighten rain cap

mounting screw.

6
8

5
4

Tools Needed:
7/16, 1/2 in 803 230

Big Blue Air Pak TM-4409 Page 15

4-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection − Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 bottom of well (maximum).
Y Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6 Battery Charger
Y Read and follow all instruc-
2 tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.

. When electrolyte is low, add

only distilled water to cells to
maintain proper level.

5 A For 30 Minutes Tools Needed:

OR

+
− rubber gloves

30 A For 12 Minutes

glasses
drybatt1 1/98 − 0886

TM-4409 Page 16 Big Blue Air Pak

4-5. Connecting The Battery
. Reinstall cover after connecting battery.

Y Connect Negative (−) Cable Last.

+

Tools Needed:
1/2 in 802 168-E / Ref. 202 705 / 802 313 / S-0756-C

4-6. Using The Optional Battery Disconnect Switch

Y Stop engine.
1 Battery Disconnect Switch
1 OFF 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,
ON turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.

803 228 / Ref. 803 324

Big Blue Air Pak TM-4409 Page 17

4-7. Engine/Compressor Prestart Checks
Full
Diesel
. Check all engine/compressor fluids
daily.
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil. The
automatic shutdown system stops engine if
oil pressure is too low or coolant 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.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 14.
Fuel
Y Do not use gasoline. Gasoline will
damage engine.
TM-4409 Page 18
Engine Oil Compressor
Oil
Too
High
Full
Too
Low
Full
803 228
Add fresh diesel fuel before starting to pre-
vent air from entering the fuel system (see
if oil is not up to full mark on indicator (see
maintenance label for oil specifications).
engine maintenance label for fuel specifica-
tions). Leave filler neck empty to allow room
for expansion. Cold Weather Starting
Engine stops if fuel level is low on units with
low fuel shutdown option. Do not run out of . To improve cold weather starting:
fuel or air may enter fuel system and cause Use Starting Aid switch (see Section
starting problems. See engine manual to 5-1).
bleed air from fuel system.
Engine Oil Keep battery in good condition. Store
battery in warm area.
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
add oil (see maintenance label for engine oil Use fuel formulated for cold weather
specifications). (diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel in-
Compressor Oil
formation.
1 Compressor Oil Level Indicator (On
Tank) Use correct grade oil for cold weather
Check oil with unit on level surface. Add oil (see Section 8-1).
Big Blue Air Pak
4-8. Connecting To Weld Output Terminals
Y Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick And TIG Welding
For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode hold-
er cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.
For Stick and TIG Direct Current Elec-
trode Negative (DCEN), connect elec-
trode holder cable to Negative (−) terminal
on right and work cable to Positive (+) ter-
minal on left.
If equipped with optional Polarity/AC Se-
lector switch, connect electrode holder
cable to Electrode terminal on left and
work cable to Work terminal on right.
MIG And FCAW Welding
For MIG welding Direct Current Electrode
Positive (DCEP), connect wire feeder
cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right. Use Process/Contactor switch to
select type of weld output (see Section
5-3).
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect wire
feeder cable to Negative (−) terminal on
right and work cable to Positive (+) termi-
nal on left. Use Process/Contactor switch
to select type of weld output (see Section
5-3).
If equipped with optional Polarity/AC Se-
lector switch, connect wire feeder cable to
1 Electrode terminal on left and work cable
to Work terminal on right.

Tools Needed:

3/4 in
803 231

Big Blue Air Pak TM-4409 Page 19

4-9. Selecting Weld Cable Sizes*
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)
Weld Output
Terminals
Y Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.

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)

2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

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

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

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (2x95) (2x120) (3x120) (3x120) (4x120) (4x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

TM-4409 Page 20 Big Blue Air Pak

4-10. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

A 24 volts ac. Protected by circuit

breaker CB5.
24 VOLTS AC
B Contact closure to A completes
24 volt ac contactor control
circuit.

C Output to remote control:+10

volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.

D Remote control circuit common.

REMOTE
OUTPUT
CONTROL E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.

115 volts, 10 amperes, 60 Hz

I ac. Protected by circuit breaker
OR CB6.
115 VOLTS AC

Contact closure to I completes

J 115 volt ac contactor control
circuit.

K Chassis common.
803 231
GND

NEUTRAL G Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Big Blue Air Pak TM-4409 Page 21

4-11. Connecting To The Air Compressor
Open Position
Closed Position
Y Air pressure is present at air shutoff
valve whenever Air Pressure Gauge
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.
TM-4409 Page 22
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 5-1).
Run engine at weld/power speed for maxi-
mum air compressor output. Compressor
output is reduced when engine is running at
idle speed.
. Close air shutoff valve before shutting
unit down
Y Stop engine and release air pres-
sure before servicing compressor.
803 231
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.
. Close valve before shutting unit down
to prevent oil burpback into air filter.
. Using the air compressor does not sig-
nificantly affect weld or generator pow-
er output.
Big Blue Air Pak
Notes

Big Blue Air Pak TM-4409 Page 23

 SECTION 5 − OPERATING THE WELDING GENERATOR
5-1. Controls (See Section 5-2)

11 12 15 16 5 7 6

17

10 1 2
13

14

18

803 229 / 217 356-A

TM-4409 Page 24 Big Blue Air Pak

5-2. Description Of Controls (See Section 5-1)
Engine Starting Controls
1 Starting Aid Switch
Use switch to energize starting aid for cold
weather starting.
Push switch up for 60 seconds to operate the
starting aid (intake air heater) before cranking
engine (see starting instructions following).
2 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.
The air compressor load does not affect en-
gine speed. Run engine at weld/power speed
for maximum air compressor output.
To Start:
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
Above 32 F (0 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 32 F (0 C) using starting aid
switch:
Turn Engine Control switch to Run/Idle posi-
tion. Push Starting Aid switch up for 60 sec-
onds. While still holding Starting Aid switch,
turn Engine Control switch to Start. Release
Engine Control switch and Starting Aid switch
when engine starts.
To Stop: turn Engine Control switch to Off
position.
Engine/Compressor Gauges
3 Engine Hour Meter
Use gauge to monitor engine running time for
scheduling maintenance.
4 Fuel Gauge
Use gauge to check fuel level. Engine stops
if fuel level is low on units with low fuel shut-
down option.
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run/Idle
position.
5 Air Pressure Gauge
Use gauge to check compressor air pressure.
Big Blue Air Pak
6 Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (206 − 414
kPa). Engine stops if pressure is below 20 psi
(138 kPa).
7 Engine Temperature Gauge
Normal temperature is 212 - 239° F (100 -
115° C). Engine stops if temperature exceeds
270° F (132° C).
8 Battery Voltmeter
Use gauge to check battery voltage and moni-
tor the engine charging system. The meter
should read about 14 volts dc when the en-
gine is running, and about 12 volts dc when
the engine is stopped.
9 Air Compressor Hour Meter (Optional)
Use gauge to monitor compressor running
time for scheduling maintenance.
Weld Controls
10 Process/Contactor Switch
See Section 5-3 for Process/Contactor
switch information.
11 Amperage Range Switch
Y Do not switch under load.
Use switch to select weld amperage range.
Use all five ranges for Stick welding, and the
lowest four ranges for TIG welding. Read the
upper set of numbers at each range for Stick
welding and the lower set at each range for
TIG welding.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
12 Voltage/Amperage Adjust Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Amperage Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
WithPanel/Remote Switch in Remote posi-
tion, control limits the remote amperage in
TIG mode, but has no effect in Stick and MIG
modes.
Weld output would be about 263 A DC with
controls set as shown (50% of 125 to 400 A).
. The numbers around the Voltage/Amper-
age Adjust control are for reference only
and do not represent an actual percent-
age value.
13 Panel/Remote Switch And Remote 14
Receptacle
Use switch to select front panel or remote
voltage/amperage control. For remote con-
trol, place switch in Remote position and con-
nect remote control to Remote 14 receptacle
RC14 (see Sections 4-10 and 5-4).
14 Polarity/AC Selector Switch (Optional)
Or Output Selector Switch (Optional)
Y Do not switch under load.
Use Polarity/AC selector switch to select AC
or DC weld output and DC weld output po-
larity.
Use Output Selector switch to select AC
Weld, DC Weld, or battery charge output (see
Section 7-1).
Weld Meters
15 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
16 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
Air Compressor Controls
17 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.
18 Air Shutoff Valve
Y Air pressure is present at valve when-
ever Air Pressure Gauge (item 5) indi-
cates air pressure.
Close valve to stop air flow when connecting
or changing tools or air hoses (see Section
4-11).
TM-4409 Page 25
5-3. Process/Contactor Switch
1 Process/Contactor Switch
Y Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the en-
gine is running.
Y DC voltage is still present at the
weld terminals when Process/
1 Contactor switch is in the Re-
mote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table be-
low and Section 5-4).
Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides addition-
al amperage during low voltage (short
arc length conditions) to prevent “stick-
ing” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.

. The engine auto idle option does

not work in the Remote On/Off
Switch Required-TIG mode.

217 638-A

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

Remote On/Off Switch Re-

GTAW With HF Unit, Pulsing
quired − TIG, HF Required At Remote 14 Receptacle Not Active
Device, Or Remote Control
Or Scratch Start TIG

Remote On/Off Switch

Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Required − Stick

Remote On/Off Switch

Required − CV Feeder MIG (GMAW) At Remote 14 Receptacle Active
Using Remote

Weld Terminals Always On −

MIG (GMAW) Electrode Hot Active
Wire

Stick (SMAW),
Weld Terminals Always On −
Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
Stick
And Gouging

Weld Terminals Always On −

TIG Scratch Start (GTAW) Electrode Hot Active
TIG, Scratch Start

TM-4409 Page 26 Big Blue Air Pak

5-4. Using Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 4-10).

803 231

Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Range = 125 to 400 A DC
Min = 125 A DC
Max = 400 A DC

Max (400 A DC)

Min (125 A DC)

Set Set Remote
Set Range Control Not Used Adjust Optional Remote Control
Panel/Remote Process
In Remote On/Off
Switch Switch Required −
Stick Mode

Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)
Range = 40 to 330 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 185 A DC (50% of 40 to 330)

Max (185 A DC)

Min (40 A DC)

Set Set Remote
Set Range Set Control Adjust Optional Remote Control
Panel/Remote Process
Switch

0774 / Ref. 206 467-A / 802 311-A

Big Blue Air Pak TM-4409 Page 27

 SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. 120 Volt And 240 Volt Receptacles

1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
1 2
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
3
receptacle. Press button to reset
GFCI1.

. At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
is working properly.
4 3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.

. If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.

. Generator power is not af-

fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW

191 624

TM-4409 Page 28 Big Blue Air Pak

6-2. Connecting To Optional AC Power Plant

. Do not weld while using optional

ac power plant.

1 2
. Place Process/Contactor switch
Single-Phase Power Connection in Weld Terminals Always On -
Stick position when using option-
al ac power plant (see Section
5-3).
Single-Phase Generator Power
1 120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional ac
power plant and supplies 60 Hz
single-phase power at weld/power
speed. Maximum output from RC5 is
12 kVA/kW. Power available at RC5
is reduced when welding.
2 Circuit Breaker CB7
Circuit breaker CB7 protects single-
phase receptacle RC5 and the load
Three-Phase Power Connection Single Three wires from overload. If CB7 opens, all
AC
Output Phase Phase generator ac output stops and the re-
1 3 ceptacle does not work.
Volts 120/240 240
Y Close panel opening Three-Phase Generator Power
Amps 50 48
if no connections are Y Stop engine.
made to power plant. KVA/KW 12 20
Y Power and weld outputs are
Frequency 60 Hz
live at the same time. Discon-
Engine Speed 1850 RPM nect or insulate unused
Lead 42 connects to GROUND stud on cables.
front of unit.
Jumper 42 is connected to 90 at factory.
. Have qualified person install ac-
cording to circuit diagram and
93 Generator Power Guidelines
(see Owner’s Manual).
Remove plug 91 Remove power panel mounting
before inserting screws. Tilt panel forward.
leads. Reinstall 90 3 Lead 93
bushing.
4 Lead 92
92 5 Lead 91
Rear Of Panel 4
5 6 Lead 42 (Circuit Grounding
91 92 93 Lead)
3
6 7 Lead 90 (Neutral)
2 8 Isolated Neutral Terminal

12 9 Jumper Lead 42
7 10 Grounding Terminal
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
10 nected from neutral to meet applica-
ble electrical codes.
Lead 42 connects to front panel
11 Ground stud.
11 User-Supplied Leads
Y Close panel
opening if no 12 Circuit Breaker CB7 User
9 connections Terminals
are made to Connect user-supplied leads to ter-
power plant. minals on CB7 and to the isolated
240V neutral terminal and grounding termi-
8 120V
nal as necessary.
1-Phase
120V
. Circuit breaker CB7 protects
240V Tools Needed: single-phase receptacle RC5
240V 3-Phase and the load wires from overload.
If CB7 opens, all ac power plant
240V
output stops and the receptacle
does not work.
Ref. 197 399 / 802 332-B Reinstall power panel.

Big Blue Air Pak TM-4409 Page 29

6-3. Optional Generator Power Receptacles
1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 16 A AC European
European Receptacle Receptacle RC1
5 1 2 3 240 V 15 A AC Australian
Receptacle RC1
4 240 V 15 A AC South African
Receptacle RC1
6
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.

. At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
Australian Receptacle
is working properly.
1 3 5 Circuit Breaker CB2
5
6 Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
6 work. Place button to reset breaker.
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.

. If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.

. Generator power is not af-

fected by weld output.
South African Receptacle Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
5 1 4 RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6 (240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW

191 624

TM-4409 Page 30 Big Blue Air Pak

SECTION 7 − OPERATING OPTIONAL BATTERY CHARGER
7-1. Battery Charge Controls
1 Output Selector Switch
Y Do not switch under load. Stop engine
or set Process/Contactor switch to any
Remote position before switching.
Use switch to select weld or battery charge
output. Output automatically decreases (but
1 does not stop) when terminal voltage is 15 to
25 percent above required battery voltage.

. Before connecting charging cables, place

Output Selector switch in position match-
ing voltage of battery being charged.
When done charging, stop engine or set Pro-
cess/Contactor switch to any Remote On/Off
Switch Required position. Move Output Selec-
tor switch to AC Weld or DC Weld position.

803 231-A / 210 149-B

7-2. Determining Battery Charging Current

1 1 Battery Charging Current
Chart
400 Find battery cold crank amp (CCA)
BATTERY CHARGING CURRENT (AMPS)

rating on battery. Use CCA rating

on chart to find charge current set-
350 ting for battery.
EXAMPLE: If battery CCA rating is
300 500, charging current from chart is
100 amperes.
250
Do not exceed charging current
found on chart. For longer battery
200 life, use lowest charge rate
possible.
150

100

50

0
0 500 1000 1500 2000
BATTERY COLD CRANK AMP RATING (CCA) 142 975-B

Big Blue Air Pak TM-4409 Page 31

7-3. Battery Charge Cable Connections
Y Stop engine.
Y Do not charge or jump start a battery
which has loose terminals or one
showing damage such as a cracked
case or cover.
Y Have only qualified persons do bat-
tery charging work.
Y Keep cables away from moving
parts.
Y Do not use damaged cables.
Y Be sure charger output voltage
matches battery voltage.
Y Read BCI Battery Service Manual
before charging or jump starting.
TM-4409 Page 32
+ 5
3
. Before connecting to battery, place
Output Selector switch in position
matching voltage of battery being
charged.
1 Battery
2 Battery Charging Cables
For battery charging, use less than 20 feet
(6.1 m) of AWG #1 or larger cable. For jump
starting, use less than 20 feet (6.1 m) of
AWG 2/0 or larger cable.
3 Terminal Lug
Use lugs of proper amperage capacity and
hole size for connecting to charge output
terminals.
803 231-A / 210 149 / Ref. S-0714 / Ref. S-0756
Install suitable connectors on remaining
ends of battery cables.
4 Battery Charge Positive (+) Output
Terminal
5 Battery Charge Negative (−) Output
Terminal
. Connect charging cables to battery
charge output terminals before con-
necting to battery terminals.
Connect Battery Charge Positive (+) cable
to battery positive (+) terminal, and battery
Charge Negative (−) cable to battery nega-
tive (−) terminal.
Big Blue Air Pak
7-4. Battery Charging Procedure
In Example:
Battery Voltage = 12 Volts
Battery CCA Rating = 500
Charge Current = 100 A (See Section 7-2)
Ampere Range Setting = 55 to 125 A
V/A Control Setting = Any Position

. This battery charging procedure uses

the front panel controls to turn charging
output on and off.

Stop Engine. Set Process/Contactor Switch To Set Output Selector Switch To

Any Remote On/Off Switch Required Voltage Of Battery Being
Position. Charged (12 Or 24 Volt).
Y Do not switch under load.

Determine Charge Current From
Battery CCA Rating And Chart
(See Section 7-2).
+
Set Ampere Range Switch To Lowest Connect Cables (Observe
Range That Exceeds Charge Current. Correct Polarity).
Y Do not switch under load.

Start Engine. Set Process/Contactor Switch Charge 10 minutes. Check

To Any Weld Terminals Always On Battery Voltage. Continue
Position To Begin Charging. Charging If Necessary.

. To control battery charging output using a

remote device connected to the Remote
14 receptacle, keep Process/Contactor
switch in Remote On/Off Switch Required
position and use remote device to turn
charging output on and off.

Big Blue Air Pak TM-4409 Page 33

7-5. Jump Starting Procedure
Stop Engine.
Set Ampere Range Switch To
300-Max Position.
Y Do not switch under
load.
Start Engine.
Switch While Cranking Engine Of Equip-
ment Being Jump Started. Release Switch
TM-4409 Page 34
. Charge battery for 10 minutes before
jump starting battery.
Set Output Selector Switch To
Voltage Of Battery Being
Set Process/Contactor Switch To
Charged (12 Or 24 Volt).
Any Remote On/Off Switch Required
Position. Y Do not switch under load.
Connect Cables (Observe
Correct Polarity).
Connect Remote
OR Control Device
(Momentary-On
Switch).
Press (close)
switch only while
cranking engine of
equipment being
started.
Press (Close) Remote Momentary-On Stop Engine.
Disconnect
Cables.
When Equipment Starts. Stop Welding
Generator And Disconnect Cables.
Big Blue Air Pak
 SECTION 8 − ENGINE/GENERATOR MAINTENANCE
8-1. Engine Maintenance Label

Big Blue Air Pak TM-4409 Page 35

Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.

8-2. Routine Engine/Generator Maintenance

NOTE See Section 11 for air compressor maintenance information.

Y Stop engine before maintaining.

Recycle . See Engine Manual and Maintenance Label for

engine important start-up, service, and storage informa-
fluids. tion. Service engine more often if used in severe
conditions.
* To be done by Factory Authorized Service Agent.

Every 8 h

FUEL Drain Water

Check Fluid
Wipe Up WATER From Fuel
Levels. See
Spills. System. See
Section 4-7.
Section 8-7.

Every 50 h

Clean And
Clean Engine
Tighten Weld
Air Filter.
Terminals.
See Section 8-4.

Every 100 h

Check Engine Air Clean And

Cleaner Hoses Tighten
For Cracks And Battery
Loose Clamps. Connections.

Every 250 h

Inspect
Replace 1/2 in. Belts And
Unreadable (13 mm)
Check
Labels. Tension.

Check And
Clean Clean Optional
Radiator. Spark Arrestor.
See Section 8-5.

Every 500 h

Change Engine Oil

Change Engine Oil. Filter. See Section 8-7.
See Section 8-7. Service more often in
dirty conditions.

Repair Or
Replace
Cracked
Cables.

TM-4409 Page 36 Big Blue Air Pak

 Every 1000 h
Service Welding
Change Engine Generator Brushes
Fuel Filters. And Slip Rings.
See Section Service More Often
8-7. In Dirty Conditions.*

Drain Sludge
FUEL From Fuel Check
Tank. See Engine Valve
SLUDGE Section 8-7. Clearance.*

Blow Out Or
Vacuum Inside.
OR During Heavy
Service,
Clean Monthly.

Every 3000 h

Clean/Set
Engine Fuel
Injectors.*

Every 6000 h / 5 Years

Replace
Engine
Timing Belt.

8-3. Checking Generator Brushes

Y Stop engine and let cool.

1 Generator Brush
Remove brushes from brush holder.
Replace brushes if damaged or if brush
material is at or near minimum length.

Minimum Length:
5/8 in (16 mm)

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

Replace
Damaged Brushes 1

Ref. 206 467

Big Blue Air Pak TM-4409 Page 37

8-4. Servicing Engine Air Cleaner
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
1 Engine Air Cleaner
. The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-

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

Blow Inspect

aircleaner1 9/00 − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B

TM-4409 Page 38 Big Blue Air Pak

8-5. Inspecting/Cleaning Optional Spark Arrestor Muffler

Y Stop engine and let cool.

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
2 Y Stop engine and let cool.
1
Reinstall cleanout plug.

Tools Needed:
3/8 in 803 228 / 803 230

Big Blue Air Pak TM-4409 Page 39

8-6. Adjusting Engine Speed
Y Stop engine and let cool.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
Turn Process/Contactor switch to
Weld Terminals Always On − Stick
position.
1 Throttle Rod
2 Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Wait 15 seconds for throttle sole-
noid to energize and lower engine
speed to idle rpm.
Turn throttle rod to adjust idle
speed. Tighten locknuts.
3 Engine Speed Adjustment
Screw
4 Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw to ad-
just weld/power speed. Tighten
locknut.

. Do not set engine speed higher

than specified.
Y Stop engine.
Close door.

1850 rpm Max.

(61.6 Hz)
1235 rpm
2 (41.1 Hz)
1
2

Tools Needed:

3/8, 7/16 in
803 228 / 802 313-A

TM-4409 Page 40 Big Blue Air Pak

8-7. Servicing Engine Fuel And Lubrication Systems
Tools Needed:
1
Y Stop engine and let cool.
Y 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 Hose And Valve
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/Water
Separator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Tank Sludge Drain Valve
To change oil and filter:
. The engine oil drain and compressor oil
drain hoses are located together in the
Big Blue Air Pak
6
base. Be sure to select the correct hose
when draining engine oil.
Route engine oil drain hose through hole in
base. See engine manual and engine main-
tenance label for oil specifications.
To drain water from fuel system:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
To replace primary fuel filter:
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 until tight. Bleed air from fuel system
according to engine manual.
Inspect fuel lines, and replace if cracked or
worn.
Right Side
2
803 228
To replace secondary fuel filter:
See engine manual.
Close doors.
To drain sludge from fuel tank:
Y 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.
Y 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-4409 Page 41
8-8. Engine/Generator Overload Protection
Y Stop engine.
. See Section 11 for air compressor
overload protection.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload.
If F1 opens, weld and generator power is
low or stops entirely. If F1 continues to
open, check integrated rectifier SR1, ca-
pacitor C9, the rotor, and brush connec-
tions.
If F2 opens, weld output is low or stops en-
tirely. 4 kVA/kW generator power is still
available. If F2 continues to open, check
field current regulator board PC1, the ro-
tor, and brush connections.
3 Circuit Breaker CB4 (Not Shown)
4 Circuit Breaker CB5
5 Circuit Breaker CB6
6 Circuit Breaker CB10 (Not Shown)
7 Circuit Breaker CB11
8 Circuit Breaker CB12
9 Circuit Breaker CB13
TM-4409 Page 42
9
8
4 5
10 Circuit Breaker CB14
(Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault is
corrected. If CB4 continues to open,
check transformer T1, and integrated rec-
tifiers SR4 and SR5.
CB5 protects the 24 volt ac output to re-
mote receptacle RC14, and 24 volt output
to field current regulator board PC1. If CB5
opens, weld output and 24 volt output to
RC14 stops. On units with optional power
plant, power at receptacle RC5 also stops
if CB5 opens. If CB5 continues to open,
check remote controls connected to
RC14, and circuit board PC6 (see Section
10-5).
CB6 protects the 115 volt ac output to re-
mote receptacle RC14. If CB6 opens, 115
volt output to RC14 stops. If CB6 contin-
ues to open, check remote controls con-
nected to RC14, and circuit board PC6
(see Section 10-5).
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
2 1
7
803 229
CB10 automatically resets when the fault
is corrected. If CB10 continues to open,
check fuel solenoid FS1. Also check for
wire(s) shorted to ground.
CB11 protects the engine wiring harness.
If CB11 opens, weld output stops (genera-
tor power is still available). If CB11 contin-
ues to open, check field current regulator
board PC1 (see Section 10-7).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available. If CB12 con-
tinues to open, check field current regula-
tor board PC1 (see Section 10-7).
CB13 protects the engine shutdown cir-
cuit. If CB13 opens, the engine cranks but
does not start. If CB13 continues to open,
check the engine alternator, engine
gauges, and relays CR2, CR5, CR6, and
CR11.
CB14 protects the throttle solenoid. If
CB14 opens, the engine will not run at idle
speed. CB14 automatically resets when
the fault is corrected. If CB14 continues to
open, check throttle solenoid TS1.
Press button to reset breaker.
Big Blue Air Pak
Notes

Big Blue Air Pak TM-4409 Page 43

 SECTION 9 − THEORY OF OPERATION
A. Block Diagram 14 13
1 Engine
Filter Board
Supplies force to turn revolving fields. PC6/Remote Circuit Breakers
2 Prior to LE118236: Control Relays Receptacle RC14 CB5, CB6 12
CR2, CR5
CR2 energizes at start-up to supply pow- LED Board PC9
er to the fuel solenoid.
CR5 energizes at start-up to supply pow-
er for field flashing.
15 16 11
Eff w/LE118236: Control Relays
CR1, CR5, TD1 Process/
Contactor Switch S6 Panel/Remote
CR1 energizes at start-up to supply pow-
Switch S5
er to starter solenoid. Remote Electrode
Hot
CR5 energizes at start-up to supply pow-
Field
er for field flashing and to the fuel sole-
Current
noid.
Regulator
TD1 energizes at start-up to supply pow- 36 35 34 10
Board
er to CR5 and enable engine gauges and Voltage/ PC1
Control Air Pressure Air Compressor
shutdown circuit. (Engine shutdown in- Amperage
Relay Switch Switch
hibited for 30 seconds after start-up.) Adjust
CR10 S11 S10 Control R1
3 Control Relays CR3, CR4, CR6
CR3 energizes at no load to supply power
to throttle solenoid TS1. 37
CR4 energizes at no load to bypass resis- Air 9 8 8
tor R3 and prevent loss of field excitation. Compressor/
CR6 energizes when engine is running to Clutch Integrated
supply power to idle module. Rectifier Fuse F1 Fuse F2
SR1
4 Idle Module PC7
Controls engine speed. Without a signal 7
from CT1, it lowers engine speed to idle 1 6
(1235 rpm). Exciter
Revolving
5 Throttle Solenoid TS1 (Pull To Idle) Engine Fields

Weld
(Rotor) Stator Windings
Decreases engine speed to idle rpm
(1235 rpm) when energized.
Generator Power
Circuit breaker CB14 protects TS1.
2 19
6 Main/Exciter Revolving Fields
Turn at 1850 rpm maximum for weld and Prior to
LE118236 HF Filter
power. The speed and excitation current Board PC5
of the field coils determine voltages in sta- Control Relays
tor windings. CR2, CR5
Eff w/LE118236
7 Stator Windings 5
Control Relays
Supply power to exciter, generator power, Throttle CR1, CR5, TD1 17 ♦ 32
and weld circuits. Solenoid TS1
8 Fuses F1, F2 (Pull To Idle) Three-Phase Transformer
Generator T1
Protect aux. stator (exciter) windings
from overload.
4 3
9 Integrated Rectifier SR1
Control Relays 18 ♦
Changes ac output of stator windings to Idle Module
dc to supply excitation current to the ex- PC7 CR3, CR4,
citer revolving field. CR6 Circuit Breaker
CB7
10 Voltage/Amperage Adjust Control
R1
Adjusts voltage/amperage within range
selected by S3. 14 Filter Board PC6/Remote 14 Receptacle
11 Field Current Regulator Board PC1 RC14 33
Adjust weld output by changing revolving PC6 protects unit from high frequency, and RC14
connects remote voltage/amperage and contac- Integrated
field current after comparing feedback to Rectifiers
voltage/amperage setting of R1. tor control to unit.
SR4, SR5
15 Process/Contactor Switch S6
12 LED Board PC9
Selects weld process and weld output on/off con-
Monitors power, remote control, com-
trol (Remote or Electrode Hot).
mand, engine rpm, and field excitation in-
puts to PC1. 16 Panel/Remote Switch S5
13 Circuit Breakers CB5 And CB6 Selects Panel or Remote voltage/amperage con-
trol.
Protect PC6/RC14 from overload.

Figure 9-1. Functional Diagram

TM-4409 Page 44 Big Blue Air Pak
 17 Three-Phase Generator
Provides connection points and power for
three-phase auxiliary equipment.
18 Circuit Breaker CB7
Protects three-phase generator power
windings from overload.
19 HF Filter Boards PC4, PC5
Protect unit from high frequency.
20 Current Transformer CT1
Senses output from either generator power
or weld windings, and signals idle module to
increase to or maintain weld speed (1850
rpm).
21 Circuit Breakers CB1 And CB2
Protect AC receptacles RC1 and GFCI1
from overload.
22 AC Receptacles RC1 And GFCI1
Provide power for auxiliary equipment.
23 Reactor Z1
Tapped reactor limits weld output and pro-
vides coarse ranges.
24 Ampere Range Switch S3
Selects coarse range of weld output from
Z1.
25 Main Rectifier SR3
Changes ac weld output to dc.
26 HF Filter Board PC3
Protects main rectifier from high frequency,
voltage spikes. Provides OCV feedback to
PC1.
27 Polarity/AC Switch S12 Or Output Se-
lector Switch S13
S12 selects AC or DC weld output and DC
weld output polarity.
S13 selects battery charging (12 or 24
volts), AC weld output, or polarity of DC weld
output.
28 Control Relay CR7
Bypasses arc drive (dig) circuit when using
battery charge option.
29 Voltmeter V1, Ammeter A1
Display weld voltage and current.
30 Electrode And Work Weld Output Ter-
minals
Provide weld output. Without S12, terminals
are labeled negative (−) and positive (+).
31 Battery Charge Positive (+) And Nega-
tive (−) Terminals
Provide battery charge/jump start output.
32 Transformer T1
Supplies power to arc drive (dig) circuit. Arc
drive circuit only active in Stick mode.
33 Integrated Rectifiers SR4, SR5
Change ac output of stator windings to dc to
supply power to arc drive (dig) circuit.
34 Air Compressor Switch S10
Turns air compressor on and off.
35 Air Pressure Switch S11
Prevents control relay CR10 from energiz-
ing and compressor from running when sys-
tem pressure is above 20 psi.
36 Control Relay CR10
CR10 energizes when air compressor
switch is closed to supply power to com-
pressor clutch.
37 Air Compressor/Clutch
Clutch engages when energized to operate
compressor. (See Section 11 for additional
air compressor information.)

OCV
Feedback
AC Or DC Control Circuits

23 24 25
3φ Power
Reactor Ampere Main
Z1 Range Rectifier
Switch S3 SR3 Weld Or Battery Charging
20♦ 26
Current Output (Optional)
Transformer HF Filter Either Mechanical Coupling
CT1 Board PC3 Or External Circuits
28♦ 27♦
Polarity/AC Magnetic Coupling
Control Switch S12 or
Relay Output Selector ♦ Optional
CR7 Switch S13 29 ♦

21 Ammeter
29♦ A2
Circuit Breakers
CB1, CB2 Voltmeter
19 V1

HF Filter
Board PC4 19 19
22♦

AC HF Filter HF Filter
Receptacles Board PC4 Board PC5
RC1, GFCI1

30 31♦ 31♦ 30
Battery Battery
Electrode Charge Charge Work
Weld Output Positive (+) Negative (−) Weld Output
Terminal Terminal
Terminal Terminal

Electrode Battery Work

Big Blue Air Pak TM-4409 Page 45

 B. Training Circuit For Models Prior To LE118236
. This circuit is for training purposes only. It has been modified for
that use and may not reflect the actual circuit for your unit.
. Reference:
DC common - lead 42 unless otherwise noted
6. Field Flashing: At start-up, battery volt- 11. Field current regulator board PC1
age (DC) goes through CR5 closed con- control circuit processes command,
7. Exciter Field: After rotor is flashed tacts, circuit breaker CB12, and PC1 voltage/current feedback, Process/
(item 6), aux. stator windings 100 and flashing diode. Battery voltage contin- Contactor switch position, and oth-
101 produce ac voltage as the rotor ues through the brushes/slip rings (on er inputs to control the dc output
turns. The ac output goes through fuse leads 105 and106) to create a magnetic current being sent to the weld re-
F1, is rectified by integrated rectifier field in the exciter/aux. revolving field volving field (rotor) on leads 105
SR1, filtered by capacitor C9, and fed (rotor). and 108.
through the brushes/slip rings to create
a strong magnetic field in the aux. re-
volving field (rotor).

10. Weld Field: Aux. stator

winding 103 and 104 pro-
duces the ac voltage need-
ed for the weld revolving
field (rotor). Fuse F2 pro-
tects this winding. An Inte-
grated rectifier on circuit
board PC1 converts this ac
input to dc output. PC1 dc
output feeds through the
brushes/slip rings on leads
105 and 108) to create a
magnetic field in the weld
revolving field (rotor).

16. Remote receptacle

RC14 provides for a
remote weld enable
signal with contact
closure between
pins A and B, or
pins I and J. RC14
pins C, D, and E are
used for remote
weld output control.

3. When fuel solenoid 15.
control relay CR2
energizes, normally-open
CR2 contacts close to
supply battery current to
fuel solenoid FS1.
When CR10 energizes 1. At start-up, engine battery 2. In Run mode, fuel solenoid
(item 14), CR10 normally- current goes through En- control relay CR2 remains
open contacts close to gine Control switch S1 and energized through safety
supply battery voltage to energizes starter control shutdown relay CR11 normal-
the clutch and engage the relay CR1, safety shut- ly-closed contacts. If engine
compressor. The clutch is down circuit bypass timer oil pressure is too low or cool-
protected by circuit TD1, and fuel solenoid ant temperature is too high,
breaker CB15. control relay CR2. CR11 energizes, normally-
closed CR11 contacts open,
and fuel solenoid control relay
CR2 deenergizes.

TM-4409 Page 46 Big Blue Air Pak

 8. The two aux. stator windings (leads 81 and
82, and leads 82 and 84) supply 120/240
volts ac to receptacles GFCI1 and RC1.
Windings 82 and 84 also supply 120 volts
ac to front panel remote receptacle RC14
Pins I and G. Circuit breakers CB1, CB2,
and CB6 protect these windings.
13. Arc Force: When arc voltage drops below
20 volts, the arc force circuit adds current
to help prevent electrode from “sticking”. In
Stick mode only, ac voltage from the aux.
stator winding is reduced by transformer
T1, rectified by integrated rectifiers SR4
and SR5 and fed to the weld output termi-
nals. Circuit breaker CB8 protects the aux.
stator winding.

9. Aux. stator
winding (leads 12. The rotation of the magnetized weld rotor induces
83 and 89) sup- an ac voltage in the stator weld windings. The
plies 24 volts ac stator weld windings supply 3-phase ac power
to front panel through Range switch S3, tapped reactor Z1, and
remote recep- main rectifier SR3 to the weld output terminals.
tacle RC14 pins
A and G. Circuit
breaker CB5
protects this
winding.

4. Control relays CR5 and CR6
are energized in Start and Run
modes. CR5 supplies battery
voltage to field flashing circuit
and field current regulator
board PC1 control circuit. CR6
supplies battery voltage to idle
module PC7 (idle circuit).
5. Idle Circuit: At no load, PC7 ener-
gizes control relay CR3 and throttle
solenoid TS1 pulls in to run engine at
idle speed. Under weld or power load,
current transformer CT1 senses out-
put from generator power or weld
windings and provides an ac input to
PC7 on leads 66 and 67. CR3 deen-
ergizes and TS1 releases to run en-
gine at weld/power speed. TS1 is pro-
tected by circuit breaker CB14.
14. Air Compressor: When Air Compressor
switch S10 is closed (On), current flows
through normally-closed air pressure
switch S11 and temperature switch S12 to
energize clutch control relay CR10. CR10
normally-open contacts close to ”latch”
CR10 on.
Training − 206 462-A

Big Blue Air Pak TM-4409 Page 47

Notes

Work like a Pro!

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

TM-4409 Page 48 Big Blue Air Pak

SECTION 10 − WELDING GENERATOR TROUBLESHOOTING
10-1. Troubleshooting Tables
. See Section 10-2 for test points and
values and Section 16 and following
for parts location.

. Use MILLER Testing Booklet (Part

No. 150 853) when servicing this unit

A. Welding

Trouble Remedy
No weld output; generator power out- Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
put okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-10, 5-2 and 5-4).

Check position of Ampere Range switch S3.

Check position of optional Output Selector switch S13.

Reset circuit breaker CB11 (see Section 8-8).

Reset circuit breaker CB5 (see Section 8-8). Check for faulty remote device connected to RC14.

Check fuse F2, and replace if open (see Section 8-8).

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-10).

Check connector board PC6 and connections, and replace PC6 if necessary (see Section 10-5).

Clean slip rings, and install new brushes if necessary (see Section 10-13).

Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-7).

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

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

Reset circuit breaker CB12 (see Section 8-8).

Check fuses F1 and F2, and replace if open (see Section 8-8).

Check diode/capacitor board D1/C1, and replace if necessary.

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-13).

Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR5 if necessary.

Disconnect leads 105 and 106 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.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

Erratic weld output. Use dry, properly stored electrodes.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Check and tighten connections inside and outside unit.

Clean slip rings, and install new brushes if necessary (see Section 10-13).

Check main rectifier SR3, and replace if necessary.

Big Blue Air Pak TM-4409 Page 49

 Trouble Remedy
High weld output. Check position of Ampere Range switch S3 and Voltage/Amperage Adjust control R1.

Check engine speed, and adjust if necessary (see Section 8-6).

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section
frequently during low voltage (short arc 8-8).
length) conditions.

Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

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

Low weld output. Check engine speed, and adjust if necessary (see Section 8-6).

Check fuses F1 and F2, and replace if open (see Section 8-8).

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

Clean slip rings, and install new brushes if necessary (see Section 10-13).

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

Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 8-6).

No remote fine amperage or voltage Place Panel/Remote switch S5 in Remote position.

control.

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-10).

Repair or replace remote control device.

Constant speed wire feeder does not Reset circuit breaker CB5 and CB13 (see Section 8-8).
work with welding generator.

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-10).

Repair or replace wire feeder.

Low CV weld output. Set Ampere Range switch S3 to highest range.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control R1 and Panel/Remote switch S5.

Repair or replace remote control device.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit.
Feedback voltage should be the same as weld terminal open circuit voltage (see Section 10-2).

B. Generator Power

Trouble Remedy
No generator power output at ac re- Reset receptacle circuit breakers.
ceptacles; weld output okay.

Check resistance of generator power windings between leads 81 and 84. Replace exciter stator (aux.
stator) if necessary.

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

Check fuses F1 and F2, and replace if open (see Section 8-8).

Reset circuit breaker CB12 (see Section 8-8).

Check integrated rectifier SR1, and replace if necessary.

TM-4409 Page 50 Big Blue Air Pak

 Trouble Remedy
No generator power output or weld out- Check capacitor C9, and replace if necessary.
put (continued).

Clean slip rings, and install new brushes if necessary (see Section 10-13).

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-14).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

High output at generator power ac Check engine speed, and adjust if necessary (see Section 8-6).
receptacles.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-14).

Low output at generator power ac re- Check engine speed, and adjust if necessary (see Section 8-6).
ceptacles.

Check fuse F1, and replace if open (see Section 8-8).

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-14).

C. Optional Three-Phase Generator

Trouble Remedy

No or low output at optional three- Place Process/Contactor switch in Electrode Hot - Stick position (see Section 5-3).
phase generator/receptacle RC5.

Reset circuit breaker CB7 (see Section 6-2).

Reset circuit breaker CB5 (see Section 6-2).

Check engine weld/power speed, and adjust if necessary (see Section 8-6).

Check slip rings, and install new brushes if necessary (see Section 10-13).

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

High output at optional three-phase Check engine weld/power speed, and adjust if necessary (see Section 8-6).
generator/receptacle RC5.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).

Erratic output at optional three-phase Clean slip rings, and install new brushes if necessary (see Section 10-13).
generator/receptacle RC5.

Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-7).

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

Check battery connections and tighten if necessary.

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

Check engine wiring harness plug connections.

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

Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR1 if necessary.

Big Blue Air Pak TM-4409 Page 51

 Trouble Remedy
Engine will not crank (continued). Check control relay TD1 for proper operation (see Section 10-12).

Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR2 if necessary.

Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR5 if necessary.

Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is too low.

Reset circuit breaker CB13 (see Section 8-8). Check engine wiring harness and components.

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

Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR2 if necessary.

Check fuel solenoid FS1 for proper coil voltage and connections (see Section 8-7). Check continuity
of coil. Replace FS1 if necessary.

Check control relay TD1 for proper operation (see Section 10-12).

Air in fuel system. See engine manual.

Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low, or engine temper-
Control switch S1 is released. ature is too high (see Section 4-7).

Check control relay TD1 for proper operation (see Section 10-12).

Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR5 if necessary.

Engine hard to start in cold weather. Use (optional) starting aid switch (see Section 5-1).

Check (optional) starting aid control relay CR8 for proper coil voltage and connections. Check conti-
nuity of coil and condition of contacts. Replace CR8 if necessary. Check Engine Control switch S2.

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 Section 8-1).

Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low, or engine temper-
ature is too high (see Section 4-7).

Check fuel level. Optional low fuel shutdown stops engine if fuel level is too low.

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 8-4 and 8-7).

See engine manual.

Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Check continuity of Engine Control switch S1, and replace if necessary.
weld speed.

Check idle module PC7 and connections, and replace if necessary (see Section 10-11).

Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.

Check for obstructed throttle solenoid.

Engine does not run at idle speed. Place Process/Contactor switch S6 in any position but Remote-TIG.

Check throttle solenoid TS1 for proper coil voltage and connections. Check continuity of coil. Replace
TS1 if necessary.

TM-4409 Page 52 Big Blue Air Pak

 Trouble Remedy
Engine does not run at idle speed (con- Check for obstructed throttle solenoid.
tinued).

Check idle module PC7, and replace if necessary (see Section 10-11).

Allow circuit breaker CB14 to reset (see Section 8-8). Check throttle solenoid TS1 for proper coil
voltage and connections. Check continuity of coil. Replace TS1 if necessary.

Check control relay CR3 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR3 if necessary.

Check control relay CR6 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR6 if necessary.

Engine uses oil during run-in period; Dry engine (see Section 14).
wetstacking occurs.

E. Optional Battery Charging

Trouble Remedy
No battery charge output; weld output Place Output Selector switch S13 in 12 Volt Charge or 24 Volt Charge position.
okay.

Check and secure lead 130, 131, 132, and 133 connections to field current regulator board PC1 and
Output Selector switch S13.

Check and tighten battery connections if necessary.

Turn on remote control device or turn Process/Contactor switch to any Electrode Hot position (see
Section 5-3).

No battery charge or weld output; gen- Disconnect equipment from generator power receptacles during start-up.
erator power output okay at ac recep-
tacles.

Check fuse F2, and replace if open (see Section 8-8).

Disconnect leads 106 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-13).

Check main rectifier SR3, and replace if necessary.

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

Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-7).

F. Air Compressor (See Section 12)

Big Blue Air Pak TM-4409 Page 53

10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)

V3, R3

V1, R1

V2,
R2

V4, R4
Adjust R3
according to
See Section Section 10-14
10-5 for V8, R7
PC6 data V9, R8

See V7
Sec- I2
tion V20 V21
4-10
for V5, I1
R5
RC14
infor- V19
mation
V6, R6

V23
V22

Throttle Solenoid
TS1 (Pull To Idle)

V27, Starter control

R14 relay CR1

V16,
R12

V18,
R13
Air
V17
compressor
clutch
Field flashing
control relay CR5

TM-4409 Page 54 Big Blue Air Pak

 V25
V24

V29, R16

V28,
R15 V26
See Sec-
tion 9
for PC3
informa-
tion
V30, R17
V10, R9 V12, R11 V31

V13,
A, B

See Section 10-4

for waveforms
V11, R10 A and B

See Section 9 for

PC4, PC5 information

V14 V15

Field current resistor Idle control

bypass relay CR4 relay CR3

Idle module
control relay CR6

Air compressor
control relay CR10
Starting aid
relay CR8

221 915-A

Big Blue Air Pak TM-4409 Page 55

10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine (no
warm-up); no load
c) Reference − single arrow: reference to
circuit common (lead 42); double arrow:
reference to points indicated
d) Process/Contactor switch S6 in Electrode
Hot − Stick position unless noted
Resistance Values
e) Wiring Connections − see Section 13
a) Tolerance − ±10% unless
V1 126 − 130 volts ac specified
V2 126 − 130 volts ac
b) Condition − 70°F (21°C); cold
V3 252 − 260 volts ac machine (no warm-up)
V4 27 volts ac
c) Wiring Connections − see
V5 101 volts ac Section 13
V6 175 volts ac
d) Stop engine before checking
V7 +135 volts dc resistance
V8 + 89 volts dc
R1 thru R6 Less than 1 ohm
V9 +89 volts dc (S6 in Electrode Hot −Stick position) R7 18.5 ohms
+33 volts dc (S6 in Electrode Hot−Scratch Start
TIG position) R8 14.2 ohms
+11.5 to 40.5 volts dc from min to max of R1 (S6 R9 thru R11 Less than 1 ohm
in Electrode Hot − MIG position) R12 Pull In: Less than 1 ohm
V10 69 volts ac (R1 at max.) Hold: 15 ohms
V11 69 volts ac (R1 at max.) R13 3.5 ohms
R14 2.5 ohms
V12 69 volts ac (R1 at max.)
R15 thru R17 Less than 1 ohm
V13 +89 volts dc (S6 in Electrode Hot − Stick position)
47 volts dc (S6 in Electrode Hot − Scratch Start
Tig position)
+16 to 56 volts dc from min to max of R1 (S6 in
Electrode hot − MIG position)
V14 +12 volts dc at idle rpm
V15 +12 volts dc 10 − 15 seconds after load is
removed and engine goes to idle rpm
Amperage Readings
V16 +12 volts dc at idle rpm
a) Tolerance − ±5% unless specified
V17 +12 volts dc with Starting Aid switch S2 closed
V18 +12 volts dc with engine running b) Condition − 70°F (21°C); cold
machine (no warm-up); no load
V19 0 to +10 volts dc from min to max of R1
V20 +10 volts dc c) Process/Contactor switch S6 in
Electrode Hot − Stick position
V21 0 to +10 volts dc from min to max of R1
unless noted
V22 +12 volts dc
V23 +12 volts dc I1 6.3 amps dc

V24 258 volts ac with Process/Contactor switch S6 I2 4.3 − 4.6 amps dc

in Stick position
V25, 18 volts ac with Process/Contactor switch S6
V26 in Stick position
V27 +12 volts dc with compressor running
V28, 260 volts ac
V29,
V30
V31 +14.4 volts dc with Output Selector switch S13
in 12 Volt Charge position
+28.4 volts dc with Output Selector switch S13 in
24 Volt Charge position

TM-4409 Page 56 Big Blue Air Pak

10-4. Waveforms For Section 10-2

. The waveforms represent the output

of the welding power source. When
operating properly, the power source
waveforms match those shown here.

1 ms 50 V 1 ms 10 V

gnd gnd

A. DC/CC Open-Circuit Voltage, Amperage B. DC/CC Output, 28 Volts DC, 200 Amperes,
Adjust Control R1 At Maximum Ampere Range Switch S3 At 125-400
Position (Resistive Load)

Test Equipment Needed:

Big Blue Air Pak TM-4409 Page 57

10-5. Filter Board PC6 Testing Information

Y Stop engine.
See Section 10-6 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.

Test Equipment Needed:

803 332 / 192 998

TM-4409 Page 58 Big Blue Air Pak

10-6. Filter Board PC6 Test Point Values

a) Tolerance − ±10% unless

specified
PC6 Voltage Readings b) Reference − to circuit common
(lead 42) unless noted
c) Condition − no load
d) Process/Contactor switch S6
in Electrode Hot − Stick
position

Receptacle Pin Value

RC2 1 Not used

2 115 volt ac input with respect to pin RC2-10

3 24 volt ac input with respect to pin RC2-10

4 24 volt ac output with respect to pin RC2-10

5 Contactor control circuit, 24 volt ac input with contact closure to pin RC2-9 and closure on RC14 be-
tween pins A and B or pins I and J

6 Command reference, 10 volt dc input

7 Command common

8 Remote command signal output, 0 to +10 volts dc input from min to max of remote voltage/amperage
control

9 Circuit common for 24 volt ac contactor control circuit

10 Circuit common for 24 volt and 115 volt ac circuits

Big Blue Air Pak TM-4409 Page 59

10-7. Field Current Regulator Board PC1 Testing Using LED Board PC9

Determine the condition of field cur-

rent regulator board PC1 by ob-
serving the LED’s on LED board
PC9 (in control box).

. Do not open the PC1 sealed

case to service PC1. If PC1 is
not working properly, replace
the entire PC1 module.
1 Be sure plugs are secure. See Sec-
tion 10-8 for diagnostic information
and specific values during testing.
1 Field Current Regulator Board
PC1 Module
2 LED Board PC9
3 Diagnostic LED’s (See Sec-
tion 10-8)

Test Equipment Needed:

803 332 / 192 226-A

TM-4409 Page 60 Big Blue Air Pak

10-8. Using Diagnostic LED’s On LED Board PC9

NOTE The LED’s on circuit board PC9 monitor all critical input voltages to field current
regulator board PC1.
If PC9 Power LED, Output On/Off LED, and AC Input LED are on with
Process/Contactor switch S6 in Electrode Hot - Stick mode and engine running at
weld/power speed, 89 volts dc should be present at brush leads 105 and 108. This
indicates field current regulator board PC1 is functioning normally.

a) Condition − no load; weld/power

rpm unless noted
b) Voltage/Amperage Adjust switch
S5 in Panel position
b) Reference − to circuit common
(lead 42) unless noted

LED Status Self-Test

POWER On Indicates +12 volts dc is present to energize PC1.

Off If LED is off:

Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR5 if necessary.
Reset circuit breaker CB10 and/or CB11.
Check for loose electrical connections to PC1.
Check for 12 volt dc supply voltage to PC1. If voltage is low, check battery or engine charging system.

OUTPUT On Indicates 24 volts ac input with Process/Contactor switch S6 in Electrode (Hot) position, or with S6 in a
ON/OFF remote position with remote contactor closed.

Off If LED is off:

Place Process/Contactor switch S6 in Electrode (Hot) position, or place S6 in Remote position and con-
nect remote contactor to remote receptacle RC14.
Reset circuit breaker CB5.
Check filter board PC6 and connections, and replace if necessary (see Section 10-5).

COMMAND On Indicates 0 to +10 volts dc input from min. to max. of Voltage/Amperage Adjust control R1 with Panel/Re-
mote switch S5 in Panel position. LED goes from dim to bright as R1 is adjusted between min. and max.

Off If LED is off:

And Power LED is on, check that Voltage/Amperage Adjust control R1 is not at min.
And Power LED is on, check and tighten connections to Voltage/Amperage Adjust control R1.
And Power LED is on, check voltage at Voltage/Amperage Adjust control R1 (see Section 10-2). If correct
voltage is not present, check connections to PC1.
And Power LED is on, check resistance and connections of Voltage/Amperage Adjust control R1; R1 is
0 to 1000 ohms ±10%. Replace R1 if necessary.

RPM On Indicates engine speed is less than 1704 rpm (approximately).

LIMIT
If LED is on:
. LED normally And AC Input LED is on, check engine weld/power speed and adjust if necessary.
off at weld/
And AC Input LED is off, check position of Engine Control switch S1 (not in idle position).
power speed)
And AC Input LED is off, check fuse F2, and replace if open.
And AC Input LED is off, reset circuit breaker CB12.

Off Indicates engine speed is above 1704 rpm (normal operation).

AC INPUT On Indicates + 175 volts ac input from field excitation circuit.

Dim or Off If LED is off, power LED is on, and normal ac voltage is present at ac receptacles (see Section 10-2):
Check fuse F2, and replace if open.
Reset circuit breaker CB12.

Big Blue Air Pak TM-4409 Page 61

10-9. LED Board PC9 Testing

Be sure plugs are secure. See Sec-

tion 10-8 for specific values during
testing.
1 LED Board PC9

Test Equipment Needed:

803 332 / 192 226-A

TM-4409 Page 62 Big Blue Air Pak

10-10. LED Board PC9 Test Point Values

a) Tolerance − ±10% unless

PC9 Voltage Readings
specified
b) Reference − to circuit common
(lead 42) unless noted
c) Condition − no load; weld/power
rpm unless noted
d) Process/Contactor Control switch
S6 in Weld Terminals Always On −
CC Stick position
. Do not exceed recommended voltage
when testing LED’s or circuit board may be
damaged.

Receptacle Pin Value

PLG13 1 Power LED, +2 volts dc input
To test power LED, apply +2 volts dc to PLG13-1 and connect negative (−) side of power supply to
PLG13-8. LED lights if okay.

2 Not used

3 Not used

4 Not used

5 AC input LED, +1.85 volts dc input with respect to pin PLG13-10 when weld exciter voltage is
present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (−) side of power sup-
ply to PLG13-5. LED lights if okay.

6 Output on/off LED, 0.13 volts dc input with contactor off; + 2 volts dc input with contactor on.
To test output on/off LED, apply +2 volts dc to PLG13-6 and connect negative (−) side of power sup-
ply to PLG13-8. LED lights if okay.

7 Command LED, 0 to 2 volts dc input from min to max of Voltage/Amperage Adjust control R1.
To test command LED, apply +2 volts dc to PLG13-7 and connect negative (−) side of power supply
to PLG13-8. LED lights if okay.

8 Circuit common

9 RPM Limit LED, +10.5 volts dc input at 1850 rpm; voltage decreases as engine speed decreases.
LED goes on when engine speed is less than 1704 rpm (approximately).
To test rpm limit LED, apply +2 volts dc to PLG13-8 and connect negative (−) side of power supply to
PLG13-9. LED lights if okay.

10 AC Input LED, +1.85 volts dc input with respect to pin PLG13-5 when weld exciter voltage is present.
To test ac input LED, apply +1.85 volts dc to PLG13-10 and connect negative (−) side of power sup-
ply to PLG13-5. LED lights if okay.

Big Blue Air Pak TM-4409 Page 63

10-11. Idle Module PC7 Testing Information And Troubleshooting Flow Chart

Voltage readings tolerance ±10%.

1 Idle Module Verify engine speeds are correct
before testing idle module.

Engine does not go to idle speed

(1235 rpm) with no load applied.

Connect meter (DC) between

terminal B (+) and terminal E (−).

Start engine, and place

Engine Control switch S1 in
Run/Idle position.
Place Process/Contactor
switch S6 in
Electrode Hot − Stick position.

Check connections
to Engine Control
NO
+12 volts dc present? switch S1, control
relay CR6, and
ground connection
YES (lead 42).

1 Connect meter (AC) between

terminal D and terminal G.

D C Check for internal

NO
load such as
0 (zero) volts ac present?
shorted diode in
main rectifier SR3.
G E YES

Connect meter (DC) between

terminal C (+) and terminal E (−).
B F
A
NO
Approximately +10 volts dc Replace
present after 12 to 18 seconds? idle module.

YES

Check control relay CR3, throttle

solenoid TS1, and connections.
Also check self-resetting circuit
Test Equipment Needed: breaker CB14 (see Section 8-8).

Reinstall cover.

TM-4409 Page 64 Big Blue Air Pak

 Engine does not go to weld/power Control Relay CR4 does not energize
speed (1850 rpm) with load applied. at idle rpm with no load applied (see
Section 9 for CR4 information).

Connect meter (AC) between Connect meter (DC) between

terminal D and terminal G. terminal A (+) and F (−).

Start engine, and place Start engine, and place

Engine Control switch S1 in Engine Control switch S1 in
Run/Idle position. Run position.
Place Process/Contactor Place Process/Contactor
switch S6 in switch S6 in
Electrode Hot − Stick position. Electrode Hot − Stick position.

NO
Connect a 100 watt light bulb to 0 (zero) volts dc present? Replace idle
120 volts ac duplex receptacle. module PC1.

YES

NO Check connections Place Engine Control switch S1

Minimum of 1 volt ac present? to current in Run/Idle position.
transformer CT2.
YES

NO
Connect meter (DC) between +12 volts dc present? Replace idle
terminal C (+) and terminal E (−). module PC1.

YES

NO
0 (zero) volts dc present? Replace Check control relay
idle module. CR4.
YES

Check control relay CR3. Reinstall cover.

Disconnect 100 watt light bulb

and meter leads.

Reinstall cover.

803 332

Big Blue Air Pak TM-4409 Page 65

10-12. Time Delay Relay TD1 Testing Information And Troubleshooting Flow Charts

Voltage readings tolerance ±10%.

1 Time Delay Relay TD1

Engine does not start.

Connect meter (DC) between

terminal +12V and terminal
GRD.

Place Engine Control switch in

Run position.

Reset circuit
breaker(s) CB10
NO
+12 volts dc present? and CB13. Check
Engine Control
switch S1 and con-
YES nections.

Connect meter (DC) between

terminal C (CM) and terminal
GRD.

NO
+12 volts dc present? Replace TD1

YES
1
Check control relay CR5
and engine fuel and
starter solenoids.

Reinstall cover.

Test Equipment Needed:

TM-4409 Page 66 Big Blue Air Pak

Engine starts, but stops within 30 seconds. Engine starts, but stops after 30 seconds.

Connect meter (DC) between Connect meter (DC) between

terminal +12V and terminal terminal +12V and terminal
GRD. GRD.

Place Engine Control switch in Place Engine Control switch in

Run position. Run position.

Reset circuit Reset circuit

breaker(s) CB10 breaker(s) CB10
NO NO
+12 volts dc present? and CB13. Check and CB13. Check
Engine Control +12 volts dc present? Engine Control
switch S1 and con- switch S1 and con-
YES nections. YES nections.

Connect meter (DC) between

Connect meter (DC) between
terminal C (CM) and terminal
terminal NC and terminal GRD.
GRD.

NO Start engine. When engine begins

+12 volts dc present? Replace TD1
to stop, quickly check voltage.

YES
Check for low oil
level or high engine
Check fuel solenoid FS1 NO temp. condition.
+12 volts dc present?
and connections.

YES

Reinstall cover. Replace TD1

Reinstall cover.

803 458 / 214 928

Big Blue Air Pak TM-4409 Page 67

10-13. Replacing Brushes And Cleaning Slip Rings

Y Stop engine.
1 Generator Power Panel
Remove screws from panel. Tilt
panel forward.
2 Spring Clip
3 Brush
4 Brush Holder Assembly
Squeeze end of spring clip to re-
move clip and brush from brush
holder assembly. Remove and in-
spect all three brushes.
Replace brushes if damaged, or if
brush is at or near minimum length.
5 Slip Rings
Visually inspect slip rings. Under
normal use, rings turn dark brown.
1
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Reinstall generator power panel.
Y Stop engine.

2
Minimum Length:
5/8 in (16 mm)

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

Replace
Damaged Brushes
803 333

TM-4409 Page 68 Big Blue Air Pak

10-14. Checking Unit Output After Servicing

. Also use output waveforms to

check unit output after servic-
ing (see Section 10-4).
Check engine speeds, and adjust if
necessary (see Section 8-6).
1 Duplex Receptacles GFCI1
And RC1
2 Resistor R3
Start engine and run at weld/power
speed (1850 rpm).
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts ac present at
GFCI1 and 252 to 260 volts ac at
RC1.
If correct voltage is not present,
stop engine and reconnect lead 102
and/or lead 106 to different taps on
R3.

. Connect R3 so at least half of

resistor length is in circuit.
z Start engine and check GFCI1 and
RC1 voltage. If necessary, change
1 R3 connections until correct volt-
age is obtained at receptacles with-
out exceeding 4.6 amperes dc ex-
citer revolving field current (see
Section 10-2).
Turn Voltage/Amperage Adjust
control R1 to max. Place Process/
Contactor switch S6 in Electrode
Hot − Stick position.
Y Stop engine before adjusting resistor R3. Check open-circuit voltage across
weld output terminals. There
should be 90 volts dc present. If
correct voltages are not present, re-
2 peat troubleshooting procedures in
Section 10-1.
Y Stop engine.
Allow engine to cool, and then com-
plete pre-operational checks in
table.

Pre-Operational Checks

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Test Equipment Needed: Tools Needed:
Check fuel and oil (see Section 4-7).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
803 334

Big Blue Air Pak TM-4409 Page 69

 SECTION 11 − SERVICING AND TROUBLESHOOTING
AIR COMPRESSOR
11-1. Component Location And System Operation
Theory Of Operation
. See illustration on adjacent page to locate
components.
1 Inlet Air Filter (Compressor Air Filter)
Removes contaminants from air entering
compressor (see Section 11-4 for location).
2 Inlet Valve Assembly
Controls amount of air entering compressor
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 leaving
compressor.
5 Oil Level Gauge
Indicates oil level in primary oil separator.
Read gauge only when compressor is Off
(see Section 11-6 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
Prevents air compressor from starting if sys-
TM-4409 Page 70
tem 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 out-
let to keep oil circulating through system.
12 Shutoff Valve
Controls air flow. Stops air flow when closed
(see Section 4-11 for location).
13 Pressure Regulator
Monitors system air pressure and sends sig-
nal to inlet valve assembly to control air flow
into compressor.
14 Blow Down Valve
Relieves system air pressure when compres-
sor stops.
209 059-A
15 High Air Temperature Switch S12
Stops compressor if compressor air/oil mix-
ture temperature exceeds 248° F (120° C).
16 Thermostatic Control Valve
Allows compressor oil to bypass oil cooler
(item 19) when oil temperature is cool; directs
oil through cooler when oil temperature ex-
ceeds 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 11-6 for
location).
19 Oil Cooler (Radiator)
Cools compressor oil to help maintain correct
system operating temperature.
20 Oil Fill
Provides convenient location to add oil to
compressor (see Section 11-6 for location).
21 Air Dryers (Optional) − Not Shown
Remove excess moisture from compressed
air to prevent damage to tools and other
equipment.
Big Blue Air Pak
 Component Location

3
19

15

16

17
9

10
8

11

13

14

803 370 / Ref 803 328

Big Blue Air Pak TM-4409 Page 71

 NOTE Use only genuine Ingersoll Rand compressor oil and filters to maintain
3-year warranty on air compressor. The air compressor warranty will be
reduced to 2 years if non-Ingersoll Rand oil and filters are used.
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.

11-2. Air Compressor Maintenance Label

TM-4409 Page 72 Big Blue Air Pak

Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.

11-3. Routine Air Compressor Maintenance

NOTE See Section 8 for engine/generator maintenance information.

Y Stop engine before maintaining.

. See Compressor Maintenance Label. Service

Recycle air compressor more often if used in severe
air compressor conditions.
fluids.
* To be done by Factory Authorized Service
Agent.

Every 8 h

Check Compressor
Wipe Up
Fluid Level. See
Spills.
Section 4-7.

Every 100 h
Check
Compressor Air
Cleaner Hoses
For Cracks And
Loose Clamps.

Every 250 h

Inspect
Clean Compressor Replace Worn
Radiator. Air Filter Or Damaged
Elements. Air/Oil Hoses

Inspect Belts
Replace
And Check
Unreadable
Tension.
Labels.

Every 500 h / 6 Months

Change Compressor
Change Compressor Oil Filter. See Section
Oil. See Section 8-7. 8-7. Service more
often in dirty
conditions.

Every 1000 h / 1 Year

Change
Compressor
Air/Oil
Separator

Big Blue Air Pak TM-4409 Page 73

11-4. Servicing Compressor Air Cleaner
Y Stop engine.
Y 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.
1 Compressor Air Cleaner
. Remove engine air cleaner cover
and element to access compressor
air cleaner (see Section 8-4)

. 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.
1
If you decide to clean the primary ele-
ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional air compressor
2 3 4 5 protection. Never clean a safety ele-
ment. Replace the safety element af-
ter servicing the primary element
three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element
6
4 Primary Element
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.
Y 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 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B

TM-4409 Page 74 Big Blue Air Pak

11-5. Compressor Overload Protection
Y Stop engine.

. See Section 8-8 for engine/genera-

tor overload protection.
1 Circuit Breaker CB15
Circuit breaker CB15 protects the air
compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.
Press button to reset breaker. If CB15
continues to open, check compressor
clutch and associated wiring (see Sec-
tion 10-2).

803 228 / 803 229

Big Blue Air Pak TM-4409 Page 75

11-6. Servicing Air Compressor

Tools Needed:
7/8, 15/16 in

Too
High

Full

Right Side
1 Too
Low
6

3
2

Y Stop engine and let cool. Wait 20 sec-
onds for system pressure to drop be-
fore changing oil.
1 Air Compressor Oil Filter
2 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 (On
Tank)
6 Oil Scavenge Tube
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 fittings
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.
803 228
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 air/oil separator:
Loosen nut securing tube on separator base.
Lift oil scavenge tube from separator. Turn fil-
ter counterclockwise. Remove 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.
Y Stop engine.

TM-4409 Page 76 Big Blue Air Pak

11-7. Adjusting Compressor Air Pressure
Tools Needed:
Check compressor air pressure using
air pressure gauge known to be accu-
rate. If necessary, adjust air pressure
as follows:
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.

803 228

Big Blue Air Pak TM-4409 Page 77

11-8. Troubleshooting Air Compressor System
. See Sections 11-2 thru 11-7 for normal
air compressor maintenance proce-
dures 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 20 seconds) before turning compressor
on again.

Reset circuit breaker CB15 (see Section 11-5).

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 relay CR10 for proper coil voltage and connections. Check continuity of coil and con-
dition of contacts. Replace CR10 if necessary.

Check for proper operation of air pressure switch S11. S11 closes (continuity) when air compressor is
off. S11 opens (infinity) when air compressor is on and air pressure is above 20 psi (138 kPa).

Check for proper operation of air temperature switch S12. S12 closes (continuity) when compressor air/oil
mixture is below 248° F (120° C). S12 opens (infinity) when compressor air/oil mixture exceeds 248° F
(120° C).

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 air compressor clutch, and replace if necessary (see Section 10-2).

Air compressor stops after short period Check compressor oil level (see Section 4-7). Automatic shutdown stops compressor if compressor tem-
of operation. perature 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 11-4).

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 11-7).

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 11-7).

Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195 117).
moisture in compressed air.

Oil in air from compressor. Check compressor oil level (see Section 4-7). If oil level is too high, system becomes saturated with oil.

Change compressor secondary air/oil separator (see Section 11-6).

Check connections of red, white, and blue control lines (see air compressor circuit diagram in Section
11-1).

Check for blocked separator scavenge check valve/filter orifice. Be sure lines are clear between oil sepa-
rator and compressor.

Oil in compressor air cleaner. . Close air shutoff valve before shutting unit down to prevent oil burpback into air filter.
Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Lubricate piston with compressor oil or replace inlet valve if
necessary.

TM-4409 Page 78 Big Blue Air Pak

 SECTION 12 − DISASSEMBLY AND REASSEMBLY

12-1. Disassembly Of Unit

Use Sections 10 and 11 to determine
if trouble is in exciter stator, weld sta-
tor, rotor, engine, compressor, or
combination of these components.
Y Stop engine and let cool. Dis-
connect battery negative (−)
cable.
Remove exhaust pipe, fuel cap, and
top cover. Reinstall fuel cap. Remove
side panels and door(s). Retain all
hardware.
1 Control Box
2 Battery Disconnect Switch S14
(Optional)
Disconnect plugs from control box.
Remove box.
Remove battery disconnect switch
and bracket from center upright.

. To aid in reassembly, mark leads

before disconnecting. See lead
list summary in Section 13 for
2 connection information.
1 Disconnect:
F stator weld leads from Ampere
Range switch S3
F stator exciter leads from termi-
3 4 nal strip 1T
F resistor R3 leads
3 Front And Center Upright
Assembly
4 Reactor Z1 Lifting Eye
The entire assembly will be removed
together. Remove bolts securing up-
rights to base. While supporting as-
sembly at front panel and reactor lift-
5 ing eye, evenly lift and remove
assembly.
5 Engine
8
6 Engine Adapter Plate
7 Front Generator Mounts
Support engine under adapter plate
with a 1 x 3 x 30 in (25 x 76 x 762 mm)
metal bar.

. Do not support engine on fuel

tank or under oil pan.
Remove front generator mounts. Go
to Section 12-2.
8 Air Compressor Assembly
If necessary, remove air compressor
assembly. See Section 12-3 for air
compressor disassembly informa-
tion.
6

803 335

Big Blue Air Pak TM-4409 Page 79

12-2. Disassembly Of Generator
2
C
D B
Y Do not damage stator or rotor win-
dings during this procedure.
1 Brushes
2 Stator
Remove brushes from brushholder assembly
on endbell before disassembling generator.
With engine properly supported with metal
bar (see Section 12-1), remove hardware se-
curing stator to engine. Remove the following
parts as needed:
TM-4409 Page 80
A
A
Torques:
A 30 ft lb (41 N.m)
B 100 in lb (11 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
E 18 ft lb (24 N.m)
803 327
3 Endbell Reinstall upright assembly. Reconnect fuel
line.
4 Exciter Stator
Reconnect all leads. Use cable ties to secure
Exciter stator comes off with endbell.
leads in existing wiring harness and away
5 Rotor from moving and hot parts.
If engine must also be removed, remove en- Reconnect negative (−) battery cable. Rein-
gine from base mounts. stall panels, doors, and exhaust pipe.
Reassembly Instructions: . See Sections 12-3 and 12-4 for addition-
Reinstall engine and generator parts as al torque values not shown in this
needed using torque values in table. drawing
Big Blue Air Pak
12-3. Air Compressor System Disassembly/Reassembly
Y Stop engine and let cool. Discon-
nect battery negative (−) cable.
Remove air compressor assembly from
engine (see Section 12-1).
A 1 Air Compressor
2 Inlet Unloader Valve
2 3 Clutch
E
. D o not attempt to repair the air com-
pressor. Remove unloader valve,
3 clutch, pulley and related compo-
nents and replace compressor.
When reassembling air compressor and
mounting brackets, hand-tighten all hard-
ware to eliminate space between compo-
E
nents.
Final-tighten hardware after all compo-
1 nents are assembled and no space ex-
B ists between mounting surfaces.
Y Be sure no space exists between
components before final-tighten-
ing hardware. Components will be
damaged if hardware is final-tight-
ened prematurely.
D
C . See Sections 12-2 and 12-4 for addi-
tional torque values not shown in this
drawing

Tools Needed:

Torques:

A 50 ft lb (68 N.m)
A B 10 ft lb (14 N.m)
C 30 ft lb (41 N.m)
D 20 ft lb (27 N.m)
E 7 ft lb (9 N.m)

Eliminate space between all

mounting surfaces before
tightening hardware.

Use c-clamp or vise-grips to

lightly clamp upper and lower
mounting brackets together
to eliminate space before
tightening hardware.

802 431-C / 803 371

Big Blue Air Pak TM-4409 Page 81

 605579
M8−1.2 X 20 HHCS 044772 070004
TORQUE − 20 FT.LB. LOCK WASHER
M12−1.7 X 30 HHCS
4−BOLTS TORQUE − 50 FT.LB.
4−BOLTS 070008
M14−2.0 X 30 HHCS
602211 TORQUE − 100 FT.LB.
LOCK WASHER 4−BOLTS
602216

TM-4409 Page 82
LOCK WASHER

605579
M8−1.2 X 20 HHCS
602211 TORQUE − 20 FT.LB.
602211 LOCK WASHER
602211
LOCK WASHER LOCK WASHER

605579 8MM−1.2 NUT

M8−1.2 X 20 HHCS
PROVIDED WITH ENGINE
TORQUE − 20 FT.LB.
2−BOLTS TORQUE − 20 FT.LB.
3−NUTS
044772
209675 M12−1.7 X 30 HHCS
EXTENSION, HYDRAULIC
37 ° FLARE 602211 TORQUE − 50 FT.LB.
TORQUE − 80 FT.LB. LOCK WASHER
208424 208423
M6−1.0 X 90 SHCS 602216 M8−1.25 X 100 HHCS
TORQUE − 12 FT.LB. LOCK WASHER TORQUE − 20 FT.LB.
3−BOLTS
8MM−1.2 NUT
PROVIDED WITH ENGINE
TORQUE − 20 FT.LB. 8MM−1.2 X 30 HHCS
602242
FLAT WASHER PROVIDED WITH ENGINE
TORQUE − 20 FT.LB.
194403 208 041 6022432
ADAPTOR, OIL SPACER
FLAT WASHER
PRESSURE SENDER
049026
M10−1.5 X 25 HHCS
193230
TORQUE − 30 FT.LB.
SENDER, OIL PRESSURE
(0−100 PSI)

208042 − SPACER
12-4. Engine Component Assembly And Torque Values

208421
M20−2.5 X 110 SHCS
TORQUE − 100 FT.LB.
605579
070004 M8−1.2 X 20 HHCS
LOCK WASHER TORQUE − 20 FT.LB.
4−BOLTS
070008
M14−2.0 X 30 HHCS 602211
TORQUE − 100 FT.LB.
LOCK WASHER
4−BOLTS
drawing

605579
M8−1.2 X 20 HHCS
TORQUE − 20 FT.LB.

602216 602211 602211

LOCK WASHER 083883
LOCK WASHER LOCK WASHER LOCK WASHER

208426 172555 602242

M12−1.75 X 40 12PT. FLG. 208422
M10−1.5 X 50 HHCS FLAT WASHER
M8−1.25 X 90 HHCS
Tools Needed:

TORQUE − 50 FT.LB. TORQUE − 30 FT.LB.

2−BOLTS 602216 TORQUE − 20 FT.LB.
4−BOLTS 4−BOLTS
LOCK WASHER

044772
M12−1.7 X 30 HHCS
083883 183915
TORQUE − 50 FT.LB.
M10−1.5 X 100 HHCS
LOCK WASHER
tional torque values not shown in this
. See Sections 12-2 and 12-3 for addi-

211 086
TORQUE − 30 FT.LB.

Big Blue 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. To order a copy, proceed as follows:

Circuit Wiring
Model Serial Or Style Number
Diagram Diagram

Big Blue Air Pak LC251836 thru LC619579 206 462-C

(Welding Generator)

LC619580 thru LE118235 215 332

LE118236 thru LE365177 217 814−B

LE365178 and following 221 915 See Table 13-1

Big Blue Air Pak LC251836 and following 209 059-A See Table 13-1
(Air Compressor)

Circuit Board PC4, PC5 LC251836 and following 189 746-A

(HF Filter)

Circuit Board PC3 LC251836 and following 188 607

(HF Filter)

Circuit Board PC6 LC251836 and following 192 997

(HF Filter)

Circuit Board PC9 LC251836 and following 192 227-A

(LED)

Big Blue Air Pak TM-4409 Page 83

 Figure 13-1. Circuit Diagram For Big Blue Air Pak (Welding Generator)
Eff w/LC251836 Thru LC619579
TM-4409 Page 84 Big Blue Air Pak
 206 462-C

Big Blue Air Pak TM-4409 Page 85

 Figure 13-2. Circuit Diagram For Big Blue Air Pak (Welding Generator)
Eff w/LC619580 Thru LE118235
TM-4409 Page 86 Big Blue Air Pak
 206 462-C

Big Blue Air Pak TM-4409 Page 87

 Figure 13-3. Circuit Diagram For Big Blue Air Pak (Welding Generator)
Eff w/LE118326 Thru LE365177
TM-4409 Page 88 Big Blue Air Pak
 206 462-C

Big Blue Air Pak TM-4409 Page 89

 Figure 13-4. Circuit Diagram For Big Blue Air Pak (Welding Generator)
Eff w/LE365178 And Following
TM-4409 Page 90 Big Blue Air Pak
 221 915−A

Big Blue Air Pak TM-4409 Page 91

 209 059-A

Figure 13-5. Circuit Diagram For Big Blue Air Pak (Air Compressor)
Eff w/LC251836 And Following
TM-4409 Page 92 Big Blue Air Pak
 189 746-A

Figure 13-6. Circuit Board PC4, PC5 (HF Filter) Eff w/LC251836 And Following

188 607−A

Figure 13-7. Circuit Board PC3 (HF Filter) Eff w/LC251836 And Following
Big Blue Air Pak TM-4409 Page 93
 192 997

Figure 13-8. Circuit Board PC6 (HF Filter) Eff w/LC251836 And Following

192 227-A

Figure 13-9. Circuit Board PC9 (LED) Eff w/LC251836 And Following
TM-4409 Page 94 Big Blue Air Pak
 Table 13-1. Lead List Summary For Big Blue Air Pak Eff w/LE365178 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 (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−B RC6 (2) − S3 (2) 42AC SPLICE K TO CR8 (OPTION)
−−−−H RC6 (1) − S3 (1) 42AD BASE GRD TO D10 (ANODE)
10A T1 SEC TO SR4 (AC) 42AE SPLICE A TO D10
11A STATOR TO EXIT 42AF SPLICE A TO HM2 (−)
12A #1 COIL TO RANGE SWITCH 42AG SPLICE A TO CR14 (85)
13A #1 COIL TO RANGE SWITCH 42AH SPLICE B TO TM (WHITE)
14A #1 COIL TO RANGE SWITCH 42AJ SPLICE B TO SPLICE A
15A #1 COIL TO RANGE SWITCH 42AK SPLICE B TO HEATER #1 LEAD
16A #1 COIL TO RANGE SWITCH 42AL SPLICE B TO HEATER #2 LEAD
17A #1 COIL TO RECTIFIER 42AM SPLICE A TO CR15 (4)
17A PC3 TO BUS BAR 42B GND (BASE) TO SPLICE K
17C PC3 TO LEAD 17 FROM VOLTMETER 42BB SPLICE (F) TO SPLICE (H)
18A T1 SEC TO SR4 (AC) 42CC RC3 (2) TO LEAD 42JJ
19A PC3 TO HEAT SINK (+) 42DD SPLICE G TO CR5 (O)
19B PC3 TO LEAD 19 FROM PC1 (E2) 42E SPLICE (B) TO SPLICE (E)
19D SR3 (+) TO WELD TERMINAL (+) 42F CR3 (85) TO SPLICE (K)
19E SR4 (+) TO SR3 (+) 42FF SPLICE E TO TIMER (−)
19F SR5 (+) TO SR3 (+) 42G SPLICE J TO FUEL SENDER
19J PC1 (PLG8−E2) TO LEAD 19 FROM PC3 42GG SPLICE H TO SPLICE J
21A STATOR TO EXIT 42H PC1 (PLG8−F3) TO PC8 (PLG13−8)
22A #2 COIL TO RANGE SWITCH 42HH SPLICE J TO SPLICE K
23A #2 COIL TO RANGE SWITCH 42J SPLICE E TO PC7 (E)
24A #2 COIL TO RANGE SWITCH 42JJ SPLICE F TO CR6 (85)
25A #2 COIL TO RANGE SWITCH 42K PC1 (PLG8−C1) TO PLG3 (2)
26A #2 COIL TO RANGE SWITCH 42KK SPLICE H TO 42 SS
27A #2 COIL TO RECTIFIER 42L END BELL (BOTTOM−LEFT) − PC4 (GND) (CV
27A PC3 TO BUS BAR ONLY)
30A PC3 TO HEAT SINK (−) 42L END BELL (BOTTOM−RIGHT) − PC5 (GND) (CV
30B PC3 TO LEAD 30 FROM PC1 (E1) ONLY)
30F SR3 (−) TO WELD TERMINAL (−) 42L END BELL (TOP−LEFT) − PC6(GND) (CV ONLY)
30G SR4 (−) TO SR3 (−) 42L HOUR METER (1) TO AIR PRESSURE GUAGE
30H SR5 (−) TO SR3 (−) (5)
30J PC1 (PLG8−E1) TO LEAD 30 FROM PC3 42LL SPLICE E TO SPLICE F
31A STATOR TO EXIT 42M SPLICE A TO TEMP GAUGE (5)
32A #3 COIL TO RANGE SWITCH 42N GND STD (BASE) TO GND STUD (AUX PANEL)
33A #3 COIL TO RANGE SWITCH 42N TS1 TO SPLICE J
34A #3 COIL TO RANGE SWITCH 42P 1T (C−RIGHT) − GND STUD
35A #3 COIL TO RANGE SWITCH 42PP SPLICE A TO SPLICE B
36A #3 COIL TO RANGE SWITCH 42R GFCI (GND) − GND STUD
36A PC8 (PLG1−G1) TO PLG6 (3) 42S RC1 (GND) − GND STUD
36C RC6 (3) − S3 (3) 42SS SPLICE TO 42KK
37A #3 COIL TO RECTIFIER 42T 076 (K) TO LEAD 42 FROM END BELL
37A PC1 (PLG8−G2) TO LEAD 37 FROM SR3 42U SPLICE A TO HM1 (−)
37A PC3 TO BUS BAR 42UU SPLICE H TO LEAD 42LL
37B PC3 TO LEAD 37 FROM PLG3 (2) 42V SPLICE A TO FUEL GAUGE (5)
37C PC3 TO LEAD 37 FROM VOLTMETER 42X PC7 (E) TO CR10 (B)
38A T1 SEC TO SR5 (AC) 42Z SPLICE B TO OIL GAUGE (5)
39A T1 SEC TO SR5 (AC) 43A CR1 (30) TO STARTER
40A CB10 (BATT COPPER) TO STARTER 44A CB10 (SILVER) TO CB14 (COPPER)
40D STARTER TO ALT (B) 44B CB14 (COPPER) TO CR10 (7)
41A CR3 (87) TO CB14 (SILVER) 44C CB8 TO CB10 (SILVER)
42A FUEL SENSOR TO PLG4 (2) 44D CB10 TO CR5 (4)
42AA SPLICE B TO BATT GAUGE (5) 44E CB10 (AUX SILVER) TO CR8 (87)
Big Blue Air Pak TM-4409 Page 95
 Table 13-1. Lead List Summary For Big Blue Air Pak Eff w/LE365178 And Following − Continued
Lead Connections Lead Connections
44E CB13 TO CR5 (4) 84B CB1 (BOTTOM) − 1T (D−RIGHT)
46A TS1 TO CR3 (30) 84D EXCITER TO S6
48A LEAD 48B TO S6 (9) 84E AUX STATOR TO S6 (11)
48B S1 (D) TO 48A 84F 1TD TO CB6
49C TD1 (+12) TO S1 (B) 85A CB2 (BOTTOM) − GFCI (HOT)
50A TD1 (COMMON) TO CR5 (1) 85B CB2 (BOTTOM) − PC4 (5)
52A CB13 TO S1 (A) 86A CB1 (TOP) − RC1 (BOTTOM−RIGHT)
52B CB13 TO CR5 (6) 86D CB1 (TOP) − CB2 (TOP)
52C CR5 (6) TO S2 (BOTTOM) 87AA CB6 TO PLG14 (2)
53A D8 (CATHODE) TO CR1 (86) 88A CB1 (TOP) − RC1 (BOTTOM−LEFT)
56A D8 (ANODE) TO TD1 (START) 88B CB1 (TOP) − PC4 (4)
56B TD1 (START) TO S1 (C) 89A EXCITER TO CB5 (TOP)
57A S2 (CENTER) TO CR8 (86) 98A S6 (12) TO CB4
57B S2 (CENTER) TO TD1 (NO) 99A T1 PRI TO CB4
58A S8 TO TD1 (NC) 100A EXCITER STATOR − PLG1 (1)
58C S8 TO S7 100B RC1 (1) TO F1
60A TD1 (AUX) TO ALT (D+) 101A EXCITER STATOR − PLG1 (3)
60D TD1 (AUX) TO CR1 (85) 101B RC1 (3) TO SR1 (AC)
61A SPLICE (D) TO CR14 (86) 102C SR1 (−) TO C9 (−)
61B CR1 (87A) TO CR5 (8) 102D RC3 (4) TO C9 (−)
61BB SPLICE (A) TO SPLICE (B) 102E R3 TO PLG3 (4)
61C SPLICE (B) TO HM1 (+) 102E SR1 (−) TO CR4 (4)
61CC SPLICE (B) TO SPLICE (C) 103A EXCITER STATOR − PLG1 (4)
61D SPLICE (A) TO FUEL GUAGE (6) 103B PC1 (PLG8−A1) TO PLG3 (6)
61E SPLICE (B) TO S10 (6) 103D RC3 (6) TO RC1 (4)
61F SPLICE (C) TO SPLICE (D) 104A EXCITER STATOR − PLG1 (6)
61FF SPLICE (C) TO AIR PRESSURE GUAGE (6) 104B RC1 (6) TO F2
61G SPLICE (C) TO OIL GUAGE (6) 105A BRUSH (CENTER) − PLG1 (2)
61H SPLICE (A) TO TEMP GUAGE (6) 105B SR1 (+) TO C9
61J SPLICE (A) TO BATT GUAGE (6) 105C SR1 (+) TO SPLICE
61K CR1 (87) TO PLG4 (1) 105D RC3 (8) TO SPLICE
61N SPLICE (D) TO CR5 (8) 105E PC1 (PLG8−D1) TO PLG3 (8)
61S SPLICE (D) TO CR6 (86) 105F RC1 (2) TO SPLICE
63A CR4 (B) TO PC7 (F) 105G D1 (CATHODE) TO SPLICE
64B PC7 (C) TO CR3 (86) 106A BRUSH (FRONT) − PLG1 (5)
65A CR4 (A) TO PC7 (A) 106B RC1 (5) TO SPLICE
66B LEAD FROM CT1 TO PC7 (D) 106C RC3 (7) TO SPLICE
67B LEAD FROM CT1 TO PC7 (G) 106D CR4 (6) TO SPLICE
68B S6 (10) TO CR6 (30) 106D R3 TO PLG3 (7)
69C OIL GAUGE (3) TO OIL PRESSURE SENDER 107A CR4 (6) TO CR4 (7)
70A S7 TO 70B 108A BRUSH (REAR) − PLG1 (8)
70B TEMP GUAGE (3) TO 70A 108B RC1 (8) TO RC3 (9)
71C FUEL GUAGE (3) TO FUEL SENDER 108C PC1 (PLG8−A2) TO PLG3 (9)
72A CR6 (87) TO PC7 (B) 110A CB12 TO D1 (ANODE)
73A CR8 (30) TO GLOW PLUGS 111A CB12 TO CB11
74A AIR PRESSURE SENDER TO AIR PRESSURE 111B CB12 TO CR5 (30)
GAUGE (3) 113A CB11 TO RC3 (12)
81A EXCITER STATOR − 1T (A−LEFT) 113B PC1 (PLG8−B1) TO PLG3 (12)
81B CB1 (BOTTOM) − 1T (A−RIGHT) 116A PC6 (PLG14−8) TO PC1 (PLG9−B1)
81D EXCITER TO T1 117A PC6 (PLG14−7) TO PC1 (PLG9−C3)
81E T1 PRI TO EXCITER STATOR 118A PC6 (PLG14−6) TO PC1 (PLG9−B2)
82A EXCITER STATOR − 1T (B−LEFT) 119A S6 (1) TO PC6 (PLG14−5)
82B GFCI (N) − 1T (B−RIGHT) 120A S6 (2) TO PC1 (PLG9−F1)
83A EXCITER STATOR − 1T (C−LEFT) 121A S6 (3) TO PC6 (PLG14−4)
83B PC6 (PLG14−10) TO (1T−83C) 121B PC6 (PLG14−3) TO CB5
83D PC6 (PLG14−9) TO PC1 (PLG9−F2) 122A PC1 (PLG9−A1) TO S6 (5)
84A EXCITER STATOR − 1T (D−LEFT) 123A PC1 (PLG9−A2) TO S6 (6)
TM-4409 Page 96 Big Blue Air Pak
 Table 13-1. Lead List Summary For Big Blue Air Pak Eff w/LE365178 And Following − Continued
Lead Connections Lead Connections
124A S6 (7) TO PC1 (PLG9−D3) 142A PC1 (PLG8−K2) TO PC8 (PLG13−7)
125A PC1 (PLG8−F1) TO PLG6 (1) 143A PC1 (PLG8−J2) TO PC8 (PLG13−9)
126A PC1 (PLG8−F2) TO PLG6 (2) 144A PC1 (PLG8−B3) TO PC8 (PLG13−10)
127A S5 (TOP) TO PC1 (PLG9−B3) 160A AIR PRESSURE LOCKOUT TO S10 (3)
128A S5 (CENTER) TO PC1 (PLG9−D2) 161A S10 (5) TO S10 (2)
129A S5 (BOTTOM) TO PC1 (PLG9−C2) 161B CR10 (9) TO S10 (5)
130A LEAD 130B TO PC1 (PLG8−K1) 162A AIR PRESSURE LOCKOUT TO HAT (SWITCH)
131A LEAD 131B TO PC1 (PLG8−H2)
162B HATS SWITCH TO CR10 (6)
132A LEAD 132B TO PC1 (PLG8−J1)
163A SPLICE TO HAT SWITCH
133A LEAD 133B TO PC1 (PLG8−H1)
163B SPLICE TO CR10 (A)
134A R1 (PLG10−1) TO PC1 (PLG9−D1)
163C SPLICE TO HM2 (+)
135A R1 (PLG10−2) TO PC1 (PLG9−C1)
136A R1 (PLG10−3) TO PC1 (PLG9−A3) 163D SPLICE TO CR15 (1)
137A SR1 (AC) TO F1 164A CB15 TO CR10 (4)
138A RC3 (1) TO F2 165A D10 (CATHODE) TO COMPRESSOR (CLUTCH)
138B PC1 (PLG8−A3) TO PLG3 (1) 165B CB15 TO D10 (CATHODE)
139A PC1 (PLG8−C3) TO PC8 (PLG13−1) 170A CB8 TO CR14 (30)
140A PC1 (PLG8−D2) TO PC8 (PLG13−5) 170B CR14 (30) TO CR15 (2)
141A PC1 (PLG8−D3) TO PC8 (PLG13−6) 172A TM (BLACK) TO CR15 (3)

Big Blue Air Pak TM-4409 Page 97

 SECTION 14 − RUN-IN PROCEDURE
run_in1 8/01

14-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
2 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.

. Do not idle engine longer than

necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
1 run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.

TM-4409 Page 98 Big Blue Air Pak

14-2. Run-In Procedure Using Load Bank
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
4
from flammables.
Y Do not perform run-in
2 procedure at less than 20
volts weld output and do not
1 exceed duty cycle or equip-
ment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
minutes.
3 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).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.

. Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Y Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

Big Blue Air Pak TM-4409 Page 99

14-3. Run-In Procedure Using Resistance Grid
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
6
from flammables.
Y Do not perform run-in
2 procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Resistance Grid
Use grid sized for generator rated
output.
1 Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3 5 Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rat-
4 ing label, or the specifications sec-
tion in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
+ loaded properly.

. Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Y Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

TM-4409 Page 100 Big Blue Air Pak

 SECTION 15 − AIR COMPRESSOR TABLES

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

Orifice Diameter (in) And Free Air Flow (CFM)

Gauge Pressure (psi)
1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4
1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85
2 0.038 0.153 0.342 0.607 1.36 2.43 5.42 9.74
3 0.046 0.188 0.471 0.750 1.68 2.98 6.71 11.9
5 0.059 0.242 0.545 0.965 2.18 3.86 8.71 15.4
10 0.084 0.342 0.77 1.36 3.08 5.45 12.3 21.8

15 0.103 0.418 0.94 1.67 3.75 6.65 15.0 26.7

20 0.119 0.485 1.07 1.93 4.25 7.7 17.1 30.8
25 0.133 0.54 1.21 2.16 4.75 8.6 19.4 34.5
30 0.156 0.632 1.40 2.52 5.6 10.0 22.5 40.0
35 0.173 0.71 1.56 2.80 6.2 11.2 25.0 44.7

40 0.19 0.77 1.71 3.07 6.8 12.3 27.3 49.1

45 0.208 0.843 1.9 3.36 7.6 13.4 30.3 53.8
50 0.225 9.14 2.05 3.64 8.2 14.5 32.8 58.2
60 0.26 1.05 2.35 4.2 9.4 16.8 37.5 67.0
70 0.295 1.19 2.68 4.76 10.7 19.0 43.0 76.0

80 0.33 1.33 2.97 5.32 11.9 21.2 47.5 85.0

90 0.364 1.47 3.28 5.87 13.1 23.5 52.5 94.0
100 0.40 1.61 3.66 6.45 14.5 25.8 58.3 103.0
110 0.43 1.76 3.95 7.00 15.7 28.0 63.0 112.0
120 0.47 1.90 4.27 7.58 17.0 30.2 68.0 121.0

130 0.50 2.04 4.57 8.13 18.2 32.4 73.0 130.0

140 0.54 2.17 4.87 8.68 19.5 34.5 78.0 138.0
150 0.57 2.33 5.2 9.20 20.7 36.7 83.0 147.0
175 0.66 2.65 5.94 10.6 23.8 42.1 95.0 169.0
200 0.76 3.07 6.90 12.2 27.5 48.7 110.0 195.0

Big Blue Air Pak TM-4409 Page 101

15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At
70-90 P.S.I.G.
MISCELLANEOUS Percent Use Factor And MISCELLANEOUS Percent Use Factor And
PORTABLE Compressed Air Consumption (CF) PORTABLE Compressed Air Consumption (CF)
TOOLS 9 sec 15 sec 21 sec 1 min TOOLS 9 sec 15 sec 21 sec 1 min
Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring Tool, Large 3.6 6.0 8.4 24

Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13

Screwdriver,
#2 to #6 Screw 1.8 3.0 4.2 12 Rammers, Medium 5.1 8.5 11.9 34

Screwdriver,
#6 to 5/16” Screw 3.6 6.0 8.4 24 Rammers, Large 6.0 10.0 14.0 40

Tapper, to 3/8” 3.0 5.0 7.0 20 Backfill Tamper 3.75 6.25 8.75 25

Nutsetters, to 3/8” 3.6 6.0 8.4 24 Compression Riveter 0.2 cu. ft. per cycle

Nutsetters, to 3/4” 4.5 7.5 10.5 30 Air Motor,

1 Horsepower 3.75 6.3 8.75 25

Impact Wrench, 1/4” 2.25 3.75 5.3 15 Air Motor,

2 Horsepower 7.5 12.5 17.5 50

Impact Wrench, 3/8” 3.0 5.0 7.0 20 Air Motor,

3 Horsepower 11.25 18.75 26.3 75
Impact Wrench, 5/8” 4.5 7.5 10.5 30
Air Motor Hoist
Impact Wrench, 3/4” 5.25 8.75 12.25 35 1000# 1 cu. ft. per foot of lift

Impact Wrench, 1” 6.75 11.25 15.75 45 Air Motor Hoist,

2000# 1 cu. ft. per foot of lift
Impact Wrench, 1-1/4” 8.25 13.75 19.2 55
Paint Spray Gun
Die Grinder, Small 2.25 3.75 5.3 15 (Production) 3.0 5.00 7.00 20

Die Grinder, Medium 3.6 6.0 8.4 24 HAMMERS

Horizontal Grinder, 2” 3.0 5.0 7.0 20 Scaling Hammer 1.3 3.0 4.2 12

Horizontal Grinder, 4” 9.0 15.0 21.0 60 Chipping Hammer 4.5 7.5 10.5 30

Horizontal Grinder, 6” 9.0 15.0 21.0 60 Riveting Hammer,

Light 2.25 3.75 5.25 15

Horizontal Grinder, 8” 12.0 20.0 28.0 80 Riveting Hammer,

Heavy 4.5 7.5 10.5 30
Vertical Grinders and
Sanders, 5” Pad 5.25 8.75 12.25 35 SAWS

Vertical Grinders and Circular, 8” 6.75 11.25 15.75 45

Sanders, 7” Pad 9.0 15.0 21.0 60
Circular, 12” 9.75 16.25 23.8 65
Vertical Grinders and
Sanders, 9” Pad 10.5 17.5 24.5 70 Chain, Lightweight 4.20 7.0 9.8 28

Burring Toll, Small 2.25 3.75 5.3 15 Chain, Heavy Duty 13.1 21.8 30.5 87

Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)

TM-4409 Page 102 Big Blue Air Pak

 TM-4409C March 2005

Processes
Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting

and Gouging

With Optional Equipment:

Battery Charging

Description

Engine Driven Welding Generator And

Air Compressor

Big Blue Air Pak

®

Eff w/LC251836 Thru LC670816

For OM-4409 (206 941) Revision * Thru G

Visit our website at

www.MillerWelds.com
 SECTION 16 − PARTS LIST FOR LC251836 THRU LC670816

. Hardware is common and not

available unless listed.

27

17 26
3
18 25

2 19
28
21 24
22
1
20 29
16 30
15 23
8
7 9
13 31
6
12
4 11 14 32

5
33
10

133

148
34
147 15 35
146 − Figure 16-5 130
132 123
134

135
136 131 − Figure 16-2

138 124
139 125
145 140
126
137
141 127
143 128
129

144 − Figure 16-3 142

Figure 16-1. Main Assembly

TM-4409 Page 104 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816

46 47
71
45 70
69

44 72
68 73
65 67
51 61 74
62 63 66
42 48
43
41 64
38 40 59
39
57 75
37
58
55 56
36 50
60 76
49 54 74
77
53

52 81 78 − Figure 16-6
88 82
89 83
93 84
113 92 90
116 91 86 85
114 117 87 102
118 94 101
115
112 − Figure 16-4 95 79
104
149 99 100 80
119
97 96 103
111
110 105
98
106
109
121 107
120

122 108

803 324

Big Blue Air Pak TM-4409 Page 105

 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 189828 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206601 . . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 208277 . . Reactor, AC Environmental Rda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . CR7 . . ♦188636 . . Relay, OCV Control (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . ♦081499 . . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 1T . . . . . 189549 . . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 038621 . . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 081499 . . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 138027 . . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1
. . . 10 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . T1 . . . . . 205636 . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 201697 . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 173352 . . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189708 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 194485 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192939 . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206556 . . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . 1
. . . 19 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 206351 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Compressor) (includes) . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 206696 . . Hose, Elbow Air Cleaner/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 198457 . . Tube, Air Intake Perkins 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 206697 . . Hose, Elbow Air Cleaner/Compressor 180 Degree . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 207268 . . Hose, Cwc Flexaust 2.000 Id X 22.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . +206610 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 210151 . . Label, Air Cleaner Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦209612 . . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . ♦209597 . . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . ♦209611 . . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . +206603 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 143915 . . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 205702 . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 205749 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 603767 . . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 46 . . . . . . . . . . . . . . 205712 . . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 205748 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4409 Page 106 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly (Continued)

. . . 48 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . . . . . . . . . . . 206552
. . . 50 . . . . . . . . . . . . . . 202633
. . . 51 . . . . . . . . . . Figure 16-6
. . . 52 . . . . . . . . . . . . . . 191577
. . . 53 . . . . . . . . . . . . . . 191809
. . . 54 . . . . . . . . . . . . . . 209632
. . . 55 . . . . . . . . . . . . . . 206548
. . . . . . . . . . . . . . . . . . . . 193256
. . . . . . . . . . . . . . . . . . . . 195748
. . . . . . . . . . . . . . . . . . . . 195746
. . . . . . . . . . . . . . . . . . . . 195745
. . . . . . . . . . . . . . . . . . . *067265
. . . . . . . . . . . . . . . . . . . *066217
. . . . . . . . . . . . . . . . . . . . 208041
. . . . . . . . . . . . . . . . . . . . 193230
. . . . . . . . . . . . . . . . . . . . 194403
. . . . . . . GLOW PLUG ♦190059
. . . 56 . . . . . . . . . . . . . . 207203
. . . . . . . . . . . . . . . . . . . . 208042
. . . 57 . . . . . . . . . . . . . *207808
. . . 58 . . . . . . . . . . . . . . 209675
. . . 59 . . . . . . . . . . . . . . 209633
. . . 60 . . . . . . . . . . . . . . 209621
. . . 61 . . . . . . . . . . . . . . 207269
. . . 62 . . . . . . . . . . . . . . 206749
. . . 63 . . . . . . . . . . . . . . 206558
. . . 64 . . . . . . . . . . . . . . 209623
. . . 65 . . . . . . . . . . . . . . 201749
. . . 66 . . . . . . . . . . . . . . 201006
. . . 67 . . . . BATT . . . . 190897
. . . 68 . . . . . . . . . . . . . . 108081
. . . 69 . . . . . . . . . . . . . . 190206
. . . 70 . . . . . . . . . . . . . . 190207
. . . 71 . . . . . . . . . . . . . . 203430
. . . 72 . . . . . . . . . . . . . +201183
. . . 73 . . . . . . . . . . . . . . 176108
. . . 74 . . . . . . . . . . . . . . 176106
. . . 75 . . . . . . . . . . . . . +206602
. . . 76 . . . . . . . . . . . . . . 207270
. . . 77 . . . . . . . . . . . . . . 210229
. . . 78 . . . . . . . . . . Figure 16-6
. . . 79 . . . . . . . . . . . . . . 208024
. . . 80 . . . . . . . . . . . . . . 206613
. . . 81 . . . . . . . . . . . . . . 199849
. . . 82 . . . . . . . . . . . . . . 071731
. . . 83 . . . . . . . . . . . . . . 191812
. . . 84 . . . . . . . . . . . . . . 071890
. . . 85 . . . . . . . . . . . . . . 071730
. . . 86 . . . . . . . . . . . . . . 083476
. . . 87 . . . . . . . . . . . . . . 135205
. . Pipe, Exhaust Deutz Bf4m2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Tubing Oil Assyw/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Engine, Deutz Dsl Elec Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1
. . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1
. . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Shroud, Fan Air Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1
. . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4
. . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4

Big Blue Air Pak TM-4409 Page 107

 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No.
. . . . . . . . . . . . . . . . . . . . 199505
. . . 88 . . . . . . . . . . . . . . 165271
. . . 89 . . . . . . . . . . . . . . 176529
. . . 90 . . . . . . . . . . . . . . 113854
. . . 91 . . . . . . . . . . . . . . 176528
. . . 92 . . . . . . . . . . . . . . 173336
. . . 93 . . . . . . . . . . . . . . 066298
. . . 94 . . . . . . . . . . . . . . 191816
. . . 95 . . . . . . . . . . . . . . 206297
. . . 96 . . . . . . . . . . . . . *192744
. . . . . . . . . . . . . . . . . . . . 199383
. . . . . . . . . . . . . . . . . . . . 191819
. . . 97 . . . . . . . . . . . . . . 190992
. . . 98 . . . . . . . . . . . . . . 206604
. . . 99 . . . . . . . . . . . . . . 209093
. . 100 . . . . . . . . . . . . . 209092
. . 101 . . . . . . . . . . . . . 174064
. . . . . . . . . . . . . . . . . . . . 196036
. . . . . . . . . . . . . . . . . . . . 125663
. . . . . . . . . . . . . . . . . . . . 175936
. . . . . . . . . . . . . . . . . . . . 127994
. . . . . . . . . . . . . . . . . . . . 127648
. . . . . . . . . . . . . . . . . . . . 124974
. . . . . . . . . . . . . . . . . . . . 601868
. . . . . . . . . . . . . . . . . . . . 126388
. . . . . . . . . . . . . . . . . . . . 089800
. . . . . . . . . . . . . . . . . . . . 108941
. . . . . . . . . . . . . . . . . . . . 156733
. . 102 . . . . . . . . . . . . . 209090
. . 103 . . . . . . . . . . . . +209089
. . 104 . . . . . . . . . . . . . 206464
. . 105 . . . . . . . . . . . . . 199592
. . 106 . . . . . . . . . . . . . 210681
. . 107 . . . . . . . . . . . . . 209091
. . 108 . . . . . . . . . . . . . 191626
. . 109 . . . . . . . . . . . . +189827
. . 110 . . . . . . . . . . . . . 207448
. . 111 . . . . . . . . . . . . . 209059
. . 112 . . . . . . . . . Figure 16-4
. . 113 . . . . . . . . . . . . . 189245
. . 114 . . . . . . . . . . . . . 124253
. . 115 . . . . . . . . . . . . . 189912
. . 116 . . . . . . . . . . . . . 189909
. . 117 . . . . . . . . . . . . . 189913
. . 118 . . . . . . . . . . . . . 190142
. . 119 . . . . . . . . . . . . . 189910
. . 120 . . . . . . . . . . . . . 189908
. . 121 . . . . . . . . . . . . . 181572
. . . . . . . . . . . . . . . . . . . . 196219
. . 122 . . . . . . . . . . . . . 191446
. . 123 . . . . . . . . . . . . . 209094
. . 124 . . . . . . . . . . . . +212224
. . 125 . . . . . . . . . . . . . 191897
. . 126 . . . . . . . . . . . . . 200864
. . 127 . . . . . . . . . . . . . 206463
. . 128 . . . . . . . . . . . . . 182761
TM-4409 Page 108
Description Quantity
Figure 16-1. Main Assembly (Continued)
. . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666
. . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fuel Filter/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1
. . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1
. . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Saftey Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Idle, Solenoid Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Arm Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ball Joint, .250−28 Type Sp Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Rod, Throttle 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ball Joint, .250−28 Type Spf Female Rod End . . . . . . . . . . . . . . . . . . . . 1
. . . . Clevis, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Solenoid, 12vdc Pull/Hold Type 1” Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Nut, 250−28 .44hex .27h Stl Pld Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−20 .44hex .22h Stl Pld .58d Flange Defor . . . . . . . . . . . . . . . . 1
. . . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . 1
. . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Maintenance Big Blue Air Pak Deutz Ce . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Maintenance I R Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Schematic Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel 23.0 Gal (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . 1
. . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . 6ft
. . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Label, Do Not Weld On Base CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 2
Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly

. . 129 . . . . R3 . . . . . 189699 . . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1

. . 130 . . . . . . . . . . . . . 191512 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 131 . . . . . . . . . Figure 16-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 132 . . . . . . . . . . . . . 189731 . . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 133 . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 134 . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 135 . . . . . . . . . . . . . 206609 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 136 . . . . . . . . . . . . +206606 . . Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 137 . . . . . . . . . . . . . 209682 . . Label, Air Power Ingersoll−Rand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 138 . . . . . . . . . . . ♦039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 139 . . . . . . . . . . +♦207095 . . Box, Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 140 . . . . . . . . . . . ♦039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 141 . . . . . . . . . . . ♦210156 . . Label, Battery Charge (Battery Charge +/−) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 142 . . . . . . . . . . . . . 207096 . . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 143 . . . . . . . . . . . . . 209683 . . Label, Warning Safety Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 144 . . . . . . . . . Figure 16-3 . . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 145 . . . CT1 . . ♦202130 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 146 . . . . . . . . . Figure 16-5 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 147 . . . . . . . . . . . . . 193453 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 148 . . . PC1 . . . . 207397 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 149 . . . . . . . . . . . . . 085963 . . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209238 . . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209240 . . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209236 . . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209241 . . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209242 . . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189975 . . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . ♦155146 . . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 3

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue Air Pak TM-4409 Page 109

 Eff w/LC251836 Thru LC670816
6

11

5 12

21
4 24
23

3
2
1
19 26
25
18

7 14
20 8
13

9 16
10
15 23
17
22

803 325

Figure 16-2. Control Box Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-2. Control Box Assembly − (Figure 16-1 Item 131)

. . . 1 . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3
. . . 4 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201077 . . Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . HM2 . . ♦145247 . . Meter, Hour Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box, Weld Control LH (includes) . . . . . . . . . . . . . . . . . . . 1
. . . 7 . CB11, CB12 . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . SR1 . . . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 9 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 204737 . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 11 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . CR1,2,3,5,6 . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 5
. . . 13 . . . . CR11 . . . . 173069 . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . PC7 . . . . 195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . TD1 . . . . 207139 . . Timer, Delay On Make/Break Open 3−60 Sec 12vdc . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 209273 . . Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4409 Page 110 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-2. Control Box Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 206375 . . Harness, Engine Deutz Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 19 . . . . CB14 . . . . 205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB13 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CB15 . . . . 083432 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S2 . . . . . 021467 . . . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 16-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 177859 . . . . Conn, Body 5 Terminal (For Ignition Switch S1) . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . CR4, CR10 . 113247 . . . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . S10 . . . . 206624 . . . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 16-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 C8/D8,C10/D10 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C14/D14
. . . . . . . . . . . . . . . . . . . . 209273 .. Label, Component Layout Control Box Bbap . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . CB6 . . ♦139266 .. Circuit Breaker, Man Reset 1p 15a 250vac Frict (Air Dryer) . . . . . . . . . . . 1
. . . 25 . . . . CR14 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Air Dryer) . . . . . . . . 1
. . . 26 . . . . CR8 . . ♦155309 .. Contactor, Solenoid 12vdc Continuous 400a Inrush . . . . . . . . . . . . . . . . . . 1

♦Optional
*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.

Notes

Work like a Pro!

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

Big Blue Air Pak TM-4409 Page 111

 Eff w/LC251836 Thru LC670816
. Hardware is common and
not available unless listed.

4
57

5
6
2 7
9
1 10

11
62
61 12
13
60 14
15
16
59 17
18
19
58 20
56 21
55
50
54
51 49 31 22
53 48
52 29 23
47 33
24
46
32 26
30
45
28 25
34 27

35

36
38
44
37

43

42 41 40 39

803 326

Figure 16-3. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front w/Components (Figure 16-1 Item 144)

. . . 1 . . . . . . . . . . . . . . 207467 . . Plate, Screened Ident Control Rating (When Ordering This Item The
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Namplate Should Also Be Ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number)
. . . 3 . . . . . . . . . . . . . . 201580 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4409 Page 112 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front w/Components (Continued)

. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB6 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S10 . . . . 206624 . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 16-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S2 . . . ♦021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 16-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . . 147632 . . . . Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 2
. . . 18 . . . . RC5 . . ♦182954 . . Rcpt, Str 3p4w 50a 125/250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025248 . . Stand-off, Insul .250-20 X 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604102 . . Connector, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197363 . . Terminal, Ring Tng Screw Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦196780 . . Circuit Breaker, Man Reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +201106 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . +♦201107 . . Panel, Generator Power (Full KVA Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197433 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦196781 . . Boot, Circuit Breaker 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 163167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . ♦197291 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197399 . . Label, Warning 3 Ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 193260 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 193258 . . Cover, Receptacle Gfci Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . ♦210149 . . Label, Battery Charge (Switch Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . ♦ . . Label, Polarity/AC Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . S12 . . . . . . . . . ♦ . . Switch, Polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S13 . . ♦210217 . . Switch, Battery Charge Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . ♦210206 . . Bracket, Support Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8
. . . 41 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Big Blue Air Pak TM-4409 Page 113
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front w/Components (Continued)

. . . 43 . . . . . . . . . . . . . . . . . . . ♦ . . Switch, Handle (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . . . . . . ♦ . . Pin (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦059773 . . Handle, Switch (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦010647 . . Pin,Spring Cs .156 X 1.250 (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦081499 . . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 49 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . HM1 . . . . 118058 . . Meter, Hour 12−24vdc 2.25 Dia High Profile Stainles . . . . . . . . . . . . . . . . 1
. . . 51 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . AIR . . . . 206599 . . Gauge, Pressure 0−200 Psi Electric Switch . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . TEMP . . . . . . . . . . . . . Gauge, Engine Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . OIL . . . . . . . . . . . . . . . Gauge, Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . A1 . . . ♦164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . CT3 . . ♦209274 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . V1 . . . ♦164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193158 . . Harness, Unit Weld Control − CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 088731 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . 059712 . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 120304 . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 025234 . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
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-4409 Page 114 Big Blue Air Pak

 Eff w/LC251836 Thru LC670816

11
14

15

13 16
10 12 17

18
8
19
7 20
6

5
3 21
4 22
23
2 25 24
1 26
27
28
29
30

31
32 803 327
33

Figure 16-4. Generator

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-4. Generator (Figure 16-1 Item 112)

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

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . STATOR . . +208287 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . STATOR +♦209220 . . Stator, Weld Assy Complete (3-Phase Generator Option) . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 17 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . 8
. . . 19 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6
Big Blue Air Pak TM-4409 Page 115
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-4. Generator (Continued)

... 23 . . . . . . . . . . . . . . 172555 .. Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

... 24 . . . . . . . . . . . . . . 602159 .. Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . 6
... 25 . . . . . . . . . . . . . . 604950 .. Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 26 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 4
... 27 . . . . . . . . . . . . . . 139341 .. Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 28 . . . . . . . . . . . . . *190823 .. Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
... 29 . . . . . . . . . . . . . . 188560 .. Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 30 . . . . . . . . . . . . . . 189142 .. Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 602242 .. Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 2
... 33 . . . . . . . . . . . . . . 604534 .. Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
*Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
TM-4409 Page 116 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
. Hardware is common and
not available unless listed.
4

1
5

802 279-A

Figure 16-5. Main Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 16-5. Main Rectifier Assembly (Figure 16-1 Item 146)

. . . . . . . . . . SR3 . . . . 208279 . . Rectifier Complete (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 188137 . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 188517 . . . . Bus Bar, Conn Bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 .............. 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 134201 . . . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 201449 . . . . Circuit Card Assy, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 188136 . . . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 7 .............. 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 208334 . . . . Diode, Rect 275. A 300v Sp Do−9 *1n4048(037956 W/R . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 208335 . . . . Diode, Rect 275. A 300v Rp Do−9 *1n4048r(037957 W/ . . . . . . . . . . . . 3
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 Air Pak TM-4409 Page 117
 Eff w/LC251836 Thru LC670816
. Hardware is common and
not available unless listed.

79
80
53
52 54
51 55 56
9
13 57
46
10
19 50
18 58
17 61
20 49
21
48
16 59
22 24 47
15 23 46
11 45 60
14 25 44
9 28
13 6 43
11 12 26 81
82
10 8 41
7 6 5
9 83
4 27
42 39

3 86 62
2 28 40
84 63
85
1
29
31 64
38
32 65
34 66
37
26 67
75 33
35 36
76
77 87
78
9 88
45 68
72
70
69
74

73 71

803 328

Figure 16-6. Air Compressor Assembly

TM-4409 Page 118 Big Blue Air Pak
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-6. Air Compressor Assembly (Figure 16-1 Item 78)

... 1 .............. 206607 . . Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 210523 . . Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 206939 . . Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 210248 . . Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 117826 . . Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 210053 . . Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 071270 . . Ftg, Pipe Brs Tee St 1/4 Npt 071 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 209854 . . Ftg, Pipe Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 209642 . . Hose, Nylon Blue 57.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 210040 . . Orifice/Muffler,120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 209640 . . Hose, Nylon Red 57.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210054 . . Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . S11 . . . . 206746 . . Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 602965 . . Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 209635 . . Hose, Assy w/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 210051 . . Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 209767 . . Ftg, Pipe Stl Connector M 3/4 Sae−npt Adapter . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 206615 . . Sender, Pressure Oil 0− 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 073655 . . Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 206937 . . Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 206743 . . Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 209754 . . Ftg, Pipe Stl Elbow M 45dg 3/4 X (Npt−jic 45dg) . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 210249 . . Hose Assy, Air W/Fittings 3/4 X 21.750 Lg (Prior to LC574021) . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 214685 . . Hose Assy, Air W/Fittings 3/4 X 20.750 Lg (Eff w/LC574021) . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 209787 . . Ftg, Pipe Stl Nipple Close 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 209636 . . Hose, Oil W/Fittings 32.460 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 210058 . . Gauge, Oil Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . Deleted ................................................................... 1
. . . 31 . . . . . . . . . . . . . . 209766 . . Ftg, Pipe Stl Tee Street 3/4 Npt M−f−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 209457 . . Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 209638 . . Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 209639 . . Hose, Oil W/Fittings 26.320 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 210254 . . Bracket, Mtg Tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O−ring . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−jic− . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 208040 . . Tensioner,Belt w/Pully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 206611 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . S12 . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 210022 . . O−ring, High Air Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 210021 . . Adapter, Airend Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 209769 . . Ftg, Flrd Stl Plug 1/2 Sae O−ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 209641 . . Hose, Nylon White 32.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 209855 . . Ftg, Pipe Stl Adapter M 1/8 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . . 015732 . . Ftg, Pipe Brs Elbow St 45 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 207265 . . Brace, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 176518 . . Ftg, Pipe Brs Elbow St 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 602887 . . Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue Air Pak TM-4409 Page 119
 Eff w/LC251836 Thru LC670816
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-5. Air Compressor Assembly (Continued)

. . . 53 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . . . . . . . . . . . 210006
. . . . . . . . . . . . . . . . . . . . 210016
. . . 55 . . CLUTCH . . 210055
. . . 56 . . . . . . . . . . . . . . 207807
. . . 57 . . . . . . . . . . . . . . 206800
. . . 58 . . . . . . . . . . . . . . 210001
. . . 59 . . . . . . . . . . . . . . 209853
. . . 60 . . . . . . . . . . . . . . 209634
. . . 61 . . . . . . . . . . . . . . 206558
. . . 62 . . . . . . . . . . . . . . 209851
. . . 63 . . . . . . . . . . . . . . 209825
. . . 64 . . . . . . . . . . . . . . 209764
. . . 65 . . . . . . . . . . . . . . 209828
. . . 66 . . . . . . . . . . . . . . 209621
. . . 67 . . . . . . . . . . . . . . 210052
. . . 68 . . . . . . . . . . . . . . 206744
. . . 69 . . . . . . . . . . . . . . 206745
. . . 70 . . . . . . . . . . . . . . 209756
. . . 71 . . . . . . . . . . . . . . 209751
. . . 71 . . . . . . . . . . . . . . 214686
. . . 72 . . . . . . . . . . . . . . 210023
. . . 73 . . . . . . . . . . . . . . 206747
. . . 74 . . . . . . . . . . . . . . 208029
. . . 75 . . . . . . . . . . . . . . 209646
. . . 76 . . . . . . . . . . . . . . 209856
. . . 77 . . . . . . . . . . . . . . 210027
. . . 78 . . . . . . . . . . . . . . 209755
. . . . . . . . . . . . . . . . . . . *210056
. . . 79 . . . . . . . . . . . . . . 044772
. . . 80 . . . . . . . . . . . . . . 602216
. . . 81 . . . . . . . . . . . . . . 198447
. . . 82 . . . . . . . . . . . . . . 602243
. . . 83 . . . . . . . . . . . . . . 208425
. . . 84 . . . . . . . . . . . . . . 198631
. . . 85 . . . . . . . . . . . . . . 208426
. . . 86 . . . . . . . . . . . . . . 602216
. . . 87 . . . . . . . . . . . . . . 214687
. . . 88 . . . . . . . . . . . . . . 214920
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.
. . Valve, Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Gasket, Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clutch, Electro Magnetic 12vdc W/5.75 Dia Pulley . . . . . . . . . . . . . . . . . . . 1
. . Belt, Micro V 21mm X 1440mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Airend, Gear−driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Tubing Oil Assyw/Fittings 15.860lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Swivel Union Jic−12 F−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Valve,Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Thermostat, 170f (w/gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Elbow 90dg 3/4bspt M X 3/4 Jic M (Prior to LC574021) . . . 1
. . Ftg, Pipe Stl Elbow 90dg 3/4bspp O−ring X 3/4 Jic M (Eff w/LC574021) . 1
. . Filter, Separator Assembly (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tubing, Ssstl .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
. . Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Oil, Compressor 1gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, M12−1.7x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 6
. . Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Flat .438idx1.000odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, M10−1.5x 60 Hex Hd−pln 8.8 Pld Din 931 . . . . . . . . . . . . . . . . . . . . 1
. . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, M12−1.75x 40 Hex Hd 12pt Flange Screw 12.9 . . . . . . . . . . . . . . . 2
. . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 2
. . Ftg, Pipe Stl 3/4bspp X 3/4 Jic M (Eff w/LC574021) . . . . . . . . . . . . . . . . . . 1
. . Seal, Ring Bonded Rbr/Stl .950 Id x 1.38 Od X .10 (Eff w/LC574021) . . . 1

TM-4409 Page 120 Big Blue Air Pak

 TM-4409C March 2005

Processes
Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting

and Gouging

With Optional Equipment:

Battery Charging

Description

Engine Driven Welding Generator And

Air Compressor

Big Blue Air Pak

®

Eff w/LC670817 And Following

For OM-4409 (206 941) Revision H Thru N

Visit our website at

www.MillerWelds.com
SECTION 17 − PARTS LIST EFF W/LC670817 AND FOLLOWING
. Hardware is common and not
available unless listed.

27

17 26
3
18 25

2 19
28
21 24
22
1
20 29
16 30
23
15
8
7 9
13 31
6
12
4 11 14 32

5
33
10

133

148 34

147 15 35
146 − Figure 17-5 130
134 123
132

135
136 131 − Figure 17-2
138
124
139 125
140
145
126
137
141 127
143
128
129

144 − Figure 17-3 142

Figure 17-1. Main Assembly

TM-4409 Page 122 Big Blue Air Pak
 Eff w/LC670817 And Following

150

46 47
71
45 70
69

44 72
68 73
65 67
51 61 74
62 63 66
42 48
43
41 64
38 40 59
39
57 75
37
58
55 56
36 50
49 60 76
54 74
77
53

52 81 78
88 82
89 83
93 84
113 92 90
116 91 86 85
114 117 87 102
118 94 101
115
112 − Figure 17-4 95 79
104
149 99 100 80
119
97 96 103
111
110 105
98
106
109
121 107
120

122 108

803 324-C

Big Blue Air Pak TM-4409 Page 123

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 189828
. . . 3 . . . . . . . . . . . . . . 206601
. . . 4 . . . . . Z1 . . . . . 208277
. . . 4 . . . . . Z1 . . . . . 189395
. . . 5 . . . . CR7 . . ♦188636
. . . 6 . . . . . . . . . . . . ♦081499
. . . 7 . . . . . . . . . . . . . . 038620
. . . . . . . . . . . 1T . . . . . 189549
. . . 8 . . . . . . . . . . . . . . 038621
. . . 9 . . . . . . . . . . . . . . 081499
. . . . . . . . . . . . . . . . . . . . 138027
. . . . . . . . . . . . . . . . . . . . 020225
. . . 10 . . SR4, SR5 . . 035704
. . . 11 . . . . CB4 . . . . 045061
. . . 12 . . . . . . . . . . . . . . 206352
. . . 13 . . . . . T1 . . . . . 205636
. . . 13 . . . . . T1 . . . . . 201613
. . . 14 . . . . . . . . . . . . . . 201697
. . . 15 . . . . . . . . . . . . . . 173352
. . . 16 . . . . . . . . . . . . . . 189708
. . . 17 . . . . . . . . . . . . . . 194485
. . . 18 . . . . . . . . . . . . . . 189764
. . . . . . . . . . . . . . . . . . . *192938
. . . . . . . . . . . . . . . . . . . *192939
. . . . . . . . . . . . . . . . . . . . 206556
. . . 19 . . . . . . . . . . . . . . 189763
. . . 20 . . . . . . . . . . . . . . 206351
. . . 21 . . . . . . . . . . . . . . 189464
. . . 22 . . . . . . . . . . . . . . 197613
. . . 23 . . . . . . . . . . . . . . 197675
. . . . . . . . . . . . . . . . . . . *197676
. . . . . . . . . . . . . . . . . . . . 197677
. . . . . . . . . . . . . . . . . . . . 197678
. . . . . . . . . . . . . . . . . . . *197679
. . . 24 . . . . . . . . . . . . . . 197829
. . . 25 . . . . . . . . . . . . . . 206696
. . . 26 . . . . . . . . . . . . . . 198457
. . . 27 . . . . . . . . . . . . . . 206697
. . . 28 . . . . . . . . . . . . . . 207268
. . . 29 . . . . . . . . . . . . . +219140
. . . 29 . . . . . . . . . . . . . +206610
. . . 30 . . . . . . . . . . . . . . 210151
. . . 31 . . . . . . . . . . . . ♦209612
. . . 32 . . . . . . . . . . . . ♦209597
. . . 33 . . . . . . . . . . . . . ♦209611
. . . 34 . . . . . . . . . . . . . . 196220
. . . 35 . . . . . . . . . . . . . . 192362
. . . 36 . . . . . . . . . . . . . +206603
. . . 37 . . . . . . . . . . . . . . 189052
. . . 38 . . . . . . . . . . . . . . 190198
. . . 39 . . . . . . . . . . . . . . 176103
. . . 40 . . . . . . . . . . . . . . 176104
. . . 41 . . . . . . . . . . . . ♦143915
. . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Reactor, AC Environmental Rda )Prior to LE118236) . . . . . . . . . . . . . . . . 1
. . Reactor, AC (Eff w/LE118326) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Relay, OCV Control (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . 2
. . . . Clamp, Nyl .875 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1
. . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Transformer, W/Brkt Environmental (Prior to LE118236) . . . . . . . . . . . . . . 1
. . Transformer, W/Brkt (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . 1
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Cleaner, Intake 5.250 In (Compressor) (includes) . . . . . . . . . . . . . . . . . 1
. . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Elbow Air Cleaner/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tube, Air Intake Perkins 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Elbow Air Cleaner/Compressor 180 Degree . . . . . . . . . . . . . . . . . . . 1
. . Hose, Cwc Flexaust 2.000 Id X 22.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Cleaner (Prior to LE136911) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Cleaner (Eff w/LE136911) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Air Cleaner Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . 1

TM-4409 Page 124 Big Blue Air Pak

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly (Continued)

. . . 42 . . . . . . . . . . . . ♦205702 . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . ♦205749
. . . 44 . . . . . . . . . . . . ♦603767
. . . 45 . . . . . . . . . . . . ♦010875
. . . 46 . . . . . . . . . . . . ♦205712
. . . 47 . . . . . . . . . . . . ♦205748
. . . 48 . . . . . . . . . . . . . . 176230
. . . 49 . . . . . . . . . . . . . . 213895
. . . 50 . . . . . . . . . . . . . . 202633
. . . 51 . . . . . . . . . . Figure 17-7
. . . 52 . . . . . . . . . . . . . . 191577
. . . 53 . . . . . . . . . . . . . . 191809
. . . 54 . . . . . . . . . . . . . . 209632
. . . 55 . . . . . . . . . . . . . . 206548
. . . 55 . . . . . . . . . . . . . . 218619
. . . . . . . . . . . . . . . . . . . . 193256
. . . . . . . . . . . . . . . . . . . . 195748
. . . . . . . . . . . . . . . . . . . . 195746
. . . . . . . . . . . . . . . . . . . . 195745
. . . . . . . . . . . . . . . . . . . *067265
. . . . . . . . . . . . . . . . . . . *066217
. . . . . . . . . . . . . . . . . . . . 208041
. . . . . . . . . . . . . . . . . . . . 193230
. . . . . . . . . . . . . . . . . . . . 194403
. . . . . . . GLOW PLUG . 190059
. . . 56 . . . . . . . . . . . . . . 207203
. . . . . . . . . . . . . . . . . . . . 208042
. . . 57 . . . . . . . . . . . . . *207808
. . . 58 . . . . . . . . . . . . . . 209675
. . . 59 . . . . . . . . . . . . . . 209633
. . . 60 . . . . . . . . . . . . . . 209621
. . . 61 . . . . . . . . . . . . . . 207269
. . . 62 . . . . . . . . . . . . . . 206749
. . . 63 . . . . . . . . . . . . . . 206558
. . . 64 . . . . . . . . . . . . . . 209623
. . . 65 . . . . . . . . . . . . . . 201749
. . . 66 . . . . . . . . . . . . . . 201006
. . . 67 . . . . BATT . . . . 190897
. . . 68 . . . . . . . . . . . . . . 108081
. . . 69 . . . . . . . . . . . . . . 190206
. . . 70 . . . . . . . . . . . . . . 190207
. . . 71 . . . . . . . . . . . . . . 203430
. . . 72 . . . . . . . . . . . . . +201183
. . . 73 . . . . . . . . . . . . . . 176108
. . . 74 . . . . . . . . . . . . . . 176106
. . . 75 . . . . . . . . . . . . . +206602
. . . 76 . . . . . . . . . . . . . . 207270
. . . 77 . . . . . . . . . . . . . . 210229
. . . 78 . . . . . . . . . . Figure 17-7
. . . 79 . . . . . . . . . . . . . . 208024
. . . 80 . . . . . . . . . . . . . . 206613
. . . 81 . . . . . . . . . . . . . . 199849
. . . 82 . . . . . . . . . . . . . . 071731
. . . 83 . . . . . . . . . . . . . . 191812
. . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Manifold, Exhaust Muffler Bf4m2011 Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Tubing Oil Assyw/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Engine, Deutz Dsl Elec Bf4m2011 (includes) (Prior to LE312114) . . . . . . 1
. . Engine, Deutz Dsl Elec Bf4m2011 (includes) (Eff w/LE312114) . . . . . . . . 1
. . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1
. . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Glow Plug (Eff w/LE312114) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1
. . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Shroud, Fan Air Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1
. . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue Air Pak TM-4409 Page 125

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No.
. . . 84 . . . . . . . . . . . . . . 071890
. . . 85 . . . . . . . . . . . . . . 071730
. . . 86 . . . . . . . . . . . . . . 083476
. . . 87 . . . . . . . . . . . . . . 135205
. . . . . . . . . . . . . . . . . . . . 199505
. . . 88 . . . . . . . . . . . . . . 165271
. . . 89 . . . . . . . . . . . . . . 176529
. . . 90 . . . . . . . . . . . . . . 113854
. . . 91 . . . . . . . . . . . . . . 176528
. . . 92 . . . . . . . . . . . . . . 173336
. . . 93 . . . . . . . . . . . . . . 066298
. . . 94 . . . . . . . . . . . . . . 191816
. . . 94 . . . . . . . . . . . . . . 218003
. . . 95 . . . . . . . . . . . . . . 206297
. . . 96 . . . . . . . . . . . . . *192744
. . . . . . . . . . . . . . . . . . . . 199383
. . . . . . . . . . . . . . . . . . . . 191819
. . . 97 . . . . . . . . . . . . . . 190992
. . . 98 . . . . . . . . . . . . . . 206604
. . . 99 . . . . . . . . . . . . . . 209093
. . 100 . . . . . . . . . . . . . 209092
. . 101 . . . . . . . . . . . . . 174064
. . . . . . . . . . . . . . . . . . . . 196036
. . . . . . . . . . . . . . . . . . . . 125663
. . . . . . . . . . . . . . . . . . . . 175936
. . . . . . . . . . . . . . . . . . . . 127994
. . . . . . . . . . . . . . . . . . . . 127648
. . . . . . . . . . . . . . . . . . . . 124974
. . . . . . . . . . . . . . . . . . . . 601868
. . . . . . . . . . . . . . . . . . . . 126388
. . . . . . . . . . . . . . . . . . . . 089800
. . . . . . . . . . . . . . . . . . . . 108941
. . . . . . . . . . . . . . . . . . . . 156733
. . 102 . . . . . . . . . . . . . 209090
. . 103 . . . . . . . . . . . . +209089
. . 104 . . . . . . . . . . . . . 206464
. . 105 . . . . . . . . . . . . . 199592
. . 106 . . . . . . . . . . . . . 210681
. . 107 . . . . . . . . . . . . . 209091
. . 108 . . . . . . . . . . . . . 191626
. . 109 . . . . . . . . . . . . +189827
. . 110 . . . . . . . . . . . . . 207448
. . 111 . . . . . . . . . . . . . 209059
. . 112 . . . . . . . . . Figure 17-4
. . 113 . . . . . . . . . . . . . 218087
. . 113 . . . . . . . . . . . . . 189245
. . 114 . . . . . . . . . . . . . 124253
. . 115 . . . . . . . . . . . . . 189912
. . 116 . . . . . . . . . . . . . 189909
. . 117 . . . . . . . . . . . . . 189913
. . 118 . . . . . . . . . . . . . 190142
. . 119 . . . . . . . . . . . . . 189910
. . 120 . . . . . . . . . . . . . 189908
. . 121 . . . . . . . . . . . . . 181572
. . . . . . . . . . . . . . . . . . . . 196219
TM-4409 Page 126
Description Quantity
Figure 17-1. Main Assembly (Continued)
. . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4
. . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4
. . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666
. . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fuel Filter/Solenoid (Prior to LE312114) . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fuel Filter/Solenoid (Eff w/LE312114) . . . . . . . . . . . . . . . . . . 1
. . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1
. . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1
. . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Saftey Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Idle, Solenoid Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Arm Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ball Joint, .250−28 Type Sp Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Rod, Throttle 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ball Joint, .250−28 Type Spf Female Rod End . . . . . . . . . . . . . . . . . . . . 1
. . . . Clevis, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Solenoid, 12vdc Pull/Hold Type 1” Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Nut, 250−28 .44hex .27h Stl Pld Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−20 .44hex .22h Stl Pld .58d Flange Defor . . . . . . . . . . . . . . . . 1
. . . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . 1
. . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Maintenance Big Blue Air Pak Deutz Ce . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Maintenance I R Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Schematic Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel (includes) (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel (includes) (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . 1
Big Blue Air Pak
 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-1. Main Assembly

. . 122 . . . . . . . . . . . . . 191446
. . 123 . . . . . . . . . . . . . 209094
. . 124 . . . . . . . . . . . . +212224
. . 125 . . . . . . . . . . . . . 191897
. . 126 . . . . . . . . . . . . . 200864
. . 127 . . . . . . . . . . . . . 206463
. . 128 . . . . . . . . . . . . . 182761
. . 129 . . . . R3 . . . . . 189699
. . 130 . . . . . . . . . . . . . 218086
. . 130 . . . . . . . . . . . . . 191512
. . 131 . . . . . . . . . Figure 17-2
. . 132 . . . . . . . . . . . . . 189731
. . 133 . . . . . . . . . . . . . 203260
. . 134 . . . . . . . . . . . . . 191448
. . 135 . . . . . . . . . . . . . 206609
. . 136 . . . . . . . . . . . . +206606
. . 137 . . . . . . . . . . . . . 209682
. . 138 . . . . . . . . . . . ♦039047
. . 139 . . . . . . . . . . +♦207095
. . 140 . . . . . . . . . . . ♦039046
. . 141 . . . . . . . . . . . ♦210156
. . 142 . . . . . . . . . . . . . 207096
. . 143 . . . . . . . . . . . . . 209683
. . 144 . . . . . . . . . Figure 17-3
. . 145 . . . CT1 . . . . 202130
. . 146 . . . . . . . . . Figure 17-5
. . 147 . . . . . . . . . . . . . 193453
. . 148 . . . PC1 . . . . 207397
. . 149 . . . . . . . . . . . . . 085963
. . 150 . . . . . . . . . . . . . 105734
. . . . . . . . . . . . . . . . . . . . 049525
. . . . . . . . . . . . . . . . . . . . 049525
. . . . . . . . . . . . . . . . . . . . 206470
. . . . . . . . . . . . . . . . . . . ♦195118
. . . . . . . . . . . . . . . . . . ♦209238
. . . . . . . . . . . . . . . . . . ♦209240
. . . . . . . . . . . . . . . . . . ♦209236
. . . . . . . . . . . . . . . . . . ♦209241
. . . . . . . . . . . . . . . . . . ♦209242
. . . . . . . . . . . . . . . . . . ♦189975
. . . . . . . . . . . . . . . . . . ♦155146
. . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . 6ft
. . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Label, Do Not Weld On Base CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Holddown Fuel Tank (Prior to LE118236) . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Holddown Fuel Tank (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . 1
. . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Air Power Ingersoll−Rand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Box, Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Battery Charge (Battery Charge +/−) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Safety Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Xfmr, Current Sensing (Auto Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . 1
. . Pipe, Muffler Extension Elbow 1.750 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
. . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 3

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue Air Pak TM-4409 Page 127

 Eff w/LC670817 And Following
6

11

5 12
25

19
4 23

21 22

3
2
1
26
24 18

17
7 13
8
21

15
9
10 16
14

20

803 325-B

Figure 17-2. Control Box Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-2. Control Box Assembly − (Figure 17-1 Item 131)

. . . 1 . . . F1, F2 . . . 085874
. . . 2 . . . . . . . . . . . . . . 046432
. . . 3 . . . . . . . . . . . . . . 134201
. . . 4 . . . . PC9 . . . . 192224
. . . 5 . . . . . . . . . . . . . . 201077
. . . 6 . . . . HM2 . . ♦145247
. . . . . . . . . . . . . . . . . . . . 219873
. . . . . . . . . . . . . . . . . . . . 206736
. . . 7 CB11,CB12,CB13 139266
. . . 8 . . . . SR1 . . . . 035704
. . . . . . . . . . RC3 . . . . 158466
. . . . . . . . . . RC1 . . . . 135133
. . . 9 . . . . . C9 . . . . . 087110
. . . 10 . . . . . . . . . . . . . . 177136
. . . . . . . . . . . . . . . . . . . . 204737
. . . 11 . . . . . . . . . . . . . . 201078
. . . 12 . . CR3,CR6 . . 090104
. . . 13 . . . . PC7 . . . . 195706
. . . 14 . . . . TD1 . . . . 214928
. . . 15 . . . . . . . . . . . . . . 201079
. . . 16 . . . . . . . . . . . . . . 217823
. . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3
. . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Meter, Hour Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Harness, Control Box, Weld Control LH (includes) (Prior to LE136911) . . 1
. . Harness, Control Box, Weld Control LH (includes) (Eff w/LE136911) . . . . 1
. . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 3
. . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2
. . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Timer, Delay On Make/Break Open 30 Sec 12vdc . . . . . . . . . . . . . . . . . . . 1
. . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4409 Page 128 Big Blue Air Pak

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-2. Control Box Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 206375 . . Harness, Engine Deutz Bf4m2011 (includes) (Prior to LE118236) . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 217815 . . Harness, Engine Deutz Bf4m2011 (includes) (Eff w/LE118236) . . . . . . . . 1
. . . 17 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to LE118236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eff W/LE118236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . CB14 . . . . 205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . CB15 . . . . 083432 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S2 . . . . . 021467 . . . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 17-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211292 . . . . Conn, Body 5 Terminal (For Ignition Switch S1) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . CR4, CR10 . 113247 . . . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . S10 . . . . 206624 . . . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 17-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8/C8, D10/C10, D14/C14 (Prior to LE118236) . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1/C1, D8/C8, D10/C10 (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . CR1 . . . . 214876 . . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CB8 . . ♦139266 . . Circuit Breaker, Man Reset 1p 15a 250vac Frict (Air Dryer) . . . . . . . . . . . 1
. . . 24 . . . . CR14 . . ♦090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Air Dryer) . . . . . . . . 1
. . . . . . . . . . CR15 . . ♦172015 . . Time Delay Relay (Air Dryer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . CR8 . . . . 197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg (Eff w/LE312114) . . . . . . . . 1
. . . 26 . . . . CR5 . . . . 199999 . . Relay, Encl 12vdc Dpst−no 30a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*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 Air Pak TM-4409 Page 129

 Eff w/LC670817 And Following

. Hardware is common and 54

not available unless listed. 3

5
1 6 9

8
10
59
58 11
12
57 13
14
15
56 16

17

18
55 19
53 20
52
47
51
48 46 21
50 45 30
49 28 22
44 23
25
31 29
43
27 24
32 26

33

34
36
42
35

41

40 39 38 37
803 326-A

Figure 17-3. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-3. Panel, Front w/Components (Figure 17-1 Item 144)

. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Plate, Screened Ident Control Rating (Order by Model and Serial No.) . . 1
. . . 2 . . . . . . . . . . . . . . 215014 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 4 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4409 Page 130 Big Blue Air Pak

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-3. Panel, Front w/Components (Continued)

. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB6 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S10 . . . . 206624 . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 17-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 17-2) (Eff w/LE312114) . . . . . . . . . . . 1
. . . 13 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . GFCI1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . . . 147632 . . . . Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 2
. . . 17 . . . . RC5 . . ♦182954 . . Rcpt, Str 3p4w 50a 125/250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197291 . . Cover, Receptacle W/Gasket (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . ♦025248 . . Stand-off, Insul .250-20 X 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦604102 . . Connector, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197363 . . Terminal, Ring Tng Screw Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . CB7 . . ♦196780 . . Circuit Breaker, Man Reset 3p 50a 250vac (Prior to LE118236) . . . . . . . . 1
. . . 22 . . . . CB7 . . ♦214926 . . Circuit Breaker, Man Reset 3p 50a 250vac (Eff w/LE118236) . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . +201106 . . Panel, Power (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . +215347 . . Panel, Power (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . +♦201107 . . Panel, Generator Power (Full KVA Option) (Prior to LE118236) . . . . . . . . 1
. . . . . . . . . . . . . . . . . +♦215363 . . Panel, Generator Power (Full KVA Option) (Eff w/LE118236) . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197433 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦196781 . . Boot, Circuit Breaker 3 Pole (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦214927 . . Boot, Circuit Breaker 1 Pole (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 163167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . ♦193258 . . Cover, Receptacle Gfci Lexan (Prior to LE118236) . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . ♦209056 . . Cover, Receptacle W/Gasket (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197399 . . Label, Warning 3 Ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 193258 . . Cover, Receptacle Gfci Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 193260 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . ♦210149 . . Label, Battery Charge (Switch Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . ♦ . . Label, Polarity/AC Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . S12 . . ♦220491 . . Switch, Polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S13 . . ♦210217 . . Switch, Battery Charge Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue Air Pak TM-4409 Page 131
 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-3. Panel, Front w/Components (Continued)

. . . 35 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 36 . . . . . . . . . . . . ♦210206 . . Bracket, Support Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8
. . . 39 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . ♦059773 . . Switch, Handle (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . ♦010647 . . Pin (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦059773 . . Handle, Switch (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦010647 . . Pin,Spring Cs .156 X 1.250 (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦081499 . . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 46 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . HM1 . . . . 210424 . . Meter, Hour 12−24vdc (Snap−in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . AIR . . . . 206599 . . Gauge, Pressure 0−200 Psi Electric Switch . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . TEMP . . . 217084 . . Gauge, Engine Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . OIL . . . . . 217083 . . Gauge, Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . A1 . . . ♦164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . CT3 . . ♦209274 . . Xfmr, Current (Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . V1 . . . ♦164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193158 . . Harness, Unit Weld Control − CV (includes) (Prior to LE118236) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215207 . . Harness, Unit Weld Control − CV (includes) (Eff w/LE118236) . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 088731 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to LE118236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eff w/LE118236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . 059712 . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 120304 . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 025234 . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
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-4409 Page 132 Big Blue Air Pak

 Eff w/LC670817 And Following

11
14

15

13 16
10 12 17

18
8
19
7 20

5
3 21
4 22
23
2 25 24
1 26
27
28
29
30

31
32
33 803 327

Figure 17-4. Generator

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-4. Generator (Figure 17-1 Item 112)

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

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . STATOR . . +208287 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . STATOR +♦209220 . . Stator, Weld Assy Complete (3-Phase Generator Option)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . STATOR +♦216320 . . Stator, Weld Assy Complete (3-Phase Generator Option)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 17 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . 8
. . . 19 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4
Big Blue Air Pak TM-4409 Page 133
 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 17-4. Generator (Continued)

... 20 . . . . . . . . . . . . . . 049026 .. Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

... 21 . . . . . . . . . . . . . . 191579 .. Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . . . . 083883 .. Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6
... 23 . . . . . . . . . . . . . . 172555 .. Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 24 . . . . . . . . . . . . . . 602159 .. Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . 6
... 25 . . . . . . . . . . . . . . 604950 .. Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 26 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 4
... 27 . . . . . . . . . . . . . . 139341 .. Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 28 . . . . . . . . . . . . . *190823 .. Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
... 29 . . . . . . . . . . . . . . 188560 .. Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 30 . . . . . . . . . . . . . . 189142 .. Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 602242 .. Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 2
... 33 . . . . . . . . . . . . . . 604534 .. Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206470.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4409 Page 134 Big Blue Air Pak

 Eff w/LC670817 And Following
. Hardware is common and 4
not available unless listed.
3

1
5

802 279-A

Figure 17-5. Main Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 17-5. Main Rectifier Assembly (Figure 17-1 Item 146)

. . . . . . . . . . SR3 . . . . 208279 . . Rectifier Complete (includes) (Prior to LE118236) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . SR3 . . . . 215909 . . Rectifier Complete (includes) (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . . 188137 . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 188517 . . . . Bus Bar, Conn Bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . . 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 134201 . . . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 201449 . . . . Circuit Card Assy, Protection (Prior to LE118236) . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PC3 . . . . 215755 . . . . Circuit Card Assy, Protection (Eff w/LE118236) . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 188136 . . . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . . 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 208334 . . . . Diode, Rect 275. A 300v Sp Do−9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *1n4048(037956 W/R (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . D3, D5, D7 . 037956 . . . . Diode, Rect 275. A 300v Sp Do−9 (Eff w/LE118236) . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 208335 . . . . Diode, Rect 275. A 300v Rp Do−9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *1n4048r(037957 W/ (Prior to LE118236) . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 037957 . . . . Diode, Rect 275. A 300v Rp Do−9 (Eff w/LE118236) . . . . . . . . . . . . . . . . 3
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 Air Pak TM-4409 Page 135

 Eff w/LC670817 And Following
. Hardware is common and
not available unless listed.

79
80
53
52 54
51 55 56
Prior To LE136911 13
9
57
46
10
19 50
18 58
17 61
20 49
21
48
16 59
22 24 47
15 23 46
11 45 60
14 25 44
9 28
13 6 43
11 12 26 81
82
10 8 41
7 6 5
9 83
4 27
42 39

3 86 62
2 28 40
84 63
85
1
29
31 64
38
32 65
34 66
37
26 67
75 33
35 36
76
77 87
78
9 88
45 68
72
70
69
74

73 71

803 328-C

Figure 17-6. Air Compressor Assembly Prior To LE136911

TM-4409 Page 136 Big Blue Air Pak
 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 17-6. Air Compressor Assembly (Figure 17-1 Item 78)
Prior To LE136911
... 1 .............. 206607 . . Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 210523 . . Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 206939 . . Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 210248 . . Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 117826 . . Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 210053 . . Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 071270 . . Ftg, Pipe Brs Tee St 1/4 Npt 071 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 209854 . . Ftg, Pipe Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 209642 . . Hose, Nylon Blue 57.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 210040 . . Orifice/Muffler,120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 209640 . . Hose, Nylon Red 57.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210054 . . Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206746 . . Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 602965 . . Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 209635 . . Hose, Assy w/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 210051 . . Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 209767 . . Ftg, Pipe Stl Connector M 3/4 Sae−npt Adapter . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 206615 . . Sender, Pressure Oil 0− 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 073655 . . Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 206937 . . Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 206743 . . Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 209754 . . Ftg, Pipe Stl Elbow M 45dg 3/4 X (Npt−jic 45dg) . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 214685 . . Hose Assy, Air W/Fittings 3/4 X 21.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 209787 . . Ftg, Pipe Stl Nipple Close 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 209636 . . Hose, Oil W/Fittings 32.460 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 210058 . . Gauge, Oil Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . Deleted ....................................................................
. . . 31 . . . . . . . . . . . . . . 209766 . . Ftg, Pipe Stl Tee Street 3/4 Npt M−f−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 209457 . . Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 209638 . . Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 209639 . . Hose, Oil W/Fittings 26.320 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 210254 . . Bracket, Mtg Tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O−ring . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−jic− . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 208040 . . Tensioner,Belt w/Pully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 206611 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 210022 . . O−ring, High Air Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 210021 . . Adapter, Airend Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 209769 . . Ftg, Flrd Stl Plug 1/2 Sae O−ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 209641 . . Hose, Nylon White 32.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 209855 . . Ftg, Pipe Stl Adapter M 1/8 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . . 015732 . . Ftg, Pipe Brs Elbow St 45 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 207265 . . Brace, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 176518 . . Ftg, Pipe Brs Elbow St 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 602887 . . Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue Air Pak TM-4409 Page 137

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 17-5. Air Compressor Assembly Prior To LE136911
(Continued)
. . . 53 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 210006 . . Valve, Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210016 . . Gasket, Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . CLUTCH . . 210055 . . Clutch, Electro Magnetic 12vdc W/5.75 Dia Pulley . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 207807 . . Belt, Micro V 21mm X 1440mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 206800 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 210001 . . Airend, Gear−driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 209853 . . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 209634 . . Hose, Tubing Oil Assyw/Fittings 15.860lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 206558 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 209851 . . Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 209825 . . Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 209764 . . Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 209828 . . Ftg, Stl Swivel Union Jic−12 F−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 210052 . . Valve,Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 206744 . . Thermostat, 170f (w/gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 206745 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 209756 . . Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 214686 . . Ftg, Pipe Stl Elbow 90dg 3/4bspt M X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 210023 . . Filter, Separator Assembly (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 206747 . . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 208029 . . Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 209646 . . Tubing, Ssstl .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 209856 . . Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 210027 . . Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 209755 . . Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *210056 . . Oil, Compressor 1gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 044772 . . Screw, M12−1.7x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 80 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 6
. . . 81 . . . . . . . . . . . . . . 198447 . . Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 602243 . . Washer, Flat .438idx1.000odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 208425 . . Screw, M10−1.5x 60 Hex Hd−pln 8.8 Pld Din 931 . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 198631 . . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 208426 . . Screw, M12−1.75x 40 Hex Hd 12pt Flange Screw 12.9 . . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 2
. . . 87 . . . . . . . . . . . . . . 214687 . . Ftg, Pipe Stl 3/4bspp X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 214920 . . Seal, Ring Bonded Rbr/Stl .950 Id X 1.380 Od X .100 . . . . . . . . . . . . . . . . 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-4409 Page 138 Big Blue Air Pak

 Eff w/LC670817 And Following

. Hardware is common and

not available unless listed.

79
80
Eff w/LE136911 And Following 53 10 9
51
56
54
57

13
19 9 55
50
18 52
17
49 58 61
21 20
48
22 24 47 59
16 46
15 23
11 45 89 60
14
9 25 44
13 6 4
12 43 28
11 26 81
82
10 41
8
9 7 6 83
5 27
4 39
42
3 86 40 62
2 4
85 84 63

1
29
31 64
38 65
32
34 66
37
26 67
75 33
35 36
76
77 87 68
78
9 88
45
72
70
69
74

73 71

803 328−E

Figure 17-7. Air Compressor Assembly Eff w/LE136911 And Following

Big Blue Air Pak TM-4409 Page 139
 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 17-7. Air Compressor Assembly (Figure 17-1 Item 78)
Eff w/LE136911 And Following
... 1 .............. 206607 . . Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 210523 . . Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 206939 . . Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 210248 . . Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 .............. 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 117826 . . Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 210053 . . Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 071270 . . Ftg, Pipe Brs Tee St 1/4 Npt 071 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 209854 . . Ftg, Pipe Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 10 . . . . . . . . . . . . . . 218602 . . Hose, Nylon Blue 44.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 210040 . . Orifice/Muffler,120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 218601 . . Hose, Nylon Red 36.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 210054 . . Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206746 . . Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 602965 . . Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 209635 . . Hose, Assy w/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 210051 . . Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 209767 . . Ftg, Pipe Stl Connector M 3/4 Sae−npt Adapter . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 206615 . . Sender, Pressure Oil 0− 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 073655 . . Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 206937 . . Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 206743 . . Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 209754 . . Ftg, Pipe Stl Elbow M 45dg 3/4 X (Npt−jic 45dg) . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 214685 . . Hose Assy, Air W/Fittings 3/4 X 21.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 209787 . . Ftg, Pipe Stl Nipple Close 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 209621 . . Fitting, Stl Adapter 3/4 SAE − 3/4 JIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 210058 . . Gauge, Oil Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . Deleted ....................................................................
. . . 31 . . . . . . . . . . . . . . 209766 . . Ftg, Pipe Stl Tee Street 3/4 Npt M−f−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 209457 . . Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 209638 . . Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 209639 . . Hose, Oil W/Fittings 26.320 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 210254 . . Bracket, Mtg Tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O−ring . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−jic− . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 208040 . . Tensioner,Belt w/Pully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 217797 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 210022 . . O−ring, High Air Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 211904 . . Manifold, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 218558 . . Screw, M 8−1.2x 50 Hex Hd−pln 8.8 Pld (Manifold Mtg.Screws) . . . . . . . 4
. . . 45 . . . . . . . . . . . . . . 209641 . . Hose, Nylon White 32.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 209855 . . Ftg, Pipe Stl Adapter M 1/8 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . . 015732 . . Ftg, Pipe Brs Elbow St 45 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 217936 . . Brace, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 176518 . . Ftg, Pipe Brs Elbow St 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 602887 . . Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TM-4409 Page 140 Big Blue Air Pak

 Eff w/LC670817 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 17-5. Air Compressor Assembly Eff w/LE136911 And
Following (Continued)
. . . 53 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 218305 . . Valve, Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210016 . . Gasket, Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . CLUTCH . . 210055 . . Clutch, Electro Magnetic 12vdc W/5.75 Dia Pulley . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 218609 . . Belt, Micro V 21mm X 1485mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 206800 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 210001 . . Airend, Gear−driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 209853 . . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 209634 . . Hose, Tubing Oil Assyw/Fittings 15.860lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 206558 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 209851 . . Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 209825 . . Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 209764 . . Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 209828 . . Ftg, Stl Swivel Union Jic−12 F−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 210052 . . Valve,Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 206744 . . Thermostat, 170f (w/gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 206745 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 209756 . . Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 214686 . . Ftg, Pipe Stl Elbow 90dg 3/4bspt M X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 210023 . . Filter, Separator Assembly (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 206747 . . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 208029 . . Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 209646 . . Tubing, Ssstl .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 209856 . . Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 210027 . . Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 209755 . . Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *210056 . . Oil, Compressor 1gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 044772 . . Screw, M12−1.7x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 80 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 6
. . . 81 . . . . . . . . . . . . . . 198447 . . Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 602243 . . Washer, Flat .438idx1.000odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 208425 . . Screw, M10−1.5x 60 Hex Hd−pln 8.8 Pld Din 931 . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 198631 . . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 208426 . . Screw, M12−1.75x 40 Hex Hd 12pt Flange Screw 12.9 . . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 2
. . . 87 . . . . . . . . . . . . . . 214687 . . Ftg, Pipe Stl 3/4bspp X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 214920 . . Seal, Ring Bonded Rbr/Stl .950 Id X 1.380 Od X .100 . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 218423 . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Air Pak TM-4409 Page 141

 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

PRINTED IN USA © 2005 Miller Electric Mfg. Co.