BB 800 800X 800CA Duo Pro Air Pak TM

TM-267 603A 2015−05
Eff w/Serial No. ME200183E

Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Engine Driven Welder/Generator And

Air Compressor
Big Blue 800X / 800CA

Duo Air Pak
)
File: Engine Drive
Visit our website at

www.MillerWelds.com
INFORMATION ON OLDER UNITS
This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-8. AC Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Using The Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 18
4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 19
4-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . 20
4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . 21
4-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 22
4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 23
4-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-15. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-16. Connecting To Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-17. Connecting To The Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-3. Engine Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-4. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-5. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5-6. Low Open-Circuit Voltage (VRD) Switch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-7. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-8. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-9. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-10. Engine Block Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-11. Optional Air Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-1. North American Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-2. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6-3. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-2. Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-3. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TABLE OF CONTENTS
7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7-5. Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-6. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-7. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-8. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7-10. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7-11. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7-12. Removing Optional Air Dryer For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9-1. Measuring Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9-2. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9-3. Troubleshooting Circuit Diagram For Welder/Generator (Use With Section 9-4) . . . . . . . . . . . . . . . . . 58
9-4. Troubleshooting Values For Circuit Diagram (Use With Section 9-3) . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9-5. Waveforms For Sections 9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9-6. Main Control Board PC1/PC21 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9-7. Main Control Board PC1/PC21 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9-8. Filter Board PC5/PC25 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-9. Filter Board PC5/25 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-10. IGBT Module LED Troubleshooting Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9-11. Engine Display Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-12. Meter Display Board PC2/PC22 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9-13. Meter Display Board PC2/PC22 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9-14. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9-15. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION 10 − SERVICING AND TROUBLESHOOTING AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 72
10-1. Component Location And System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10-2. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10-3. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-4. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-5. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10-6. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10-7. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-8. Troubleshooting Air Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SECTION 11 − SERVICING AND TROUBLESHOOTING OPTIONAL AIR DRYER . . . . . . . . . . . . . . . . . . . . 82
11-1. Component Location For JP Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11-2. Air Dryer Operation And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11-3. Replacing Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11-4. Troubleshooting Optional Air Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 12 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12-1. Disassembly For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12-3. Replacing IGBT Modules/Heat Sink Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SECTION 13 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SECTION 14 − TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14-1. Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
SECTION 15 − ENGINE INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SECTION 16 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
16-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
16-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
SECTION 17 − PARTS LIST EFF W/SERIAL NO. ME200183E AND FOLLOWING . . . . . . . . . . . . . . . . . . . 120
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

OM-267 603D - 2015−04, safety_rtm 2015-04
DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Servicing Hazards

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

BATTERY ACID can BURN SKIN and EYES.
Wear safety glasses with side shields or face
shield during servicing. Do not tip battery.
Be careful not to short metal tools, parts, or Replace damaged battery.
wires together during testing and servicing. Flush eyes and skin immediately with water.
Big Blue 800X/800CA Duo Air Pak TM-267 603 Page 1
Have the installation regularly checked and maintained.
STEAM AND HOT COOLANT can burn.
Keep high-frequency source doors and panels tightly shut, keep
If possible, check coolant level when engine is spark gaps at correct setting, and use grounding and shielding to
cold to avoid scalding. minimize the possibility of interference.
Always check coolant level at overflow tank, if
present on unit, instead of radiator. OVERUSE can cause OVERHEATING.
If the engine is warm, checking is needed, and there is no overflow Allow cooling period; follow rated duty cycle.
tank, follow the next two statements. Reduce current or reduce duty cycle before
Wear safety glasses and gloves and put a rag over radiator cap. starting to weld again.
Turn cap slightly and let pressure escape slowly before completely Do not block or filter airflow to unit.
removing cap.
ELECTRIC AND MAGNETIC FIELDS (EMF) SHOCK HAZARD from testing.

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

Failed parts can explode or cause other parts to Before working on hydraulic system, turn off and
explode when power is applied to inverters. lockout/tagout unit, release pressure, and be sure
Always wear a face shield and long sleeves hydraulic pressure cannot be accidentally applied.
when servicing inverters. Relieve pressure before disconnecting or con-
necting hydraulic lines.
H.F. RADIATION can cause interference. Check hydraulic system components and all con-
High-frequency (H.F.) can interfere with radio nections and hoses for damage, leaks, and wear
navigation, safety services, computers, and before operating unit.
communications equipment. Wear protective equipment such as safety
Have only qualified persons familiar with elec- glasses, leather gloves, heavy shirt and trousers,
tronic equipment perform this installation. high shoes, and a cap when working on hydraulic
system.
The user is responsible for having a qualified electrician promptly
Use a piece of paper or cardboard to search for
correct any interference problem resulting from the installation.
leaks−−never use bare hands. Do not use equip-
If notified by the FCC about interference, stop using the equipment ment if leaks are found.
at once.
TM-267 603 Page 2 Big Blue 800X/800CA Duo Air Pak
HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid. COMPRESSED AIR can injure or kill.
Reinstall doors, panels, covers, or guards when servicing is Before working on compressed air system,
finished and before starting unit. turn off and lockout/tagout unit, release pres-
If ANY fluid is injected into the skin, it must be surgically removed sure, and be sure air pressure cannot be acci-
within a few hours by a doctor familiar with this type of injury or gan- dentally applied.
grene may result. Relieve pressure before disconnecting or con-
necting air lines.
Check compressed air system components
COMPRESSED AIR EQUIPMENT can and all connections and hoses for damage,
leaks, and wear before operating unit.
injure or kill.
Do not direct air stream toward self or others.
Before working on compressed air system, turn Wear protective equipment such as safety glasses, hearing pro-
off and lockout/tagout unit, release pressure, tection, leather gloves, heavy shirt and trousers, high shoes, and a
and be sure air pressure cannot be accidentally cap when working on compressed air system.
applied. Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
Do not work on compressed air system with unit running unless found.
you are a qualified person and following the manufacturer’s in- Reinstall doors, panels, covers, or guards when servicing is
structions. finished and before starting unit.
If ANY air is injected into the skin or body seek medical help imme-
Do not modify or alter compressor or manufacturer-supplied diately.
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system. TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system. Release air pressure from tools and system be-
Do not work under or around any equipment that is supported only fore servicing, adding or changing attach-
by air pressure. Properly support equipment by mechanical ments, or opening compressor oil drain or oil fill
means. cap.
1-3. California Proposition 65 Warnings

For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling.
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-4. EMF Information

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

SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions

Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05

Do not work on unit if engine is running. Stop engine first.
Safe21 2012−05
Do not smoke while fueling or if near fuel.
Safe22 2012−05
Stop engine before fueling.
Safe23 2012−05
Do not fuel a hot engine.
Safe24 2012−05
Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).
Safe25 2012−05
Do not spray water on electrical parts, including Engine Control Unit (ECU).
Safe 118 2014−10
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2015−02
Hot muffler and exhaust pipe can cause severe burns.
Safe90 2012−07
Welding, cutting, drilling, or grinding on base can cause fire or explosion.
Safe91 2012−07
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the

machine or welding.
Safe40 2012−05
Engine fuel plus flames or sparks can cause fire.
=
Safe45 2012−05
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Safe46 2012−05
Read Owner’s Manual. Read labels on unit.
Safe47 2012−05
<12.4 V
Read Owner’s Manual for battery maintenance information.
/ + − + −
Safe117 2014−06
0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.
Safe54 2012−05
50 h std
After the first 50 hours of operation, change the engine oil and filter.
Safe55 2012−05
Never use generator inside a home or garage, even if doors and win-
dows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
2-2. Miscellaneous Symbols And Definitions

Some symbols are found only on CE products.
A Amperage
Clock, Time
Switch
Direct Current
(DC)
V Voltage
Read Operator’s
Manual
Alternating
Current (AC)
Hz Hertz Negative
Protective Earth
(Ground)
Seconds Positive Single Phase

Three Phase Engine
I Current
I2
Suitable For
s Welding In An Engine Rated Welding

Environment With Current
Increased Risk Of
Electric Shock
n
Engine RPM Rated Load
Speed
Off
n0
Engine Stop Rated No−Load
Speed
On
Increase/Decreas
e of Quantity
Slow
n1 Rated Idle Speed
(Rotating)
Remote
Fast
X Duty Cycle
Do Not Switch
While Welding
Engine Belt
h Hours
P1max
Air Compressor Maximum Power
Consumption
Welding (General)
Call for Engine−Driven
Maintenance 3−Phase
Shielded Metal Alternator with
Arc Welding Rectifier
(SMAW) Check
Injectors/Pump Circuit Breaker
Flux Cored Arc Supplementary
Welding (FCAW) Check Valve Protector
Clearance
Gas Metal Arc Output
Welding (GMAW) Certified/Trained
Mechanic
Gas Tungsten Arc
Welding (GTAW) / Previous
Tungsten Inert
Gas (TIG) Spark Arrestor
Welding
Lift Arc TIG Air Cleaner

Next
Air Temperature
Engine Oil Engine
Temperature Menu
Fuel Filter Cancel Function
Engine Coolant Increase View
Battery (Engine)
U0 Rated No−Load
Voltage (OCV) Enter
Engine
U2 Conventional
Load Voltage Diagnostics

SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the right side. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
3-2. Weld, Power, And Engine Specifications

Maximum
Rated Output
Welding Rated Output Open-Circuit Fuel Tank
Dual Operator Generator Power Rating Engine
Mode Single Operator Voltage Capacity
(Each Side)
(Nominal)
Stick: 400A, 36 Independent of Weld Output

Stick: 800A, 38 Single-Phase,
VDC, 100% Duty
VDC, 100% Duty 4 kVA/kW, 34/17 A,
Cycle Deutz TD2011L04w
CC/DC Cycle 95* 120/240 V AC, 50/60 Hz
TIG: 400A, 26 Oil-Cooled,
TIG: 800A, 38 VDC, 3-Phase Generator Four-Cylinder,
VDC, 100% Duty 25 gal
100% Duty Cycle (In Addition To Standard Turbo-Charged
Cycle (95 L)
4 kVA/kW Generator Power) 63.4 HP Diesel Engine
Single-Phase/
Three-Phase,12/20 kVA/kW,
400A, 34 VDC, 800A, 38 VDC, 50/48 A, 120/240 VAC,
CV/DC 95
100% Duty Cycle 100% Duty Cycle 50/60 Hz
* With Low OCV Voltage Reducing Device (VRD) switch enabled, open−circuit voltage is 13 to 15 volts DC until arc initiation for Stick Welding.
3-3. Air Compressor Specifications
Compressor Model And Air Output At Effective Working Safety Relief

Factory Pressure Setting
Type Pressure Valve Rating
60 scfm (1.7 m3 min−1),

Ingersoll Rand CE55 G
100 psi (690 kPa), 125 psi (862 kPa) 150 psi (1034 kPa)
Rotary Screw
100% Duty Cycle
3-4. Environmental Specifications

IP Rating Operating Temperature Range
IP23S
−40 to 104°F (−40 to +40°C)
This equipment is designed for outdoor use. It may be stored, but is not intended IP23S 2014−06
to be used for welding outside during precipitation unless sheltered.
TM-267 603 Page 8 Big Blue 800X/800CA Duo AirPak

3-5. Dimensions, Weights, And Operating Angles
Dimensions
53.75 in. (1365 mm)
Height
(to top of exhaust)
28-1/2 in. (724 mm) G

(mtg. brackets turned in)
Width
30-3/4 in. (781 mm)
(mtg. brackets turned out)
Depth 69.5 in. (1765 mm)
! Do not exceed tilt angles or engine could
A 69.5 in. (1765 mm) be damaged or unit could tip.
B* 57.9 in. (1470 mm) ! Do not move or operate unit where it could
tip.
C* 46.375 in. (1178 mm)
A
D* 11.5625 in. (294 mm) B C
E 27-1/2 in. (699 mm)
F 1 in. (25 mm)
30°
G 29-13/16 in. (757 mm)
H 30°
9/16 in. (14 mm) Dia.
H
4 Holes 20°
D 20°
* With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight E 907 634−1
No fuel: 2020 lb ( kg) 802 161-A

W/fuel: 2195 lb ( kg)
Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum
3-6. Duty Cycle And Overheating
1 100% Duty Cycle

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

400 amperes continuously in
dual operator mode or 800 am-
peres continuously in single
operator mode.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Big Blue 800X/800CA Duo AirPak TM-267 603 Page 9

3-7. Volt-Ampere Curves
The volt-ampere curves show the
A. Stick Mode minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
100 other settings fall between the
curves shown.
80
DC VOLTS
Parallel Mode
60
Dual Operator
40
20
0
0 100 200 300 400 500 600 700 800
DC AMPERES
B. TIG Mode
100
80
DC VOLTS
Parallel Mode
60
40
Dual Operator
20
0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
C. MIG Mode
50
30
DC VOLTS
10
0
0 100 200 300 400 500 600 700 800
DC AMPERES
259 678-A
−10
3-8. AC Generator Power Curves
The AC power curve shows the
A. Single Phase 4 kW generator power in amperes.
280
260
AC VOLTS
240
220
200
180
0 10 20 30 40
AC AMPERES
B. Single Phase 12 kW
140 280
135 270
130 260
125 250
AC VOLTS
120 240
115 230
110 220
105 210
100 200
95 190
90 180
0 10 20 30 40 50 60 70 80 90 100
AC AMPERES
C. Three Phase 20 kW
280
260
AC VOLTS
240
220
200
180
0 10 20 30 40 50 60
AC AMPERES
253 021-A / 254 115-A / 254 114-A

3-9. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
4.00
3.75
3.50
No Air Output
3.25
3.00
2.75 With Air Output
2.50
2.25
US Gal./Hr.
2.00
Dual Weld Mode
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
DC WELD AMPERES AT 100% DUTY CYCLE
268 071-A
Notes

SECTION 4 − INSTALLATION
4-1. Installing Welder/Generator
Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)
OR OR
18 in.
18 in. (460 mm)
(460 mm)
Location/Mounting
Welding Bolting
Unit In Unit In
Place 2 Place 3
2
OR
OR
Tools Needed: 1 1
9/16 in. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
Go to MillerWelds.com for more ! Do not weld on base. Welding on

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

4-2. Grounding Generator To Truck Or Trailer Frame
1 2
GND/PE
rot_grnd2 2014−11 − 800 652-D
! Always ground generator frame to frame. Always connect a ground 1 Equipment Grounding Terminal (On
vehicle frame to prevent electric wire from the generator equipment Front Panel)
shock and static electricity hazards. grounding terminal to bare metal on 2 Grounding Cable (Not Supplied)
the vehicle frame as shown.
! Also see AWS Safety & Health Fact 3 Metal Vehicle Frame
Sheet No. 29, Grounding of Portable
! Use GFCI protection when operat- Connect cable from equipment ground
And Vehicle Mounted Welding Gen-
ing auxiliary equipment. If unit does terminal to metal vehicle frame. Use #8
erators.
not have GFCI receptacles, use AWG or larger insulated copper wire.
! Bed liners, shipping skids, and GFCI-protected extension cord. Do
some running gear insulate the not use GFCI receptacles to power Electrically bond generator frame to ve-
welder/generator from the vehicle life support equipment. hicle frame by metal-to-metal contact.
4-3. Installing Exhaust Pipe

! Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in. Ref. 907 634−1 / 907 535−3 / Exhaust3

4-4. Connecting The Battery
Tools Needed:
1/2 in.
Conn_batt1 2014−06 802 168-E / S-0756-C
NOTICE − Lead acid batteries discharge Battery is most easily accessed through Never start the engine when the
when stored in any temperature. Units that the rear panel. Remove battery access cables are loose or poorly connected
are stored should have the battery panel from rear panel. Connect battery, to the battery terminals.
recharged every three months and before negative cable last. Reinstall battery ac- Never disconnect the battery while
being put into service. To preserve opti- cess panel. the engine is running.
mum battery performance and life,
Do not allow the battery cables to Never use a quick battery charger to
recharge battery in storage when the
touch opposing terminals. When con- start the engine.
open−circuit voltage drops to 12.4 volts
necting the battery cables attach the
DC when measured across the battery Do not charge battery with Engine
positive (+) cable to the positive (+)
terminals. Control switch On.
battery terminal first, followed by neg-
! Connect negative (−) cable last. ative (−) cable to negative (−) battery Always disconnect the negative (−)
NOTICE − Wait two minutes after engine terminal. battery cable before charging battery.
shutdown before disconnecting battery or
engine controller may be damaged.
4-5. Using The Battery Disconnect Switch
! Stop engine.
1 Battery Disconnect Switch
The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.
907 634−2

4-6. Engine Prestart Checks
NOTICE − Follow run-in procedure in
engine manual. If unburned fuel and oil
collect in exhaust pipe, see Section 16.
Full
Diesel
Full
907634−1 / 907 634−2
Check all engine fluids daily. NOTICE − Diesel engines in MILLER equip-
ment are meant to operate optimally at mod-
Oil
After fueling, check oil with unit on level sur-
Automatic warning and shutdown indi- erate to rated load. Using light or no load for
face. If oil is not up to full mark on dipstick,
cators are displayed on the Engine Dis- extended periods of time may cause wet-
add oil (see engine maintenance label).
play. See Section 15 for engine display stacking or engine damage.
information. Follow run-in procedure in engine manual. To improve cold weather starting:
If unburned fuel and oil collect in exhaust
Engine must be cold and on a level surface. pipe, see Section 16. Keep battery in good condition. Store
Automatic shutdown system stops engine if Fuel battery in warm area.
oil pressure is too low or engine tempera-
ture is too high. NOTICE − Do not use gasoline. Gasoline Use fuel formulated for cold weather
will damage engine. (diesel fuel can gel in cold weather).
This unit has a low oil pressure shut- Add fresh diesel fuel before starting (see Contact local fuel supplier for fuel in-
down switch. However, some condi- engine maintenance label for fuel specifica- formation.
tions may cause engine damage before tions). Leave filler neck empty to allow room
the engine shuts down. Check oil level for expansion. Use correct grade oil for cold weather
often and do not use the oil pressure (see engine maintenance label or en-
shutdown system to monitor oil level. Engine stops if fuel level is low. gine manual).

4-7. Connecting To Weld Output Terminals
! Stop engine.
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your ma-
chine.
Tools Needed:
3/4 in. Do not place anything between weld
1 2 cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
1 Correct Weld Cable Connection
6
3 2 Incorrect Weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
4 weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
5
803 778-B
Notes
Work like a Pro!

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

4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.
Direct Current Electrode Positive

(DCEP) connections are shown.
Welder A (Left) Side Welder B (Right) Side
1
1
258 836
! Stop engine. 1 Electrode Holder Cables For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
NOTICE − Do not exceed machine duty 2 Work Cables
Positive (+) terminals and electrode holder
cycle.
For Stick/TIG welding Direct Current Elec- cables to Negative (−) terminals.
Use Dual Operator mode for CC and trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
CV welding (see Section 5-2).
trode holder cables to Positive (+) ter- Be sure Process Selector switches
See Section 4-15 for proper cable size. minals. are set correctly. See Section 5-4.

4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.

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

4-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.

1
1
258 836
! Stop engine. 1 Wire Feeder Cables For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
NOTICE − Do not exceed machine duty
2 Work Cables cables to Positive (+) terminals and wire
cycle.
feeder cables to Negative (−) terminals.
Use Dual Operator mode for CC and For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire Be sure Process Selector switches are
See Section 4-15 for proper cable size. feeder cables to Positive (+) terminals. set correctly. See Section 5-4.

4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.

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

4-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in.

3
2
258 836
! Stop engine. For Stick/TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect work Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and elec- cable to Negative (−) terminal and wire
cycle.
trode holder cable to Positive (+) terminal. feeder cable to Positive (+) terminal.
Use Dual Operator mode for CC and For Stick/TIG Direct Current Electrode For MIG and FCAW Direct Current Elec-
Negative (DCEN), connect work cable to trode Negative (DCEN), connect work
See Section 4-15 for proper cable size. Positive (+) terminal and electrode holder cable to Positive (+) terminal and wire feed-
1 Electrode Holder Cable cable to Negative (−) terminal. er cable to Negative (−) terminal.
2 Wire Feeder Cable Be sure Process Selector switches Be sure Process Selector switches
3 Work Cables are set correctly. See Section 5-4. are set correctly. See Section 5-4.

4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in.

3
2
Ref. 251 340-A / Ref. 802 292-A
! Stop engine. 4-15 for proper cable size). Connect electrode holder cable to one Pos-
! Failure to properly size and connect itive (+) terminal.
weld cables may cause excessive cycle. Connect wire feeder cable to remaining
heat and start a fire, or damage your Positive(+) terminal.
machine. Use Dual Operator mode for CC and Be sure Process Selector switches are
NOTICE − When making weld connections CV welding (see Section 5-2).
set correctly. See Section 5-4.
with a common work cable, connect weld 1 Electrode Holder Cable
cable of adequate size between Negative For Direct Current Electrode Negative
(−) weld output terminals, and connect a 2 Wire Feeder Cable (DCEN), connect common work cable and
single weld cable of adequate size from work jumper cable to Welder B (right) Posit-
Welder B (right) Negative (−) terminal to the 3 Work Jumper Cable ive (+) terminal. Connect other end of work
workpiece. jumper cable to Welder A (left) Positive (+)
4 Common Work Cable
terminal.
NOTICE − When using these connections For Direct Current Electrode Positive
as a common work terminal, all connec- Connect electrode holder cable to one
(DCEP), connect common work cable and Negative (−) terminal, and wire feeder
tions must be of the same polarity. work jumper cable to Welder B (right) Neg- cable to remaining Negative (−) terminal.
NOTICE − For common work connection, ative (−) terminal. Connect other end of
work cable must be able to carry combined work jumper cable to Welder A (left) Nega- Be sure Process Selector switches are
weld output of both modules (see Section tive (−) terminal. set correctly. See Section 5-4.

4-14. Making Single Operator CC Weld Connections

Welder B (right) Terminals
Inactive In Single Operator Mode
Welder A (Left) Side
Tools Needed:
3/4 in.
1
2
258 836
! Stop engine. Use Single Operator mode for CC weld- For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
ing only. Welder B weld output termi-
to Negative (−) terminal and electrode hold-
NOTICE − Do not exceed machine duty nals are disabled in Single Operator
mode. (see Section 5-2). er cable to Positive (+) terminal.
cycle.
For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to Posit-
Welder B (right) weld output terminals See Section 4-15 for proper cable size. ive (+) terminal and electrode holder cable
are disabled in Single Operator mode. to Negative (−) receptacle.
Connect only to Welder A (left) termi- 1 Electrode Holder Cable
nals for Single Operator mode opera- Be sure Process Selector switch is set
tion. 2 Work Cable correctly. See Section 5-4.

4-15. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding Duty Duty 10 − 100% Duty Cycle
Amperes Cycle Cycle AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
Weld Output
Terminals 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
! Turn off power be-
fore connecting to 2x2/0 2x2/0
weld output termi- 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
nals.
2x2/0 2x3/0 2x3/0
! Do not use worn, 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
damaged, under-
sized, or repaired 2x2/0 2x3/0 2x3/0 2x4/0
cables. 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2x2/0 2x3/0 2x4/0 2x4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2x2/0 2x3/0 2x4/0 3x3/0 3x3/0

500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
2x2/0 2x3/0 2x4/0 3x3/0 3x4/0 3x4/0

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

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

4-16. Connecting To Remote 14 Receptacle
Socket* Socket Information
Not all models have contactor control. See description of front panel controls and
circuit diagram.
A 24 volts AC. Protected by supplementary protector.

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

Accessories depend OUTPUT
on unit capabilities. CONTROL E DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.
F Current feedback: 1 volt per 100 amperes.

OR
H Voltage feedback: 1 volt per 10 arc volts.
K Chassis common.
GND
NEUTRAL G Circuit common for 24 volt AC circuit.

Rmt14_1 2010−04
Notes

4-17. Connecting To The Air Compressor
! Stop engine and release air pres-

sure before servicing compressor.
Open Position
1
Closed Position
907 634−1
! Air pressure is present at air shutoff Be sure valve is in open position when us- The air compressor will not start if still under
valve whenever Engine Display on ing air compressor. pressure. If air compressor is turned off,
front panel indicates air pressure. The compressor runs and air pressure is wait for air pressure to bleed off (about 20
available whenever the engine is running seconds) before turning air compressor on
1 3/4 in. NPT Air Pressure
and the front panel Compressor switch is again.
Fitting
moved to the On position (see Section 5-2).
2 Air Shutoff Valve Run engine at weld/power speed for maxi-
mum air compressor output. Compressor Using the air compressor does not sig-
Connect air hose with 3/4 in. NPT fitting (not output is reduced when engine is running at nificantly affect weld or generator pow-
supplied) to air shutoff valve. idle speed. er output.

SECTION 5 − OPERATING WELDER/GENERATOR
5-1. Front Panel Controls (See Section 5-2)
5 4 3
7 8 9 11 1
10
12
258 833 / 907 535−1

5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
If a remote device connected to Remote
1 Engine Control Switch Receptacle is faulty or is disconnected
necessarily the welding arc due to resistance
during operation, the meters display Help
Use switch to start engine, select engine of cable and connections. 25 (see Section 7-11). Clear fault by
speed, and stop engine.
To set voltage, turn Process/Contactor switch stopping and restarting the unit or by turn-
In Run position, engine runs at weld/power to MIG or FCAW position. Turn V/A control ing Process/Contactor switch to another
speed. In Run/Idle position, engine runs at until desired voltage is displayed on Voltme- position.
idle speed with no generator power or weld ter. When welding is finished, voltmeter dis- 10 Welder Selector Switch
load, and weld/power speed with load ap- plays weld voltage and then defaults to preset
plied. voltage. Use switch to select Dual Operator or Single
Operator welding mode.
The air compressor load does not affect en- Weld Controls
gine speed. Run engine at weld/power speed Place switch in Welder A/Welder B (dual op-
5 Arc Control
for maximum air compressor output. erator) position for CC and CV output from
See Section 5-5 for Arc Control information. Welder A (left) and Welder B (right) weld out-
NOTICE − Diesel engines in MILLER equip-
put terminals. Control the weld output from the
ment are meant to operate optimally at mod- 6 Voltage/Amperage Control
terminals on each side using the weld con-
erate to rated load. Using light or no load for
With Process/Contactor switch in any Stick or trols on that same side.
extended periods of time may cause wet-
TIG setting, use control to adjust amperage.
stacking or engine damage. If unburned fuel Place switch in Welder A (single operator)
With Process/Contactor switch in any Wire
and oil collect in exhaust pipe, see Section 16. position for weld output from Welder A (left)
(MIG or FCAW) position, use control to adjust
To Start: see Section 5-3 for engine starting voltage. Control limits the remote amperage weld output terminals only.
sequence. in Stick or TIG mode, but has no effect in Wire
modes.
Welder B (right) weld output terminals are
To Stop: turn Engine Control switch to Off disabled in Single Operator mode. Con-
position. 7 Process/Contactor Switch nect only to Welder A (left) terminals for
2 Engine Display See Section 5-4 for Process/Contactor Single Operator operation.
switch information. Compressor Controls
See Section 15 for engine display infor-
mation. 8 24 Volts AC Overload Protection 11 Air Compressor Switch
Weld Meters See Section 7-10 for overload protection in-
Use switch to turn air compressor on and off.
formation.
Air pressure is present at the compressor air
Weld meters also work in combination to 9 Remote Control Receptacle shutoff valve whenever the compressor is
display troubleshooting help codes (see running. The compressor shuts off when the
Section 7-11). Use receptacle to connect remote controls,
engine stops. To use air, the compressor must
wire feeders, and tools requiring 24 VAC.
3 DC Ammeter be turned on each time the engine is started.
When a remote control is connected to the
Ammeter displays preset amperage (Stick The air compressor will not start if still under
Remote receptacle, the Auto Sense Remote
and TIG only) when not welding, and actual pressure. If air compressor is turned off, wait
feature automatically switches voltage/am-
output amperage when welding. for air pressure to bleed off (about 20 sec-
perage control to the remote control (see Sec-
onds) before turning air compressor on again.
To set amperage, turn Process/Contactor tion 5-9).
switch to Stick or TIG position. Turn V/A con- 12 Air Shutoff Valve
With remote control connected, weld output is
trol until desired amperage is displayed on ! Air pressure is present at valve when-
determined by a combination of front panel
Ammeter. When welding is finished, ammeter ever Air Pressure display (part of en-
and remote control voltage/amperage set-
displays weld amperage and then defaults to gine display, see Section 15) indicates
tings.
preset amperage. air pressure.
If no remote control is connected to the Re-
4 DC Voltmeter
mote receptacle, the front panel Voltage/Am- Close valve to stop air flow when connecting
Voltmeter displays preset voltage (MIG weld- perage control adjusts voltage and amper- or changing tools or air hoses (see Section
ing) with contactor off, and actual output voltage. 4-17).

5-3. Engine Starting Sequence
Wait to Start/Preheating
Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
1 Compressor Oil 0 Compressor Oil 495
NOTICE − Do not use ether. The Wait to Start display appears when the Once this message clears, the engine can
Engine Control switch is placed in the Run be started.
If engine does not start, let engine or Run/Idle position. Glow plugs function Turn Engine Control switch to Start. Re-
come to a complete stop before at- automatically according to ambient tem- lease Engine Control switch when engine
tempting restart. starts.
perature. The operator needs to pause at
To Start: either switch position while the engine con- To Stop: turn Engine Control switch to Off
1 Wait to Start/Preheating Display troller goes through the preheat sequence. position.
5-4. Process/Contactor Switch
1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot
position and the engine is run-
ning.
Use switch to select weld process and
weld output on/off control (see table be-
low).
1
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the en-
gine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-8).
Ref. 258 833-A

Switch Setting Typical Process Applications (DC Only)
MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable
ELECTRODE HOT Electrode Hot – MIG VS back to the welder/generator.
FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not re-
Electrode Hot – FCAW VS quire a control cable back to the welder/generator.
Electrode Hot - Stick Stick welding with or without a remote amperage control. Strike an arc to start welding.
Lift Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
Electrode Hot – TIG Lift Arc welder/generator to aid arc start. Can be used with or without a remote control.
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with re-
REMOTE ON/OFF REQUIRED
Remote ON/OFF Required - TIG mote foot control allows remote On/Off and Amperage control. Another typical application
is a simple TIG rig with a remote control device.
Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can
Remote On/Off Required - Stick help eliminate accidental arc strikes.
FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a
Remote On/Off Required - FCAW Spoolmatic 30A with WC 24 control.
MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or
Remote On/Off Required - MIG use a Spoolmatic 30A with WC 24 control.
Notes

5-5. Arc Control
1 Arc Control
Stick
Control adjusts Dig when Stick is se-
lected on mode switch.
When control is set toward minimum,
1 short-circuit amperage at low arc
voltage is the same as normal weld-
ing amperage.
When set toward maximum, short-
circuit amperage is increased at low
arc voltage to help prevent the elec-
trode from sticking while welding.
Select setting best suited for applica-
tion.
FCAW/MIG
Control adjusts inductance when
FCAW or MIG position is selected on
the mode switch. Inductance deter-
mines the “wetness” of the weld
puddle. Increasing Arc Control set-
ting decreases inductance, thereby
increasing puddle fluidity (“wet-
ness”). Decreasing Arc Control set-
ting increases inductance, decreas-
ing puddle fluidity.
TIG
When the control is set below 1, Auto
Stop is a variable function of preset
weld amperage. This is used with a
short arc length where flare at arc
shutdown cannot be tolerated.
When the control is set above 1, Auto
Stop voltage threshold is a set value
based on preset-set weld amperage
(I) as follows:
I <= 50 A, V=17
I >50 to <=100 A, V=22
I >100 to <=190 A, V=25
I >190A, V=30
This allows for a longer arc length
(such as when “walking the cup”),
where nuisance shutdowns are un-
desirable.
Control is not functional when TIG
Remote mode is selected.
257 145-A

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

the switch in the On position.
OFF
1
907 535-2
5-7. Stick Start Procedure − Scratch Start Technique

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

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

5-9. Remote Voltage/Amperage Control
1 Remote 14 Receptacle
2 3 Connect optional remote control to receptacle
(see Section 4-16).
When a remote control is connected to the

Remote receptacle, the Auto Sense Re-
mote feature automatically switches volt-
age/amperage control to the remote con-
1 trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
2 Voltmeter
3 Ammeter
CC Welding
In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
85 205
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding
Connect Remote Set V/A Control

Control To Remote To Desired Maximum
Turn Remote Control On. Ad- Weld Output Using Weld
Receptacle RC14 just Optional Remote Meters
Set TIG or STICK Process Control to 100%
CV Welding Max (205 A DC)
28
Electrode Hot: Voltmeter tog-
gles between preset and ac-
tual output when not welding,
actual voltage while welding.
0 Min (20 A DC)
Adjust Optional Remote

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

Control To Remote Control to desired
Receptacle RC14 weld output
Set WIRE Process
0774 / Ref.246 345-B / Ref. 907 428−1

5-10. Engine Block Heater Operation
1 Engine Block Heater Plug

Use heater to maintain a constant
engine coolant temperature.
To turn on heater, connect heater
Coolant Heater plug to 120 volts AC receptacle.
Specifications
! Do not run engine while en-
Watts Volts ±10% gine block heater is on.
NOTICE −In extremely cold weath-
530 120 er, heater should be connected to
120 volts AC receptacle when en-
gine is warm.
! The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.
Coolant heater1 2012−05 907 634−1 / Ref. 803 145
Notes

5-11. Optional Air Dryer Operation
The air dryers blow out (purge) mois-

ture and debris when the air compres-
sor is being used. The air dryer heaters
operate whenever the welder/genera-
tor is running.
See the supplied air dryer Owner’s
Manual for air dryer maintenance and
service information.
When battery access is required,

disconnect and remove the air
dryer assembly as described in
Section 7-12.
1 Circuit Breaker CB14
CB14 protects the dryer heaters from
damage due to overload. If CB14
opens, the heaters do not work and the
dryer does not discharge moisture in
cold weather.
Press button to reset circuit breaker
2 CB14.
When a circuit breaker opens, it

usually indicates a more serious
problem exists. Contact a Factory
Authorized Service Agent.
Start engine, and turn on air compres-
sor. Check fittings for air leaks and
tighten fittings if necessary.
2 Timer Control LED
Verify dryer solenoid is functioning by
listening for dryer canisters to purge, or
by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.
907 535−2 / 803 228 / 803 229

SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. North American Auxiliary Power Receptacles
1
8 6 7
4 5
3 2
264 773-A
Single-Phase Generator Power erator winding from overload. If CB6 (240 V x 13 A) + (120 V x 7 A) =
! Use GFCI protection when operat- opens, RC1, RC2, GFCI1 and GFCI2 do 4.0 kVA/kW
ing auxiliary equipment. If unit not work. Place switch in On position to re-
6 120/240 V 50 A Receptacle RC5
does not have GFCI receptacles, set.
use GFCI-protected extension RC5 is connected to the three-phase gen-
CB7 protects GFCI1 from overload. If CB7 erator and supplies 60 Hz single-phase
cord. Do not use GFCI receptacles opens, GFCI1 does not work. Press but-
to power life support equipment. power at weld/power speed. Maximum
ton to reset. output from RC5 is 12 kVA/kW. Power
! Unplug power cord before attempt- available at RC5 is reduced when welding.
ing to service accessories or tools. CB8 protects GFCI2 from overload. If CB8
opens, GFCI2 does not work. Press but- Three-Phase Generator Power
1 120 V 20 A AC GFCI ton to reset.
Receptacle GFCI1 or GFCI2 7 240 V 50 A Three-Phase Receptacle
RC4
! Test GFCI monthly. See Section 6-3 If a supplementary protector contin-
for GFCI information and for reset- ues to open, contact Factory Autho- RC4 is connected to the three-phase gen-
ting and testing procedures. rized Service Agent. erator and supplies 60 Hz three-phase
power at weld/power speed. Maximum
2 240 V 30 A AC Twistlock output from RC4 is 20 kVA/kW. Power
Receptacle RC1 or RC2 Generator power is not affected by available at RC4 is reduced when welding.
weld output.
Receptacles supply 60 Hz single-phase 8 Supplementary Protector CB1
power at weld/power speed. Maximum output is 2.4 kVA/kW from
GFCI1 and 4 kVA/kW from RC1. Maxi- Supplementary protector CB1 protects
3 Supplementary Protector CB6 three-phase receptacle RC4,
mum output from all receptacles is 4 kVA/
4 Supplementary Protector CB7 kW. single-phase receptacle RC5, and the
load wires from overload. If CB1 opens, all
5 Supplementary Protector CB8 EXAMPLE: If 13 A is drawn from RC1, only generator output stops and the recept-
CB6 protects RC1 and RC2, and the gen- 7 A is available at GFCI1: acles do not work.

6-2. Export Auxiliary Power Receptacles
6 5 8
4 9
3 10
1 2
12 11
Ref. 251 252-A / 251 965-A
1 110 V 16 A AC Receptacle RC1 6 Supplementary Protector CB1 10 Supplementary Protector CB8

(Deluxe Model)
2 220 V 16 A AC Receptacle RC3 CB8 protects GFCI2 and RC2 from over-
Receptacles supply 50/60 Hz single-phase CB1 protects RC5 from overload. If supple- load. If supplementary protector opens, the
power. mentary protector opens, the receptacle receptacles do not work. Press button to re-
does not work. Place switch in On position set.
3 Supplementary Protector CB7 to reset.
11 220 V 16 A AC Receptacle RC4
CB7 protects GFCI1 and RC1 from over-
7 380 V 30 A 3-Phase Receptacle RC5
load. If supplementary protector opens, the 12 110 V 16 A AC Receptacle RC2
(Deluxe Model)
receptacles do not work. Press button to re-
set. Receptacles supply 50/60 Hz single-phase
Receptacle supplies 50/60 Hz three-phase
power.
! Use GFCI protection when operating power
auxiliary equipment. If unit does not 8 Supplementary Protector CB5 Maximum combined output of all standard
have GFCI receptacles, use GFCI- receptacles is 4 kVa/kW.
protected extension cord. Do not CB5 protects the auxiliary power winding
use GFCI receptacles to power life from over current. If CB5 opens, the 110 volt At least once a month, run engine at
support equipment. receptacles and 220 volt receptacles do not weld/power speed and press test but-
! Unplug power cord before attempt- work. Press button to reset. ton to verify ELCB1 is working properly.
ing to service accessories or tools.
9 Earth Leakage Circuit Breaker ELCB1
4 110 V 20 A AC Receptacle GFCI1
If a supplementary protector or circuit
ELCB1 protects receptacles RC3 and RC4 breaker continues to open, contact
5 110 V 20 A AC Receptacle GFCI2 from overload and earth leakage fault. If cir- Factory Authorized Service Agent.
! Test GFCI monthly. See Section 6-3 cuit breaker opens, the receptacles do not
for GFCI information and for reset- work. Place switch in On position to reset Generator power decreases as weld
ting and testing procedures. circuit breaker. output increases.

6-3. GFCI Receptacle Information, Resetting And Testing
2
3
4
! Test and reset GFCI only at Run speed.
RotGFCI1 2014−09
! Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles
auxiliary equipment. If unit does not button pops out, and the circuit opens to dis-
If a GFCI fault occurs, stop engine and dis-
have GFCI receptacles, use GFCI- connect power to the faulty equipment. A
connect equipment from GFCI receptacle.
protected extension cord. Do not GFCI receptacle does not protect against
Check for damaged or wet tools, cords,
use GFCI receptacle to power life circuit overloads, short circuits, or shocks
plugs, etc. connected to the receptacle.
support equipment. not related to ground faults. Reset and test
Start engine and operate at Run (weld/
GFCI receptacle according to the following
power) speed. Press GFCI Reset button.
! Unplug power cord before attempt- procedures.
Reconnect equipment to GFCI receptacle.
ing to service accessories or tools. If GFCI Reset button pops out again, check
Resetting/Testing GFCI Receptacle
the equipment and repair or replace if faulty.
1 120 V 20 A AC GFCI Receptacle ! Test GFCI monthly. See Testing Testing GFCI Receptacles
GFCI Receptacle.
2 GFCI Receptacle Test Button
! Do not test or reset GFCI receptacles
GFCI testing must be done with engine
3 GFCI Receptacle Reset Button at idle speed/low voltage or the GFCI running at Run (weld/power) speed.
will be damaged and not provide Start engine and operate at Run (weld/
4 GFCI Indicator Light (LED) protection from electric shock power) speed.
caused by a ground fault.
Press the GFCI Test button. The GFCI Re-
GFCI Receptacles ! If LED blinks, stop using GFCI reset button should pop out.
ceptacle and have it replaced by a Press the GFCI Reset button.
GFCI receptacles protect the user from Factory Authorized Service Agent.
electric shock if a ground fault occurs in Have GFCI replaced by a Factory Au-
equipment connected to the receptacle. A ! Extension cords with bad insulation thorized Service Agent if any of the fol-
ground fault occurs when electrical current or of extended length can allow lowing occur:
takes the shortest path to ground (which enough leakage current to trip the GFCI does not trip when tested
could be through a person) rather than fol- GFCI circuit. Reset and test as fol- LED blinks
low its intended safe path. lows. GFCI does not reset.

Big Blue 800X/800CA Duo AirPak
7-1. Maintenance Label
NOTICE − The total initial oil fill requires approximately

18 qt (17 L).Service oil fill is 11 qt (10.4 L)
Check engine dipstick as filling. Do not overfill.
SECTION 7 − MAINTENANCE
TM-267 603 Page 41

DEUTZ Service: http://www.deutzamericas.com
To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer: http://www.deutzamericas.-
com/deutznew/distributors/index.htm.They are staffed with highly qualified parts, service and engine specialists to handle your different needs.
The DEUTZ Service Desk enhances this support and can be contacted by completing and submitting the Service Support Form. Customer in the
US and CANADA can also contact the service desk by calling our toll free number, 1-800-241-9886.
Our normal hours of operation are from 8:00 AM to 6:00 PM Monday through Friday EST. You may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us, please have available or provide specific engine information (serial number, model number etc.) as shown
on the Service Support Form.
7-2. Cleaning Unit
Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust.
NOTICE − Use of a power washer is acceptable; however, cover or avoid electrical parts and the Engine Control Unit (ECU) located on the upper
left side of the center upright.
7-3. Routine Maintenance

! Stop engine before maintaining.
See Engine Manual and Maintenance Label
Recycle engine for important start-up, service, and storage
fluids. information. Service engine more often if
used in severe conditions.
= Check = Change = Clean = Replace Reference

* To be done by Factory Authorized Service Agent
Every See engine Section 4-6
8 FUEL
WATER manual for fuel
Hours
specifications.
Primary Fuel Filter Fuel Level Oil Level Oil, Fuel Spills
= Clean unit exterior, in-
cluding stainless steel, fre-
quently to prevent rust and
corrosion.
Coolant Level
Every Section 7-7
100
Hours
Battery Terminals Air Cleaner Hoses Air Cleaner Element Weld Terminals
Every Engine
250 1/2 in.
(13 mm) Manual
Hours
Unreadable Labels Fan Belt Tension Cooling System Spark Arrestor

Every NOTICE − Change engine Section
500 oil and filter after initial 50 7-9, and
Hours to 75 hours of use. Engine
See engine manual for oil Manual
specifications.
Oil Oil Filter Fuel Filters Weld Cables
Every Section
FUEL
1000 OR 7-4, 7-9,
Hours and Engine
Manual
SLUDGE
Slip Rings* Inside Unit Valve Clearance* Drain Sludge
Brushes*
Every NOTICE − Use extended
2000 life coolant only.
Hours See engine manual for
coolant specifications.
Coolant
Every Every
3000 6000
Hours Hours or
5 Years
Injectors* Engine Timing Belt
7-4. Checking Generator Brushes
! Stop engine and let cool.

1 Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Minimum Length: Replace brushes if damaged or if brush
5/8 in. (16 mm) material is at or near minimum length.
New Length:
1-1/4 in. (32 mm)
1
Replace
Damaged Brushes
GenBrush1 2014−10 / Ref 190 823
7-5. Battery Replacement

! Stop engine.
1 Battery Locator Bracket
Mounting Holes
Access battery as shown in Section
4-4. Disconnect battery.
View From Top Of Unit
Remove J-bolts securing battery
Larger Battery and remove battery.
Smaller Battery
Battery locator brackets can be
moved to accommodate batteries
of different physical sizes.
Install and secure replacement bat-
tery.
! Connect negative (−) battery
cable last.
1
Tools Needed:
255 858
7-6. Battery Maintenance

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

7-7. Servicing Air Cleaner
! Stop engine.
! Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
1 2 by the warranty.
Remove compressor air cleaner cov-

er and element to access engine air
cleaner.
The air cleaner primary element can

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

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
3 4 Never clean a safety element. Re-
5 6
place the safety element after servic-
ing the primary element three times.
1 Engine Air Cleaner
2 Compressor Air Cleaner
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
Optional cleanings.
7 3 Housing
4 Safety Element (Optional)
5 Primary Element
6 Cover
7 Dust Ejector
To clean air filter:
Wipe off cover and housing. Remove
Keep nozzle cover and dump out dust. Remove ele-
2 in. (51 mm) ment(s). Wipe dust from inside cover and
from element. housing with damp cloth. Reinstall cover.
! Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary ele-
Blow Inspect ment if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).
aircleaner1 9/02− ST-153 929-B / ST-153 585 / Ref. S-0698-B
7-8. Engine Speed Adjustment

Engine functions are controlled by the engine ECU. Tampering with the engine ECU may void engine warranty. Contact engine Factory Authorized
Service Agent for engine adjustments.
7-9. Servicing Fuel And Lubrication Systems
4 5
Tools Needed: 6
907 634−2
! Stop engine and let cool. To replace fuel filters: To drain sludge from fuel tank:
! After servicing, start engine and
check for fuel leaks. Stop engine, Turn filter counterclockwise. Remove filter. ! Beware of fire. Do not smoke and
tighten connections as necessary, keep sparks and flames away from
and wipe up spilled fuel. Apply thin coat of fuel to gasket on new filter. drained fuel. Dispose of drained fuel
1 Oil Filter Fill filter with fuel. Install filter and turn clock- in an environmentally-safe manner.
wise. For primary fuel filter, reconnect water Do not leave unit unattended while
2 Oil Drain Valve And Hose draining fuel tank.
sensor. Bleed air from fuel system accord-
3 Oil Fill Cap ing to engine manual.
4 Primary Fuel Filter ! Properly lift unit and secure in a level
5 Secondary Fuel Filter Inspect fuel line, and replace if cracked or position. Use adequate blocks or
worn. stands to support unit while drain-
6 Fuel Tank Sludge Drain Valve ing fuel tank.
To change oil and filter: Close doors.
Route oil drain hose and valve through hole Attach 1/2 ID hose to drain valve. Put metal
in base. See engine manual and engine To reset service reminder intervals shown container under drain, and use screwdriver
maintenance label for oil/filter change in- on the Engine Display, see Sections 15-12 to open sludge drain valve. Close valve
formation. and 15-13. when sludge has drained. Remove hose.

7-10. Engine/Generator Overload Protection
9
8
7
3
4
6
5
907 634−2
! Stop engine. 3 Fuse F1 See Section 5-6 for VRD switch informa-
tion.
When a supplementary protector, cir- 4 Fuse F2
8 Supplementary Protector CB14
cuit breaker or fuse opens, it usually in- F1 and F2 protect the stator exciter winding
dicates a more serious problem exists. from overload. If F1 opens, weld and gen- Air dryer overload protection, see Section
Contact Factory Authorized Service erator power is low or stops entirely. If F2 5-11.
Agent. opens, weld output is low or stops entirely. 9 Supplementary Protector CB15
4 kVA/kW generator power is still available.
See Section 10-5 for air compressor Compressor overload protection, see Sec-
overload protection. 5 Supplementary Protector CB3 tion 10-5.
See Section 5-11 for air dryer overload 6 Supplementary Protector CB4 10 Circuit Breaker CB10 (Not Shown)
protection. CB3 protects the engine weld control cir- CB10 protects the engine battery circuit. If
1 Supplementary Protector CB9/CB29 cuit. If CB3 opens, weld output stops, CB10 opens, the engine will not crank.
CB9 and CB29 protect the 24 volt AC out- meters will be blank; however, generator CB10 automatically resets when the fault is
put to remote receptacles. If CB opens, power is still available. corrected.
weld output and 24 volt output to remote re- CB4 protects the field flashing circuit. If 11 Circuit Breaker CB16 (Not Shown)
ceptacle stops. CB4 opens, the generator may not excite at CB16 protects the glow plug circuit. If
2 Supplementary Protector CB2 start-up and weld and generator power out- CB16 opens, the glow plug will not operate.
CB2 protects the engine control circuit. If put may not be available. CB16 automatically resets when the fault is
CB2 opens, the engine does not crank. 7 VRD Switch corrected.

7-11. Voltmeter/Ammeter Help Displays
2
HL.P 20
3
HL.P 21
4 HL.P 22
5 HL.P 25
HL.P 26
Use the Voltmeter/Ammeter help displays side) on the heat sink has failed. If this dis- and then disconnected. Clear fault by stop-
to diagnose and correct fault conditions. play is shown, have Factory Authorized ping and restarting the unit or by turning
Service Agent check TH1 (each side), and Process/Contactor switch to another posi-
When a help code is displayed normal- the wiring between TH1 and PC1/PC21. tion. If problem continues, have Factory
ly weld output has stopped but genera- Authorized Service Agent check the re-
tor power output may be okay. 3 Help 22 Display
mote device, filter board PC5/PC25, and
Indicates the IBGT module heat sink (each
To reset help displays, stop unit and side) has overheated. If this display is
main control module PC1/PC21.
then restart. See item 4 below to reset 5 Help 26 Display
shown, check generator cooling system
Help 25 display. and/or reduce duty cycle. Keep engine ac- Indicates a fault when attempting to oper-
1 Help 20 Display cess door closed when running to maintain ate the unit in single operator mode (out-
proper cooling air flow past the heat sinks. puts internally paralleled). Help 26 indic-
Indicates a failure of meter display module
Allow unit to cool before restarting. If prob- ates a failure of either side A or side B or
PC2/PC22, or the wiring between
lem continues, have Factory Authorized the communications between them which
PC2/PC22 and main control module PC1
Service Agent check unit. prevents the unit from being operated in
(A Side)/PC21 (B Side), or PC1/PC21. If
the single operator mode. Return to dual
this display is shown, have Factory Autho- 4 Help 25 Display operator mode and check for output at both
rized Service Agent check PC1/PC21,
Indicates a remote device connected to sides. If output is normal, contact Factory
PC2/PC22, and the wiring between them.
Remote Receptacle RC14 may be faulty. Authorized Service Agent to check internal
2 Help 21 Display Help 25 is also displayed whenever a re- wiring and communications between
Thermistor TH1 in the IGBT module (each mote device has been connected to RC14 sides.

7-12. Removing Optional Air Dryer For Service
Follow this procedure whenev-
er the air dryer must be re-
moved to gain access to the
battery.
1 Air Line
2 Timer Control Cable
3 Air Dryer Heater Plug
4 Solenoid LED
Disconnect air line from dryer as-
sembly bottom inlet.
Disconnect heater cable from bot-
tom of air dryer assembly.
Loosen hardware securing battery
access panel to rear panel. Careful-
ly pull access panel/air dryer as-
sembly away from unit rear panel.
Support dryer assembly to relieve
strain on timer control cable.
3 Disconnect battery negative (−)
cable. When service is complete,
reconnect battery negative (−)
2 cable.
Reinstall battery access panel/air
dryer assembly. Reconnect air dry-
er heater cable.
Reconnect air line to dryer bottom
inlet.
Final-tighten all hardware, and
air line and air dryer fittings.
Start engine, and turn on air com-
pressor. Check fittings for air leaks
and tighten fittings if necessary.
Verify dryer solenoid is functioning
by listening for dryer canisters to
purge, or by checking solenoid
1 LED. LED lights at start-up and ev-
ery two minutes when the canisters
automatically purge.
803 511

Notes

SECTION 8 − THEORY OF OPERATION
1 Engine
Engine supplies force to turn revolving 6
fields. 8
Supplementary AC
Control Relay CR5 Protector CB4 Receptacles
Energizes at start up to supply power to GFCI1, GFCI2,
the exciter circuit and Control Board RC1, RC2
5
PC1
7
2 Engine Control (ECU) Compo- Fuses F1, F2
nents Supplementary
1 Protectors
Regulate engine speed in response to
CB6 CB7, CB8
changes in weld or power load. Control
Control Relay
interprets signal from engine sensors CR5
and maintains idle or weld/power speed. Current
Feedback
Control relay CR4 and CR24 are pow-
to PC1
ered by PC1 and PC21 to control the au-
tomatic idle function. The engine will ac- 1 3 4
celerate to high speed when both relays 3φ
are de−energized. Revolving Exciter
Engine Fields
Weld
3 Revolving Fields (Rotor) (Rotor) Stator Windings
Turn at 1890 rpm maximum for weld and Generator Power
power. The speed and excitation current
of the field coils determine voltages in 10
stator windings. 37
Air Supplementary
4 Stator Windings Protector
Compressor/
Supply power to exciter, generator pow- Clutch 7 CB9
er, and weld circuits.
Supplementary
5 Fuses F1 And F2 Protector 24 VAC
Protect exciter windings from overload. 36 CB1
11
6 Supplementary Protector CB4 Control
8 Filter Board
Relay
Protects the field flashing circuit. PC5/Remote
CR10 AC
7 Supplementary Protectors CB1, Receptacle
Receptacles RC14
CB6, CB7, and CB8 RC4, RC5
Protect AC receptacles from overload. 35
8 AC Receptacles GFCI1, GFCI2 Air Pressure Current Feedback
and RC1, RC2, RC4, RC5 Switch
Provide connection points and power for S11
auxiliary equipment.
9
9 Supplementary Protector CB3 34 Supplementary
Protects the power supply to control Protector
board PC1, PC21. Air Compressor CB3
Switch
The following descriptions use Side S10
A circuit diagram designators. Side
B has identical components with dif- 2
ferent designators.
See circuit diagram. Engine
ECU
10 Supplementary Protector CB9
Provides overload protection for 24 volts +10 VDC Output
AC portion of Remote 14 receptacle 17 Command Voltage
RC14.
2 2
11 Filter Board PC5/Remote Recep-
tacle RC14 Control
Glow Plug Relay CR8
Relay
PC5 protects unit from high frequency, CR4
and RC14 connects remote amperage/ Control
voltage and contactor controls to unit. Board
PC1
When a remote control is connected to
the Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperage control to the remote
control.
12 VRD Switch S5
Turns low open−circuit voltage circuit on
and off.

13 Voltage/Amperage Control R2
Adjusts weld output amperage or volt-
AC Or DC Control Circuits
age level.
Weld Current Circuit 14 Process/Contactor Switch R1
External Circuits or Selects weld process and weld output
Mechanical Coupling on/off control.
15 Arc Control R5
3φ Power
Adjusts dig and hot start for Stick weld-
ing, inductance for MIG welding, and arc
Indicates Side A. Side B stop parameters for Lift Arc TIG weld-
has identical components ing.
with different designators. 16 Meter Board PC2
See circuit diagram. Displays preset and actual (rectified
and filtered) values of the weld voltage
and amperage.
17 Control Board PC1
Controls weld output by changing the
gate pulses to IGBT (power modules
PM1 and PM2) after comparing current
or voltage feedback to reference level
20 24 set by voltage/amperage adjustment
control or remote control connected
Hall Device Positive (+) through RC14.
Weld Output 18 Main Rectifier
HD1 Terminal
Changes AC weld current to DC.
19 Resistor R10
Provides a bleed path for a capacitor
23 Electrode bank C3.
18 22 19 20 Hall Device HD1
IGBT Provides current feedback signal to
Burden
Capacitor Power PC1.
Main Resistor
Rectifier Bank C3 Modules
R10 21 Stabilizer Z1
PM1 and
PM2 Smooths (filters) weld output current.
22 Capacitor Bank C3
Filters the DC output voltage of main
rectifier.
23 IGBT Power Modules PM1 And
21 24 PM2
Power modules use pulse width modu-
Work (−) Weld lation to control the amount of output
Stabilizer Output
Z1 Terminal from the welding generator.
24 Positive (+) And Work (−) Weld
Output Terminals
Current Provide weld output and allow manual
IGBT Feedback Work changing of output polarity.
Gating
Signals Voltage 25 Air Compressor Switch S10
Feedback Turns air compressor on and off.
17 26 Air Pressure Switch S11
Prevents control relay CR10 from ener-
gizing and compressor from running
when system pressure is above 20 psi.
27 Control Relay CR10
CR10 energizes when air compressor
switch is closed to supply power to com-
pressor clutch.
28 Air Compressor/Clutch
Clutch engages when energized to op-
16 erate compressor. (See Section 11 for
12 13 14 15
additional air compressor information.)
Voltage/ Voltage/ Process/
Arc Control Meter
Reducing Amperage Contactor Board PC2
Switch S5 Control R2 Switch R1 R5

SECTION 9 − TROUBLESHOOTING
9-1. Measuring Capacitor Voltage

! Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
! Stop engine and disconnect
negative (−) battery cable.
Remove cover.
1 Side A Burden Resistors R 10
2 Side B Burden Resistor R210
Locate burden resistors.
3 Voltmeter
Check capacitor bank voltage
across burden resistors as shown.
Measure the DC voltage across
each burden resistor until voltage
drops to near 0 (zero) volts.
4 Side A Vault PC1
4 5 Side B Vault PC21
6 Side A Rectifier SR6
6
7 Side B Rectifier SR26
Proceed with job inside unit.
Reinstall cover and side panels, if
side panels are removed, when
finished.
5
7
1
2
3
Tools Needed:
3/8 in.
907634−TP2 / 907634−TP12

9-2. Troubleshooting Tables
See Section 9-3 for test points and values and Section 17 and follow-
ing for parts location.
Use Testing Booklet (Miller Part No. 150 852) when servicing this unit.
See the Partners of ITW web site for service memos that may aid in
the repair of this product.
Equipment serviced may need to meet additional requirements as

specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic In-
spection and Testing.
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 7-11). See Section 15 for engine display
information.
A. Welding
Trouble Remedy
No weld output; generator power output Check Voltmeter/Ammeter help displays (see Section 7-11) if available.
okay at AC receptacles.
Place Process/Contactor switch in an Electrode Hot position, or place switch in a Remote On/Off Re-
quired position and connect remote contactor to Remote 14 receptacle (see Sections 4-16).
Reset supplementary protector CB3 (see Section 7-10).
Reset supplementary protector CB9 (see Section 7-10). Check for faulty remote device connected to
Remote 14 receptacle.
Check and secure connections to Remote 14 receptacle (see Section 4-16).
Check filter board PC5 and connections (see Section 9-8).
Check fuse F2, and replace if open (see Section 7-10). Check brushes and slip rings, weld excitation cir-
cuit, and the rotor.
Check connections between Process Switch R1 and main control board PC1.
Check main rectifier (weld), and leads and connections. Replace main rectifier if necessary.
Check stabilizer Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.
Check current transducer HD1 and replace if necessary (see Sections 9-3 and 9-4).
Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).
Check VRD switch, voltage feedback wiring and main control board PC1. Repair or replace as necessary.
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check integrated rectifier SR2, ca-
pacitor C6, and the rotor and brushes.
Check integrated rectifiers SR4 and SR5, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 9-14).
Disconnect leads 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and
tight.
Be sure weld cables have no nicks or gouges and no kinks.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.

Trouble Remedy
Erratic weld output. Check main rectifier (weld), and leads and connections. Replace main rectifier if necessary.
Disconnect leads 42 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.
High open-circuit voltage with VRD Check IGBT modules and main control board PC1.
switch S5 On.
High weld output. Repair or replace remote control device (if used).
Check position of Voltage/Amperage Adjust control.
Check voltage feedback circuit.
Check current transducer HD1, and replace if necessary (see Sections 9-3and 9-4).
Check main control board PC1 and connections, and replace PC1 if necessary.
Low weld output. Have authorized engine service agent check engine speed.
Check fuse F1, and replace if open (see Section7-10). If F1 is open, check capacitor C6, integrated recti-
fier SR2, and the rotor and brushes.
Increase Voltage/Amperage Adjust control R2 setting.
Repair or replace remote control device.
Place VRD switch S5 in Off position and weld. If machine operates normally, check S5 and main control
board PC1.
sary.
Check main control board PC1 and connections, and replace PC1 if necessary.
Low open-circuit voltage. Check position of VRD switch.
Check position of Process/Contactor switch.
Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).
Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
check engine speed.
No remote fine amperage control. Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 4-16).
No 24 volt AC output at Remote recep- Reset supplementary protector CB9 (24 volt) (see Section 7-10). If CB9 continues to open check devices
tacle RC14. connected to RC14.
Check filter board PC5, and replace if necessary.
With VRD Switch S5 On, machine does Check main control board PC1 and connections, and replace PC1 if necessary (see Section 9-6).
not return to low open−circuit voltage at
the end of weld.
B. Generator Power
Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 6-1). If they continue to open, check devices
tacles; weld output okay. connected to receptacles.
Press GFCI receptacle Reset button (see Section 6-3).
Check fuse F1, and replace if open (see Section 7-10). Check integrated rectifiers SR1 and SR2, resistor
R3, and capacitor C6.
Check resistance of generator power windings between leads 91 and 92. Replace stator if
necessary.

Trouble Remedy
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check condition of brushes and slip
rings and check rotor windings and insulation to chassis ground.
Reset supplementary protector CB16.

Check Voltmeter/Ammeter help displays (see Section 7-11) if available.
Clean slip rings, and install new brushes if necessary (see Section 9-14).
Check integrated rectifier SR2, and replace if necessary.
sary.
necessary.
High output at generator power AC Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
receptacles. check engine speed.
Adjust generator power field current resistor R3.
Low output at generator power AC Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check capacitor C6, integrated recti-
receptacles. fier SR2, and the rotor and brushes.
Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
check engine speed.
C. Three-Phase Generator Power
Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protector CB1 (see Section 6-1). If it continues to open, check devices
tacles; weld output okay. connected to receptacles.
Check wiring at receptacles RC4 and RC5. Check receptacles and replace if necessary.
No generator power or weld output. Check fuse F2, and replace if open (see Section 7-10). If F2 is open, check integrated rectifier SR4 and
the rotor and brushes.
Disconnect leads 108 and 105 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
necessary.
Check weld stator phase to phase voltage at main rectifier SR6. Check phase to phase voltage at
CB1. Replace stator if necessary.
High or low output at generator power Check frequency (Hertz) at GFCI1 receptacle. If out of tolerance, have authorized engine service agent
AC receptacles. check engine speed.
Adjust generator output resistor R8 (see Section 9-15).
D. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections, clean and tighten if necessary.
Circuit breaker CB10 may be open. CB10 will automatically reset after several minutes if the cause of
over−current is corrected. (see Section 7-10). Check engine wiring harness and components.
Reset supplementary protector CB3 (see Section 7-10). Check engine alternator, engine harness,
and the fuel pump.
Check engine wiring harness plug connections.
Check continuity of Engine Control switch S1, and replace if necessary.
Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Trouble Remedy
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check fuel pump according to engine manual.
Air in fuel system. See engine manual.
Have engine manufacturer’s authorized service agent check electronic speed control system.
Engine hard to start in cold weather. Use proper engine starting procedure (see Section 5-2).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see engine manual).
Engine hard to start in cold weather. Check control relay CR8: Check all connections, check coil continuity, check for proper coil voltage, and
Check glow plug for proper operation, and replace if necessary.
Install engine block heater option.
Engine suddenly stops. Check fuel gauge display. Check fuel level. Unit is equipped with low fuel level shutdown to prevent fuel
tank from running dry.
Check fuel gauge display. Check oil, and coolant levels. Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high (see Sections 4-6, and 15).
Check engine display for diagnostic codes (see Section 15). If other codes appear, contact engine
manufacturer’s factory authorized service agent.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section
7-10). Check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 7-10). Check engine alternator, engine harness,
and the fuel pump.
Check continuity of Engine Control switch S1, and replace if necessary.
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
Have engine manufacturer’s authorized service agent check electronic speed control system.
See engine manual.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 7-7 and 7-9).
See engine manual.
Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to Have engine manufacturer’s authorized service agent check electronic speed control system.
weld speed.
Engine does not run at idle speed. Have engine manufacturer’s authorized service agent check electronic speed control system.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 16).
wetstacking occurs.

Notes

9-3. Troubleshooting Circuit Diagram For Welder/Generator (Use With Section 9-4)
! Measure capacitor bank C3 voltage according to Section 9-1, and

be sure voltage is near zero (0) before touching any parts.
V11 V11
V5, R3
V2, R2
V7
V13
V10, R9 V11, R8
V6, R4
V4, R5
V10, R10 V12
V3, R6
V1, R1 I1
I2
V9 V8
V9 Engine
control
Flashing V27 relay CR5
Diode
V8, R7
V31
R16 R15 V17
R12
R13
V34
V17
V15, R11
V31
V33
V17 R14
V32
V29 Air compressor clutch

1 VDC/100 A Output
V14
V24
V16
V18
V28 V18 V21

V23 V20 V22 V20
V27 V25
V26
V20
V19
V13
V16
See Section 9-6

for PC1 and PC21
Information
See Section 9-8 for

RC14 and RC 214
Information
266 206-B

9-4. Troubleshooting Values For Circuit Diagram (Use With Section 9-3)
Test Equipment Needed:
Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine (no warm-up); no load;
weld/power RPM unless noted
c) Reference − single arrow: reference to circuit common (lead 42);
double arrow: reference to points indicated
Resistance Values
d) Process/Contactor switch R1/21 in Electrode Hot − Stick position
unless noted a) Tolerance − ±10% unless
specified
e) Wiring Connections − see Table 13-1
b) Condition − 70°F (21°C); cold
V1 96 volts DC
machine (no warm-up)
V2 97 volts DC
c) Wiring Connections − see
V3 109 volts AC Table 13-1
V4 132 volts AC
d) Stop engine before checking
V5 132 volts AC resistance
V6 132 volts AC R1 22 ohms
V7 264 volts AC R2 14 ohms
V8 264 volts AC R3 thru R11 Less than 1 ohm
V9 132 volts AC R12 30 ohms = full fuel tank
240 ohms = empty tank
V10 21.5 volts AC R13 304 ohms
V11 64 volts AC R14 2.8 ohms
V12 43 volts AC R15 2.35k ohms
V13 58 volts DC R16 2.3 ohms
V14 95 volts DC
V15 28 volts AC
V16 12 volts DC at idle RPM
Amperage Readings
V17 12 volts DC, hot battery bus a) Tolerance − ±5% unless specified
V18 1.9 volts DC at 75°F b) Condition − 70°F (21°C); cold
V19 VRD switch S5 On = 0 volts, Off = +5 volts DC machine (no warm-up); no load;
weld/power RPM unless noted
V20 5 volts DC Control Power Supply
c) Process/Contactor switch R1/21
V21 0 to +5 volts DC from min to max of Voltage/Amperage control R2
in Weld Terminals Always On −
V22 0 to +5 volts DC from Electrode Hot−Wire position to Remote−Wire position Stick position unless noted
of Process Contactor switch R1 (in 0.71 volt increments)
I1 4.4 Amps
V23 0 to +5 volts DC from min to max of Arc Control control R5
V24 Open Circuit Voltage (See Chart) I2 7.0 Amps
V25 10 volts DC with respect to chassis ground I3 50 Amps inrush, 30 Amps hot
V26 0 to 10 volts DC min to max remote command input with respect to chassis
ground Open Circuit Voltage
V27 12 volts DC battery voltage V24 VRD On
V28 28 volts AC Stick Hot 15 volts DC
V29 12 volts DC with respect to chassis ground when glow plugs are energized TIG Hot 15 volts DC
FCAW MIG 13 to 39.9 volts DC
V30 12 volts DC when engine is running R2 Min to Max
V31 12 volts DC with relay CR5 energized V24 VRD Off
V32 12 volts DC when glow plugs are energized Stick Hot 95 volts DC
V33 12 volts dc with compressor running TIG Hot 15 volts DC
FCAW MIG 13 to 39.9 volts DC
V34 1.8 volts = idle speed R2 Min to Max
2.0 volts = high speed

9-5. Waveforms For Sections 9-3
The waveforms represent the output of the welder/generator. When unit is operating properly, the waveforms match those shown.
10 ms 50 V 10 ms 50 V
gnd gnd
A. CC/DC Open-Circuit Voltage, Process/Con- B. CV/DC Open-Circuit Voltage, Process/Con-

tactor Switch R1 In Electrode Hot − Stick Posi- tactor Switch R1 In Electrode Hot − Wire Posi-
tion, Voltage/Amperage Control R2 At Max tion, Voltage/Amperage Control R2 At Max
20 ms 20 V
20 ms 20 V
gnd gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro- D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Electrode Hot − cess/Contactor Switch R1 In Electrode Hot −
Stick Position, (Resistive Load) Wire Position, (Resistive Load)
Oscilloscope Load Bank

9-6. Main Control Board PC1/PC21 Testing Information
Test Equipment Needed: ! Stop engine.

See Section 9-7 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Main Control Board
PC1/PC21
2 Plug PLG6/26
3 Plug PLG7/27
4 Plug PLG11/211
4
1
Rear View Of Plug Where Leads Go Into Plug 3 And 4

2
907 535−TP2 / 193 183 / 193 184

9-7. Main Control Board PC1/PC21 Test Point Values

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power RPM unless noted
PC1/PC21 Voltage Readings d) Process switch R1/R21 in Stick position
e) Pins not listed are not used on this model
Plug Pin Value

PLG6/26 A1 Serial data line
A2 +5 volts DC output
A3 Arc Control signal input: 0 to +5 volts DC
B2 Command signal input: 0 to +5 volts DC input from min to max of Voltage/Amperage control R2
B3 Voltage feedback reference
C1 Serial data line
C2 Circuit common for Voltage/Amperage control R2/22
C3 Weld feedback with respect to pin PLG6/26-B3; same as OCV or load voltage
D3 Circuit common for Arc Control R5/25
E3 Current feedback for idle speed control; +1 volt AC or greater with respect to G3
F2 Voltage feedback: 1 volt DC per 10 arc volts
F3 Idle speed control signal from Engine Control switch S1: +12 volts DC in Run position
G1 VRD switch S5 input: On = 0 volts DC, Off = +5 volts DC
G2 Command reference: +10 volt DC
G3 Current feedback for idle speed control; +1 volt AC or greater with respect to E3
H2 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
H3 Circuit common
J3 Circuit common
K1 +5 volts DC output
K3 24 volts AC input
PLG7/27 A1 0 to +5 volts DC from Weld Terminals Always On − Wire position to Remote Wire position of Process
Contactor switch R1/21 (0.71 volt increments)
A2 1 volt DC input per 100 amperes of weld output with respect to pin PLG7/27-C2
A3 +5 volts DC output
B1 Circuit common for Process/Contactor switch R1/21
B2 +15 volts DC output with respect to pin PLG7/27-C2
B3 Contactor control circuit: 24 volt AC input with respect to circuit common and closure on RC14/214
between pins A and B
C2 Circuit common
C3 Idle control signal: 0 volts DC at idle speed; +12 volts DC with welding load applied
D2 −15 volts DC with respect to pin PLG7/27-C2
E1 +12 volts DC power input
F3 Current feedback: 0 volts DC input per 100 arc amperes
PLG11/211 A1 Circuit common
A2 +5 volts DC
A3 +1.9 volts DC to RC10 Pin 7 at room temperature
B1 Circuit common

Plug Pin Value
PLG11/211 B2 +5 volts DC
B3 +1.9 volts DC to RC20 Pin 7 at room temperature
C1 −24 volts DC with respect to pin PLG11/211-D1
C2 PWM drive (PM2) +18 volts dc with respect to pin PLG11/211-D1 at open circuit
D1 Reference for gate drive supply
E1 +24 volts DC with respect to pin PLG11/211-D1
E2 −9 volts DC with respect to pin PLG11/211-D1
E3 +18 volts DC with respect to pin PLG11/211-D1
F1 −9 volts DC with respect to pin PLG11/211-D1
F2 PWM drive (PM1) +18 volts dc with respect to pin PLG11/211-D1 at open circuit
F3 +18 volts DC with respect to pin PLG11/211-D1
9-8. Filter Board PC5/PC25 Testing Information
! Stop engine.
See Section 9-9 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Filter Board PC5/25
2 Receptacle RC8/RC28
Plug PLG8/PLG28
907 634−TP3 / 217 008 / 231 708

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

d) Process switch R1/R21 in Stick position
PC5/25 Voltage Readings
Receptacle Pin Value

RC8/28 1 Not used on this model
2 Not used on this model
4 Voltage feedback: 1 volt DC per 10 arc volts
6 Command reference: +10 volt DC input
7 24 volt AC input with respect to pin RC6/26−J3
8 Command common
9 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
10 Current feedback: 1 volt DC per 100 arc amperes
Notes

9-10. IGBT Module LED Troubleshooting Indicators
Voltage signals come from
PC1 for PM1 and PM2 on side
A IGBT assembly and from
PC21 for PM21 and PM22 on
1 side B IGBT assembly.
1 IGBT Assembly
2 LED1 (Green)
Lit when +18 volts DC supply is
present.
3 LED2 (Green)
Lit when −9 volts DC supply is
3
present.
4 LED3 (Yellow)
2 Lit when PWM signal is present in-
dicating that weld contactor is on
driving IGBTs.
Ref. 907535−TP3 / 246 580-1A / 246 323-B
IGBT PM1/PM21 Information

PM1/21 Receptacle/ PC1/PC21 Plug/ Value
Pin Socket
RC20/220 1 PLG11/211 F3 Power Supply: +18 volts DC from PC1, LED1 lights when supply is present
RC20/220 2 PLG11/211 F1 Power Supply: −9 volts DC from PC1, LED2 lights when supply is present
RC20/220 3 PLG11/211 D2 Circuit common from PC1
RC20/220 4 PLG11/211 F2 PWM signal from PC1, LED3 lights when signal is present
RC20/220 5 PLG11/211 A2 +5 volts DC to Pin 6
RC20/220 6 PLG11/211 A1 Circuit common
RC20/220 7 PLG11/211 A3 +1.9 volts DC to pin 6 at room temperature
RC20/220 8 N/A
IGBT PM2/PM22 Information

Receptacle/Pin PC1/PC21 Plug/ Value
Socket
RC10/210 1 PLG11/211 E3 Power Supply: +18 volts DC from PC1, LED1 lights when supply is present
RC10/210 2 PLG11/211 E2 Power Supply: −9 volts DC from PC1, LED2 lights when supply is present
RC10/210 3 PLG11/211 D3 Circuit common from PC1
RC10/210 4 PLG11/211 C2 PWM signal from PC1, LED3 lights when signal is present
RC10/210 5 PLG11/211 B2 +5 volts DC to Pin 6
RC10/210 6 PLG11/211 B1 Circuit common
RC10/210 7 PLG11/211 B3 +1.9 volts DC to pin 6 at room temperature
RC10/210 8 N/A

9-11. Engine Display Testing Information
1 Rear of Engine Display
See Section 15 for explanation of
engine display functions.
Wiring harness plugs PLG4 and
PLG12 connect to receptacles on
rear of display.
Test functions by checking pin in-
puts and outputs as specified.
Voltage readings tolerance ±10%.
Plug PLG4
Pin Description
1 +12 Volts DC Input
2 CAN Hi
3 CAN lo
4 +12 Volts DC to CR5
5 not Used
6 Ground
Plug PLG12
Pin Description
8 31 ohms = full fuel tank
237 ohms = empty fuel tank
Ref. 907535−TP2 / 256 689

9-12. Meter Display Board PC2/PC22 Testing Information
! Stop engine.
See Section 9-13 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
1
1 Meter Display Board PC2/22
2 Receptacle RC1/21
Pin 1
Pin 8
907634−TP4 / 250 310-A
9-13. Meter Display Board PC2/PC22 Test Point Values

d) Process switch R1/R21 in Stick position
PC2/22 Voltage Readings
Receptacle Pin Value

RC1/21 1 +12 volts DC input with respect to pin RC1/21-2
2 Circuit common
3 Serial data line
4 Serial data line
5 Serial data line
6 Serial data line
7 Not Used
8 Circuit common side B only.

9-14. Replacing Brushes And Cleaning Slip Rings
Tools Needed:
Minimum Length:
5/8 in. (16 mm)
New Length:
1-1/4 in. (32 mm)
907 634-TP5 / 255 861 / Ref: 190 823

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

9-15. Checking Unit Output After Servicing
Use output waveforms to check unit

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

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

resistor length is in circuit.
2 Start engine and and run at weld/power
speed (1890 rpm). Check weld output
voltage. If necessary, change R8 connec-
tions until correct voltage is obtained.
3 Perform a load bank test to ensure
welder/generator operates properly
after servicing. Be sure load bank is
capable of handling the rated output
of the welder/generator being tested
(see load bank Owner’s manual).
The load bank will simulate a weld
load and the electrical demand on the
unit. See Specifications for rated
load.
If unit does not perform at rated load,
Test Equipment Needed: repeat troubleshooting procedures.
Pre-Operational Checks ! Stop engine.
Allow engine to cool, and then complete
Wipe engine surfaces clean. pre-operational checks in table.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-5).

Check and correct any fluid leaks. Tools Needed:
Clean weld output and battery terminals. Tighten connections.

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

Notes

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

Component Location
19 2
3 1
15
4
11
13 14
2
19
12
1
20
16
4 17
5
10 18
9
12
255 862-A

The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment. The compres-
sor will require service more often if used in dirty, humid conditions.
10-2. Air Compressor Maintenance Label

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

10-3. Routine Air Compressor Maintenance
See Section 7 for engine/generator maintenance information.
Recycle air
compressor
fluids.
! Stop engine before maintaining.
Service air compressor more often if used in severe conditions.

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

Every Section
250 10-4
Hours
Unreadable Labels Belt Tension Air Cleaner Hoses Air Filter Element
Worn or Damaged Air/Oil Cooling System

Hoses
Every Section
500 10-6
Hours
Oil Oil Filter

Every Section
1000 10-6
Hours
Air/Oil Separator

10-4. Servicing Compressor Air Cleaner
! Stop engine.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
1 damaged element is not covered by the
warranty.
1 Compressor Air Cleaner
The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional air compressor
protection. Never clean a safety ele-
ment. Replace the safety element af-
ter servicing the primary element
three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
2 3 4 5 place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element
4 Primary Element
5 Cover
6 Dust Ejector
To clean air filter:
6 Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.
NOTICE − Do not clean housing with air
hose.
Keep nozzle
2 in. (51 mm) Clean primary element with compressed
from element. air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).
Blow Inspect
aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B / 907 634-TP9

10-5. Compressor Overload Protection
! Stop engine.
When a circuit breaker or fuse

opens, it usually indicates a more
serious problem exists. Contact
Factory Authorized Service Agent.
See Section 7-10 for engine/gener-

ator overload protection.
Circuit breaker CB15 protects the air
compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.
Press button to reset breaker.
907 634−2 / Ref. 907 634-5

10-6. Servicing Air Compressor
Tools Needed:
Air Compressor Assembly Right Side 7/8, 15/16 in.
7
4
Too
High
2
Full Full
3
Too
Low
1
907 535−2 / 2555 862-A
! Stop engine and let cool. Wait 60 sec- To change compressor oil and filter: Add recommended oil until oil level indicator
onds for system pressure to drop be- shows system is full (see compressor mainte-
fore changing oil.
The engine oil drain and compressor oil nance label for oil specifications). Reinstall oil
drain hoses are located together in the fill cap. Tighten cap with wrench.
1 Air Compressor Oil Filter base. Be sure to select the correct hose
when draining compressor oil. To replace secondary air/oil separator:
2 Secondary Air Compressor Air/Oil Be sure o-rings at oil drain and oil fill fit-
Separator tings are in place before reinstalling caps. Loosen nut securing oil scavenge tube on
separator base. Lift oil scavenge tube from
Drain compressor oil while compressor is still separator. Turn filter counterclockwise. Re-
3 Air Compressor Oil Drain Hose warm. move filter.
w/Removable Cap
Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Re- Apply thin coat of oil to gasket on new filter.
4 Air Compressor Oil Fill Cap move cap from oil drain hose and drain oil into Install filter and turn clockwise. Reinstall oil
a suitable container. Reinstall oil drain hose scavenge tube.
5 Air Compressor Oil Level Indicator cap. Tighten cap with wrench.
Remove filter by turning filter counterclock- Start engine, run air compressor, and check
6 Air Compressor Primary Air/Oil for oil leaks.
Separator Tank wise. Remove filter. Apply thin coat of oil to
gasket on new filter. Install new filter and turn
7 Oil Scavenge Tube clockwise until tight. ! Stop engine.

10-7. Adjusting Compressor Air Pressure
Check compressor air pressure using

air pressure gauge known to be accu-
rate. If necessary, adjust air pressure
as follows:
Tools Needed: 1 Screw
5/16, 3/8 in. Loosen jam nut securing screw. Turn
screw clockwise (increase pressure)
or counterclockwise (decrease) until
pressure is 125 psi (862 kPa).
Maximum weld output is reduced

if compressor air pressure is set
above 125 psi (862 kPa).
Tighten nut.
2 Pressure Relief Valve
Pressure relief valve opens and re-
leases pressure at 150 psi (1034
kPa). The pressure relief valve is not
adjustable.
Air Compressor Assembly Left Side
255 862-A / Ref: 803 228

10-8. Troubleshooting Air Compressor System
See Sections 10-1 thru 10-7 for normal air
compressor maintenance procedures See
Section 17 and following for parts location.
Trouble Remedy
Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If
pressure at air shutoff valve. compressor is turned off, wait for air pressure to bleed off (about 60 seconds) before turning compressor
on again.
Reset supplementary protector CB15 (see Section 11-2).

Check compressor belt tension. Be sure correct belt is used and is properly installed.
Check continuity of Air Compressor switch S10, and replace if necessary.
Check control relay CR10: Check all connections, check coil continuity, check for proper coil voltage,
and check contact voltage (input to common and output to common) to ensure contacts are operating.
Replace CR10 if necessary.
Check for proper operation of air pressure switch S11. S11 closes (continuity) when air compressor is
off. S11 opens (infinity) when air compressor is on and air pressure is above 20 psi (138 kPa).
Check for proper operation of air temperature switch S12. S12 closes (continuity) when compressor air/oil
mixture is below 248° F (120° C). S12 opens (infinity) when compressor air/oil mixture exceeds 248° F
(120° C).
Check compressor air pressure. Pressure relief valve opens if air pressure is above 125 psi (862 kPa).
If pressure relief valve continues to open, verify secondary oil separator is not plugged. Replace pressure
relief valve if necessary.
Verify secondary air/oil separator is not plugged. Replace separator if necessary.

Verify compressor inlet valve is operating properly. With engine stopped, remove air hose from inlet valve
and verify inlet valve piston moves freely. Replace inlet valve if necessary.
Check minimum pressure check valve and replace if necessary.
Check air compressor clutch and replace if necessary.
Air compressor stops after short period Check compressor oil level (see Section 10-6). Automatic shutdown stops compressor if compressor
of operation. temperature is too high.
Clean debris from outside of radiator. Automatic shutdown stops compressor if compressor temperature
is too high.
Low air pressure. Check for leaks in air lines and hoses.
Check air compressor air cleaner (see Section 10-4).
and verify inlet valve piston moves freely. Lubricate piston with compressor oil or replace inlet valve if
necessary.
Adjust compressor air pressure (see Section 10-7).

Check compressor for rated output, and replace if necessary.
High air pressure. Be sure control line is connected at regulator valve and inlet valve.
necessary.
Adjust compressor air pressure (see Section 10-7).

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

Trouble Remedy
Oil in air from compressor. Check compressor oil level (see Section 10-6). If oil level is too high, system becomes saturated with oil.
Change compressor secondary air/oil separator (see Section 10-6).
Check connections of red, white, and blue control lines (see compressor circuit diagram in Section 10-1).
Check for blocked separator scavenge check valve/filter orifice. Be sure lines are clear between oil sepa-
rator and compressor.
Oil in compressor air cleaner. Close air shutoff valve before shutting unit down to prevent oil burpback into air filter.
necessary.
Notes

SECTION 11 − SERVICING AND TROUBLESHOOTING
OPTIONAL AIR DRYER
WARNING
AIR DRYER EXHAUSTS AT HIGH PRESSURE. NOISE AND FLYING DIRT AND SMALL OBJECTS can cause
injury and damage.
• Always vent air dryer exhaust to safe area.
• Wear safety glasses when servicing dryer or working around unit.
• Alert others nearby to be prepared for loud noises each time the air dryer discharges.
11-1. Component Location For JP Models
1 3/4 NPT To 3/4 JIC Female Adapter

2 3/4 NPT To 3/4 JIC Male Adapter
3 Air Hose
4 3/4 NPT Street Elbow
5 3/4 NPT Nipple
6 Air Shutoff Valve
7 Timer Control
8 Thumbscrew
4
5
1
8
7
6
2
3
803 338-B

11-2. Air Dryer Operation And Overload Protection
The air dryers blow out (purge) mois-
ture and debris when the air compres-
sor is being used. The air dryer heaters
operate whenever the welding genera-
tor is running.
The timer control regulates the drying
JP Models and regeneration cycles of the air dry-
er. The timer control energizes and
de-energizes the air control valve at
two-minute intervals during normal op-
eration. At start-up, this cycle repeats
at 15-second intervals four times.
The air control valve controls airflow
direction through the dryer. During op-
eration, one cartridge is drying air and
the other is being regenerated.
During operation there will be a light
flow of air from one exhaust port; this is
normal regeneration. Every two
minutes there will be a momentary
burst of air from one of the exhaust
ports as the timer control cycles.
The system includes a valve body
heater. If this is not operating properly,
the valve can freeze and not allow the
system to cycle.
CB14 protects the dryer heaters from
damage due to overload. If CB14
opens, the heaters do not work and the
dryer does not discharge moisture in
cold weather.
Press button to reset circuit breaker
CB8.
2 Timer Control LED
Verify dryer solenoid is functioning by
2 listening for dryer canisters to purge, or
3 by checking solenoid LED. LED lights
at start-up and every two minutes
when the canisters automatically
purge.
3 Screw
Screw is used to manually override the
Timer Control for certain troubleshoot-
ing functions.
907 634−2 / 803 229 / 236 974

11-3. Replacing Desiccant Cartridge
! Stop engine and let cool. Wait

20 seconds for system pres-
sure to drop before working
on any part of the air dryer
system.
Tools Needed:
1 Desiccant Cartridge
The expected life of the desiccant
cartridge is two to three years de-
pending on operating condition and
usage. Replace cartridge as follows:
Be sure system pressure is relieved.
Using a strap wrench, remove desic-
cant cartridge.
An excessive accumulation of
oil in the air dryer or desiccant
cartridge indicates the com-
1 pressor may require service.
Contact the Factory Service De-
partment.
Remove and discard O-ring from
adapter plate stud. Clean adapter
plate surface and threaded stud.
Apply a light coating of grease to the
new O-ring and install on threaded
stud.
Apply a generous coating of grease
on the new desiccant cartridge gas-
ket surface.
Thread new desiccant cartridge onto
stud, turning clockwise. Hand tight-
en until gasket contacts adapter
plate. Turn cartridge 1/2 to 3/4 turn
more.
Do not overtighten cartridge as

it may be extremely difficult to
remove.
803 511-B / 236 974
11-4. Troubleshooting Optional Air Dryer System
! Stop engine and let cool. Wait 20 seconds for system pressure
to drop before working on any part of the air dryer system.
Trouble Remedy
Air dryer system does not purge. Desiccant cartridge saturated. Replace cartridge.
Valve body heaters not working. Reset circuit breaker CB14 (see Section 11-2). Check for 12 volts DC
at heaters. Check resistance of the heater element; with the heater assembly removed from the valve
body, resistance should be approximately 2 ohms. Contact the Factory Service Department.
Check for valve malfunction: With system pressurized, turn the brass screw (see Section 11-2) to the right
(clockwise) 1/2 turn to horizontal. If air purge does not occur, see air dryer Service Manual available at
www.dry−air−systems.com.
O−rings and seals worn. Replace worn parts, see air dryer Service Manual available at www.dry−air−sys-
tems.com.
Notes

SECTION 12 − DISASSEMBLY AND REASSEMBLY
12-1. Disassembly For Service
Lift Here
907 634-TP5 / 907 634-TP10 / 907 634-TP11

! Stop engine and let cool. Disconnect 1 Auxiliary Power Panel Disconnect resistors R3 and R8 and discon-
battery negative (−) cable. Remove hardware securing auxiliary power nect stabilizers Z1 and Z21.
Use Section 9-2 to determine if trouble is in panel. Tilt panel forward. Disconnect wires Disconnect ground leads attached to base.
stator, rotor, engine or combination of these from generator to CB1.
Disconnect plug at control box. Remove
components. To aid in reassembly, mark leads before screws securing control box to base.
These instructions will remove components disconnecting. See lead list summary in Remove engine air intake hose. Remove
surrounding the engine/generator assembly; Table 13-1, for connection information. hardware from valve ball box located in lower
thereby allowing the engine/generator as- Disconnect leads 11, 12, 13, 21, 22 and 23 front panel. Remove steel air line clamp from
sembly to remain on the unit base. from main rectifiers SR6 and SR26. front to center upright brace. Remove steel oil
When the front panel assembly and compo- Disconnect remaining leads coming from the cooler line clamp from center upright.
nents up to the center upright are removed, stator.
the center upright needs to be supported. Remove hardware securing front panel and
Prepare proper supporting blocks. 2 Control Box center upright to base and pull assembly up
3 Resistors R3 and R8 and out of unit.
Should it be necessary to remove the stator
or engine, prepare proper supporting blocks 4 Stabilizer Z1 and Z21 Go to Section 12-2.
to shim under the engine adapter 5 Valve Ball Box Proceed with engine service/repair. When
Remove exhaust pipe and fuel tank cap. Re- Disconnect wires from fuel sender and dis- service/repair is complete, reverse proced-
move top cover, left side panels, and right connect wiring harness from engine and ure to reinstall upright. Tighten center upright
side panels. Replace fuel tank cap. wires from air compressor. assembly hardware to 30 ft lb (41 N.m).

12-2. Disassembly Of Generator
3
C
1
Torques:
A 30 ft lb (41 N.m)
D B 18 ft lb (24 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
255 861
NOTICE − Do not damage stator or rotor win- 3 Endbell with Exciter Stator Reassembly Instructions:
dings during this procedure.
Exciter stator comes off with endbell. Reinstall engine and generator parts as
1 Brushes needed using torque values in table.
4 Rotor
Remove brushes from brushholder assembly Reinstall upright assembly. Reconnect fuel
If engine must also be removed, remove en-
before disassembling generator. line.
gine from base mounts.
2 Stator Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
With engine properly supported, remove
from moving and hot parts.
hardware securing stator to engine. Remove
the following parts as needed: Reconnect negative (−) battery cable. Rein-
stall panels, doors, and exhaust pipe.

12-3. Replacing IGBT Modules/Heat Sink Assembly
A. Removing Vault And Bracket
! Stop engine and let cool. Discon-

nect battery negative (−) cable.
Remove top cover, left side panels, and
right side panels.
1 Vault
2 IGBT/Capacitor Assembly
Disconnect plugs from vault and IGBT/
capacitor assembly. Disconnect output
leads at IGBT/capacitor assembly. Re-
move top IGBT/capacitor assembly. Re-
pair if necessary.
3 Vault Mounting Bracket
4 Vault And Capacitor Pan
Remove hardware securing bracket to
pan. Remove bracket.
Disconnect plugs and output leads at
lower vault and IGBT/capacitor as-
sembly.
2
Remove hardware securing IGBT/Ca-
pacitor assembly to the pan and remove
assembly from unit.
1
907 535-5 / 907535−TP4 / 907535−TP6

B. Replacing IGBT Modules/Heat Sink Assembly
1 Capacitors/Buss Plates As-

sembly
2 IGBT Modules/Heat Sink As-
sembly
Remove capacitor assembly from
IGBT modules/heat sink assembly.
A Replace IGBT modules/heat sink
assembly.
Reassemble capacitor assembly
onto IGBT modules/heat sink as-
2 sembly.
When reassembling the capacitor
assembly to the IGBT assembly,
torque screws according to table
below.
NOTICE − Apply Noalox joint com-
pound to the positive and negative
contact surfaces of the capacitors
and to the top surface of the stan-
doffs.
Reassemble unit.
C C
Torques:
B
A All Hardware To C
IGBT Modules
55 in lb 45 in. lb 70 in. lb
(6.2 N⋅m) (5.1 N⋅m) (7.9 N⋅m)
252 915-C

SECTION 13 − ELECTRICAL DIAGRAMS
The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Number Circuit Diagram Wiring Diagram
Big Blue 800CA Duo Air Pak ME200183E and following 266 206-B See Table 13-1
Big Blue 800X Duo Air Pak ME200183E and following 266 207-B See Table 13-1
Big Blue 800X/800CA Air Pak TM-267 603 Page 91

Figure 13-1. Circuit Diagram For CA Model Welder/Generator
266 206-B

Figure 13-2. Circuit Diagram For Export Model Welder/Generator
266 207-B

Table 13-1. Lead List Summary For Big Blue 800X Duo Air Pak Eff w/Serial No. ME200183E And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections

−− ATTACH END A TO 22 GA ON CT 42Q PLG26 (J1) TO EXIT
NEGC BUSS PLATE (−) TO R3 42R R3 TO PLG98 (9)
POSC BUSS PLATE (+) TO R3 42S PLG26 (F3) TO TE2 (A/B)
11A WELD STATOR TO SR6 42T PLG26 (H3) TO TE2 (A/B)
12A WELD STATOR TO SR6 42TT CR1 (85) TO GND STRIP (BOTT)
13A WELD STATOR TO SR6 42TT S5 (BOT) TO TE2 (A/B)
15A BUS PLATE (−) TO SR6 (−)(MASTER) 42UU S5 (BOT) TO TE2 (A/B)
16A Z1 TO MOD1/MOD2 BUS BAR (MASTER) 42W COMPRESSOR CLUTCH TO GROUND TERMINAL
18A BUS PLATE (+) TO SR6 (+)(MASTER) 42X GND STRIP (BOTT) TO CR10 (B)
18C S3 (1) TO POS OUTPUT STUD (A+) 42Z GND TO TE2 (A/B)
18D POS OUTPUT STUD (A) TO POS BUS PLATE (LOOSE) 42ZZ PLG101 (1) TO GND STRIP (BOTT)
18D PLG6 (C3) TO RC30 (4) 43A CR1 (30) TO STARTER
18F S3 (1) TO PLG30 (4) 44B CB10 (SIL) TO CR10 (4)
20A Z21 TO MOD21/MOD22 BUS BAR 44C CR14 TO CB10 (SIL)
21A WELD STATOR TO SR26 44D CB10 TO CR5 (1)
22A WELD STATOR TO SR26 44E CB2 TO CR5 (1)
23A WELD STATOR TO SR26 45A CB16 (SIL) TO CR8 (87)
24A BUS PLATE (+) TO SR26 (+)(SLAVE) 46A PLG101 (18) TO CR4 (30)
24B S3 (2) TO POS BUS PLATE (B+)(LOOSE) 46B CR4 (30) TO CR24 (30)
24C PLG26 (C3) TO RC30 (2) 48A SPLICE (WIRE 48B) TO S1 (PLG409)
24E S3 (2) TO PLG30 (2) 48B PLG6 (F3) TO LEAD 48A
25A BUS PLATE (−) TO SR26 (−)(SLAVE) 49A PLG4 (1) TO CR5 (5)
26A PLG26 (B3) TO RC30 (3) 49B S1 (1) TO CR5 (5)
26B S3 (5) TO Z2 (LOOSE) 51A PLG4 (4) TO CR5 (6)
26C S3 (5) TO PLG30 (3) 52A CB2 TO S1 (B)
27A S3 (3) TO POS OUTPUT STUD (B+) 52B CB2 TO CR5 (3)
28A S3 (6) TO NEG OUTPUT STUD (B−) 56A CR1 (86) TO S1 (S)
30B PLG6 (B3) TO RC30 (8) 57A PLG100 (3) TO CR8 (85)
30C S3 (4) TO PLG30 (8) 60A D12 (CATH) TO ALT (D+)
30D S3 (4) TO NEG OUTPUT STUD (A−) 61A CR14 (86) DRYER OPTION TO TE3
30E NEG OUTPUT STUD (A) TO Z1 (LOOSE) 61B CR1 (87A) TO CR5 (4)
40A CB3 TO TE2 (C) 61C D12 (ANODE) TO TE3
40B PLG15 (CR4 (85)) TO TE2 (C) 61E S10 (6) TO TE3
40C PLG7 (E1) TO TE2 (C) 61P CR5 (4) TO TE3
40D PLG5 (1) TO TE2 (C) 61Q PLG101 (14) TO TE3
40E PLG27 (E1) TO TE2 (C) 61R PLG102 (A) TO TE3
40F PLG25 (1) TO TE2 (C) 61T TE3 TO CR8 (86)
40G CB3 TO CR24 (85) 61U TE3 TO TE3
41A PLG101 (17) TO CR4 (87A) 66A PLG6 (E3) TO CT LEAD
41B CR4 (87A) TO CR24 (87A) 67A PLG6 (G3) TO CT LEAD
42AA GND STUD TO RC3 (PE) 71C PLG12 (8) TO FUEL SENDER
42AB RC1 (PE) TO RC3 (PE) 72A AIR PRES SENDER TO PLG12 (7)
42AC RC4 (PE) TO RC3 (PE) 73A CB8 (30) TO GLOW PLUGS
42AD RC4 (PE) TO RC2 (PE) 74A PLG7 (C3) TO PLG16 (86)(CR4)
42AE RC4 (PE) TO GFCI 2 (GREEN) 75A PLG101 (11) TO PLG102 (K)
42AE D10 (ANODE) TO GND STRIP (BOTT) 76A PLG101 (10) TO PLG102 (L)
42AF RC1 (PE) TO GFCI 1 (GREEN) 77A PLG101 (2) TO PLG102 (B)
42AG GND STUD TO NEUTRAL STUD 80 PC6−80 TO TE1−80
42AG CR14 (85) DRYER OPTION TO GND STRIP (BOTT) 80B TE1 (F) TO PC5 (LEAD 80)
42AH GROUND STUD TO RC5 (PE) 80C TE1 (F) TO PC25 (LEAD 80)
42AH GND STRIP (BOT) TO SPLICE (WHITE LEAD−DRYER) 81B TE1 (E) TO CB9
42AK SPLICE (AIR DRYER KIT) TO GND STRIP (BOT) 81C PLG6 (K3) TO CB9
42AM CR15 (1) TO GND STRIP (BOT) 81D CB9 TO CB29
42BA CHASSIS GND TO GND (BOTTOM) 81E PLG26 (K3) TO CB29
42BB CHASSIS GND TO GND STUD (AUX POWER PANEL) 82B RC99 (1) TO SR3 (AC)
42BC CHASSIS GND TO TE1 (F−LEFT) 83B PLG11 (D1) TO RC99 (2)
42C PLG4 (6) TO GND STRIP (BOTT) 84A GFCI 1 (LINE−HOT) TO CB7
42EA CHASSIS GND TO BASE 85A GFCI 2 (LINE−HOT) TO CB8
42EA 86B RC99 (3) TO SR3 (AC)
42F BASE RAIL TO ENGINE GND STRAP 87 PC6−87 TO CB7
42G FUEL SENDER TO GND STRIP (BOTT) 87A PLG11 (E1) TO SR3 (+)
42H S3 (7) TO PLG30 (1) 88A PLG11 (C1) TO SR3 (−)
42I GND (TOP) TO GND (BOT) 89A STATOR TO EXIT
42J PLG6 (H3) TO TE2 (A/B) 89B NEUTRAL STUD TO RC5 (N)
42K RC30 (1) TO TE2 (A/B) 90B TE1 (C−RIGHT) TO ELCB 1 (LINE)
42L PLG5 (2) TO TE2 (A/B) 91B TE1 (B−RIGHT) TO CB5 (LINE RIGHT)
42M GND STRIP (BOTT) TO BASE RAIL 92B TE1 (A−RIGHT) TO CB5 (LINE LEFT)
42M PLG25 (2) TO TE2 (A/B) 93A STATOR TO EXIT
42N PLG25 (8) TO TE2 (A/B) 94A NEUTRAL STUD TO CB5 (LOAD LEFT)
42O RC98 (9) TO TE2 (A/B) 94B NEUTRAL STUD TO ELCB1 (LINE)
42Q BRUSH (FRONT) TO R3 94C GFCI 2 (LINE−WHITE) TO CB5 (LOAD LEFT)
94D GFCI1 (LINE WHITE) TO CB5 (LOAD LEFT) 175A CB15 TO CR10 (7)
96A ELCB1 (LEFT−LOAD) TO RC4 (N) 181A PLG6 (G1) TO S5 (POLE)
96B ELCB1 (LEFT−LOAD) TO RC3 (N) 181B PLG26 (G1) TO S5 (POLE)
97A ELCB1 (RIGHT−LOAD) TO RC4 (L) 182A PLG26 (H1) TO EXIT
97B ELCB1 (RIGHT−LOAD) TO RC3 (L) 183A PLG6 (E1) TO RC30 (6)
98A STATOR TO EXIT 183B PLG26 (E1) TO RC30 (7)
99A STATOR TO EXIT 183C S3 (8) TO PLG30 (6)
100B F1 TO RC98 (1) 183D S3 (8) TO PLG30 (7)
101B RC98 (2) TO SR2 (AC) 190A PLG6 (A1) TO PLG5 (3)
102A R3 TO PLG98 (3) 190B PLG5 (5) TO PLG25 (3)
102B RC98 (3) TO C6 (−) 190D PLG25 (5) TO PLG26 (A1)
102C SR2 (−) TO C6 (−) 191A PLG6 (C1) TO PLG5 (4)
104B F2 TO RC98 (5) 191B PLG5 (6) TO PLG25 (4)
105A BRUSH (CENTER) TO PLG98 (6) 191D PLG25 (6) TO PLG26 (C1)
105B RC98 (6) TO C6 (+) 200A SPLICE TO PLG100 (9)
105C SR2 (+) TO C6 (+) 200B SPLICE TO PLG105 (1)
105D SR1 (+) TO SR2 (+) 201A SPLICE TO PLG100 (8)
105E SR4 (+) TO SR1 (+) 201B SPLICE TO PLG105 (2)
106A F1 TO SR2 (AC) 202A PLG104 (1) TO PLG100 (12)
107A SR4 (AC) TO F2 203A PLG104 (2) TO PLG100 (13)
108A BRUSH (REAR) TO PLG98 (7) 204A PLG103 (5) TO PLG100 (18)
108B RC98 (7) TO SR4 (−) 205A PLG103 (4) TO PLG100 (19)
110A CB4 TO SR1 (AC) 206A PLG103 (3) TO PLG100 (17)
111A CB4 TO CB3 207A PLG103 (2) TO PLG100 (15)
111B CB3 TO CR5 (2) (TWISWTED PAIR WITH 208A)
112A R8 TO PLG98 (4) 208A PLG103 (1) TO PLG100 (14)
112B SR4 (AC) TO RC98 (4) (TWISTED PAIR WITH 207A)
120A PLG11 (C2) TO PLG10 (4) 209A PLG106 (1) TO PLG100 (22)
121A PLG11 (F2) TO PLG20 (4) 210A PLG106 (2) TO PLG100 (21)
122A PLG11 (D3) TO PLG10 (3) 211A PLG106 (3) TO PLG100 (20)
123A PLG11 (D2) TO PLG20 (3) 212A CB10 (BATT) TO STARTER
124A PLG11 (E2) TO PLG10 (2) 212B CB10 TO CB16
125A PLG11 (F1) TO PLG20 (2) 212C STARTER TO ALT
126A PLG11 (E3) TO PLG10 (1) 220A PLG211 (C2) TO PLG210 (4)
127A PLG11 (F3) TO PLG20 (1) 221A PLG211 (F2) TO PLG220 (4)
129A PLG11 (A3) TO PLG20 (7) 222A PLG211 (D3) TO PLG210 (3)
131A PLG11 (A1) TO PLG20 (6) 224A PLG211 (E2) TO PLG210 (2)
132 PC6−132 − CB8 225A PLG211 (F1) TO PLG220 (2)
133A PLG11 (B1) TO PLG10 (6) 226A PLG211 (E3) TO PLG210 (1)
134A PLG11 (B3) TO PLG10 (7) 227A PLG211 (F3) TO PLG220 (1)
135 PC6−135 TO RC2−6 229A PLG211 (A3) TO PLG220 (7)
135A PC6−135A TO RC13 (1) 230A PLG211 (A2) TO PLG220 (5)
135A PLG6 (G2) TO PLG8 (6) 231A PLG211 (A1) TO PLG220 (6)
136 PC6−136 TO RC2−8 233A PLG211 (B1) TO PLG210 (6)
136A PC6−136A TO RC13 (3) 234A PLG211 (B3) TO PLG210 (7)
136A PLG6 (J3) TO PLG8 (8) 235A PLG26 (G2) TO PLG28 (6)
137 PC6−137 TO RC2−9 236A PLG26 (J3) TO PLG28 (8)
137A PLG6 (H2) TO PLG8 (9) 237A PLG26 (H2) TO PLG28 (9)
140 PC6−140 TO RC2−10 240A PLG27 (F3) TO TE2
140A PLG7 (F3) TO PLG8 (10) 240B PLG28 (10) TO TE2
141 PC6−141 TO RC2−4 240C PLG7 (E2) TO TE2
141A PLG6 (F2) TO PLG8 (4) 241A PLG26 (F2) TO PLG28 (4)
143A PLG11 (B2) TO PLG10 (5) 243A PLG211 (B2) TO PLG210 (5)
148A PC6−148A TO RC13 (2) 260A PLG27 (B1) TO RC23 (6)
150 PC6−150 TO RC2−7 261A PLG27 (A1) TO RC23 (5)
150A PLG7 (B3) TO PLG8 (7) 262A PLG26 (K1) TO RC23 (4)
160A PLG7 (B1) TO RC3 (6) 265A PLG26 (C2) TO PLG22 (1)
161A PLG7 (A1) TO RC3 (5) 266A PLG26 (B2) TO PLG22 (2)
162A PLG6 (K1) TO RC3 (4) 267A PLG26 (A2) TO PLG22 (3)
163A TE3 TO HAT SWITCH (S12) 270A PLG26 (D3) TO PLG29 (1)
163B TE3 TO CR10 (A) 271A PLG26 (A3) TO PLG29 (2)
163D TE3 TO CR15 (2) 272A PLG27 (A3) TO PLG29 (3)
164A S10 (5) TO S10 (2) 274A PLG27 (C3) TO PLG17 (CR24)(86)
164B CR10 (9) TO S10 (5) 282A RC99 (4) TO SR23 (AC)
165A D10 (CATHODE) TO COMPRESSOR (CLUTCH) 283A PLG211 (D1) TO RC99 (5)
165A PLG6 (C2) TO PLG2 (1) 286A RC99 (6) TO SR23 (AC)
165B CB15 TO D10 (CATHODE) 287A PLG211 (E1) TO SR23 (+)
166A PLG6 (B2) TO PLG2 (2) 288A PLG211 (C1) TO SR23 (−)
167A PLG6 (A2) TO PLG2 (3) 300A CB1 (TOP−LEFT) TO RC5 (L1)
168A S11 AIR PRESSURE LOCKOUT TO S12 (SWITCH) 301A CB1 (TOP−CENTER) TO RC5 (L2)
168B S12 (SWITCH) TO CR10 (6) 302A CB1 (TOP−RIGHT) TO RC5 (L3)
169A S11 AIR PRESSURE LOCKOUT TO S10 (3) 303A RC1 (L) TO GFCI 1 (LOAD−HOT)
170A PLG6 (D3) TO PLG9 (1) 304A RC1 (N) TO GFCI 1 (LOAD−WHITE)
171A PLG6 (A3) TO PLG9 (2) 305A RC2 (L) TO GFCI 2 (LOAD−HOT)
172A TIMER (BLACK) TO CR15 (6) 306A RC2 (N) TO GFCI 2 (LOAD−WHITE)
172A PLG7 (A3) TO PLG9 (3) 307A CB5 (LOAD RIGHT) TO CB8
307B CB5 (LOAD RIGHT) TO CB7 435C R6 TO PLG102 (H) (TWISTED PAIR WITH 436C)
311A CB14 TO CR14 (30) 436A PLG101 (13) TO R6 (TWISTED PAIR WITH 435A)
311B CR14 (30) TO CR15 (4) 436B R6 TO PLG4 (3) (TWISTED PAIR WITH 435B)
435A PLG101 (12) TO R6 (TWISTED PAIR WITH 436A) 436C R6 TO PLG102 (G) (TWISTED PAIR WITH 435C)
435B R6 TO PLG4 (2) (TWISTED PAIR WITH 436B)

Table 13-1. Lead List Summary For Big Blue 800CA Duo Air Pak Eff w/Serial No. ME200183E And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

−− ATTACH END A TO 22 GA ON CT 42R R3 TO PLG98 (9)
NEGC BUSS PLATE (−) TO R3 42S PLG26 (F3) TO TE2 (A/B)
POSC BUSS PLATE (+) TO R3 42T PLG26 (H3) TO TE2 (A/B)
11A WELD STATOR TO SR6 42TT CR1 (85) TO GND STRIP (BOTT)
12A WELD STATOR TO SR6 42TT S5 (BOT) TO TE2 (A/B)
13A WELD STATOR TO SR6 42UU S5 (BOT) TO TE2 (A/B)
15A BUS PLATE (−) TO SR6 (−)(MASTER) 42W COMPRESSOR CLUTCH TO GROUND TERMINAL
16A Z1 TO MOD1/MOD2 BUS BAR (MASTER) 42X GND STRIP (BOTT) TO CR10 (B)
18A BUS PLATE (+) TO SR6 (+)(MASTER) 42Z GND TO TE2 (A/B)
18C S3 (1) TO POS OUTPUT STUD (A+) 42ZZ PLG101 (1) TO GND STRIP (BOTT)
18D POS OUTPUT STUD (A) TO POS BUS PLATE (LOOSE) 43A CR1 (30) TO STARTER
18D PLG6 (C3) TO RC30 (4) 44B CB10 (SIL) TO CR10 (4)
18F S3 (1) TO PLG30 (4) 44C CR14 TO CB10 (SIL)
20A Z21 TO MOD21/MOD22 BUS BAR 44D CB10 TO CR5 (1)
21A WELD STATOR TO SR26 44E CB2 TO CR5 (1)
22A WELD STATOR TO SR26 45A CB16 (SIL) TO CR8 (87)
23A WELD STATOR TO SR26 46A PLG101 (18) TO CR4 (30)
24A BUS PLATE (+) TO SR26 (+)(SLAVE) 46B CR4 (30) TO CR24 (30)
24B S3 (2) TO POS BUS PLATE (B+)(LOOSE) 48A SPLICE (WIRE 48B) TO S1 (PLG409)
24C PLG26 (C3) TO RC30 (2) 48B PLG6 (F3) TO LEAD 48A
24E S3 (2) TO PLG30 (2) 49A PLG4 (1) TO CR5 (5)
25A BUS PLATE (−) TO SR26 (−)(SLAVE) 49B S1 (1) TO CR5 (5)
26A PLG26 (B3) TO RC30 (3) 51A PLG4 (4) TO CR5 (6)
26B S3 (5) TO Z2 (LOOSE) 52A CB2 TO S1 (B)
26C S3 (5) TO PLG30 (3) 52B CB2 TO CR5 (3)
27A S3 (3) TO POS OUTPUT STUD (B+) 56A CR1 (86) TO S1 (S)
28A S3 (6) TO NEG OUTPUT STUD (B−) 57A PLG100 (3) TO CR8 (85)
30B PLG6 (B3) TO RC30 (8) 60A D12 (CATH) TO ALT (D+)
30C S3 (4) TO PLG30 (8) 61A CR14 (86) DRYER OPTION TO TE3
30D S3 (4) TO NEG OUTPUT STUD (A−) 61B CR1 (87A) TO CR5 (4)
30E NEG OUTPUT STUD (A) TO Z1 (LOOSE) 61C D12 (ANODE) TO TE3
40A CB3 TO TE2 (C) 61E S10 (6) TO TE3
40B PLG15 (CR4 (85)) TO TE2 (C) 61P CR5 (4) TO TE3
40C PLG7 (E1) TO TE2 (C) 61Q PLG101 (14) TO TE3
40D PLG5 (1) TO TE2 (C) 61R PLG102 (A) TO TE3
40E PLG27 (E1) TO TE2 (C) 61T TE3 TO CR8 (86)
40F PLG25 (1) TO TE2 (C) 61U TE3 TO TE3
40G CB3 TO CR24 (85) 66A PLG6 (E3) TO CT LEAD
41A PLG101 (17) TO CR4 (87A) 67A PLG6 (G3) TO CT LEAD
41B CR4 (87A) TO CR24 (87A) 71C PLG12 (8) TO FUEL SENDER
42AA GND STUD TO RC1 (GRN) 72A AIR PRES SENDER TO PLG12 (7)
42AB RC1 (GRN) TO RC2 (GRN) 73A CB8 (30) TO GLOW PLUGS
42AC RC2 (GRN) TO GFCI 1 (GRN) 74A PLG7 (C3) TO PLG16 (86)(CR4)
42AD GFCI 1 (GRN) TO GFCI 2 (GRN) 75A PLG101 (11) TO PLG102 (K)
42AE GROUND STUD TO RC5 (GREEN) 76A PLG101 (10) TO PLG102 (L)
42AE D10 (ANODE) TO GND STRIP (BOTT) 77A PLG101 (2) TO PLG102 (B)
42AG GROUND STUD TO NEUTRAL STUD 80 PC6−80 TO TE1−80
42AG CR14 (85) DRYER OPTION TO GND STRIP (BOTT) 80A EXCITER STATOR TO TE1 (E−LEFT)
42AH GROUND STUD TO RC4 (GREEN) 80B TE1 (F) TO PC5 (LEAD 80)
42AH GND STRIP (BOT) TO SPLICE (WHITE LEAD−DRYER) 80C TE1 (F) TO PC25 (LEAD 80)
42AK SPLICE (AIR DRYER KIT) TO GND STRIP (BOT) 81A EXCITER STATOR TO TE1 (F−LEFT)
42AM CR15 (1) TO GND STRIP (BOT) 81B TE1 (E) TO CB9
42BA CHASSIS GND TO GND (BOTTOM) 81C PLG6 (K3) TO CB9
42BB CHASSIS GND TO GND STUD (AUX POWER PANEL) 81D CB9 TO CB29
42BC CHASSIS GND TO TE1 (F−LEFT) 81E PLG26 (K3) TO CB29
42C PLG4 (6) TO GND STRIP (BOTT) 82A EXCITER STATOR TO PLG99 (1)
42EA CHASSIS GND TO BASE 82B RC99 (1) TO SR3 (AC)
42EA 83A EXCITER STATOR TO PLG99 (2)
42F BASE RAIL TO ENGINE GND STRAP 83B PLG11 (D1) TO RC99 (2)
42G FUEL SENDER TO GND STRIP (BOTT) 84A CB7 TO GFCI 1 (BRASS)
42H S3 (7) TO PLG30 (1) 85A CB8 TO GFCI 2 (BRASS)
42I GND (TOP) TO GND (BOT) 86A EXCITER STATOR TO PLG99 (3)
42J PLG6 (H3) TO TE2 (A/B) 86B RC99 (3) TO SR3 (AC)
42K RC30 (1) TO TE2 (A/B) 87 PC6−87 TO CB7
42L PLG5 (2) TO TE2 (A/B) 87A PLG11 (E1) TO SR3 (+)
42M GND STRIP (BOTT) TO BASE RAIL 88A PLG11 (C1) TO SR3 (−)
42M PLG25 (2) TO TE2 (A/B) 89A STATOR TO EXIT
42N PLG25 (8) TO TE2 (A/B) 89B NEUTRAL STUD TO RC5 (WHITE)
42O RC98 (9) TO TE2 (A/B) 90A EXCITER STATOR TO TE1 (C−LEFT)
42Q BRUSH (FRONT) TO R3 90B TE1 (C−RIGHT) TO CB6 (TOP−LEFT)
42Q PLG26 (J1) TO EXIT 91A EXCITER STATOR TO TE1 (B−LEFT)
91B TE1 (B−RIGHT) TO NEUTRAL STUD 165A PLG6 (C2) TO PLG2 (1)
91C GFCI 1 (SILVER) TO GFCI 2 (SILVER) 165B CB15 TO D10 (CATHODE)
91D GFCI 2 (SILVER) TO NEUTRAL STUD 166A PLG6 (B2) TO PLG2 (2)
92A EXCITER STATOR TO TE1 (A−LEFT) 167A PLG6 (A2) TO PLG2 (3)
92B TE1 (A−RIGHT) TO CB6 (TOP−RIGHT) 168A S11 AIR PRESSURE LOCKOUT TO S12 (SWITCH)
93A STATOR TO EXIT 168B S12 (SWITCH) TO CR10 (6)
96A CB6 (LEFT−LINE) TO RC2 (TOP−LEFT) 169A S11 AIR PRESSURE LOCKOUT TO S10 (3)
96B CB6 (LEFT−LINE) TO RC1 (TOP−LEFT) 170A PLG6 (D3) TO PLG9 (1)
96C CB6 (LEFT−LINE) TO CB7 171A PLG6 (A3) TO PLG9 (2)
97A CB6 (RIGHT−LINE) TO RC2 (BOTTOM−RIGHT) 172A TIMER (BLACK) TO CR15 (6)
97B CB6 (RIGHT−LINE) TO RC1 (BOTTOM−RIGHT) 72A PLG7 (A3) TO PLG9 (3)
97C CB6 (RIGHT−LINE) TO CB8 175A CB15 TO CR10 (7)
98A STATOR TO EXIT 181A PLG6 (G1) TO S5 (POLE)
99A STATOR TO EXIT 181B PLG26 (G1) TO S5 (POLE)
100A EXCITER STATOR TO PLG98 (1) 182A PLG26 (H1) TO EXIT
100B F1 TO RC98 (1) 183A PLG6 (E1) TO RC30 (6)
101A EXCITER STATOR TO RC98 (2) 183B PLG26 (E1) TO RC30 (7)
101B RC98 (2) TO SR2 (AC) 183C S3 (8) TO PLG30 (6)
102A R3 TO PLG98 (3) 183D S3 (8) TO PLG30 (7)
102B RC98 (3) TO C6 (−) 190A PLG6 (A1) TO PLG5 (3)
102C SR2 (−) TO C6 (−) 190B PLG5 (5) TO PLG25 (3)
103A EXCITER STATOR TO R8 190D PLG25 (5) TO PLG26 (A1)
104A EXCITER STATOR TO PLG98 (5) 191A PLG6 (C1) TO PLG5 (4)
104B F2 TO RC98 (5) 191B PLG5 (6) TO PLG25 (4)
105A BRUSH (CENTER) TO PLG98 (6) 191D PLG25 (6) TO PLG26 (C1)
105B RC98 (6) TO C6 (+) 200A SPLICE TO PLG100 (9)
105C SR2 (+) TO C6 (+) 0200B SPLICE TO PLG105 (1)
105D SR1 (+) TO SR2 (+) 201A SPLICE TO PLG100 (8)
105E SR4 (+) TO SR1 (+) 201B SPLICE TO PLG105 (2)
106A F1 TO SR2 (AC) 202A PLG104 (1) TO PLG100 (12)
107A SR4 (AC) TO F2 203A PLG104 (2) TO PLG100 (13)
108A BRUSH (REAR) TO PLG98 (7) 204A PLG103 (5) TO PLG100 (18)
108B RC98 (7) TO SR4 (−) 205A PLG103 (4) TO PLG100 (19)
110A CB4 TO SR1 (AC) 206A PLG103 (3) TO PLG100 (17)
111A CB4 TO CB3 207A PLG103 (2) TO PLG100 (15) (TWISWTED PAIR WITH
111B CB3 TO CR5 (2) 208A)
112A R8 TO PLG98 (4) 208A PLG103 (1) TO PLG100 (14) (TWISTED PAIR WITH 207A)
112B SR4 (AC) TO RC98 (4) 209A PLG106 (1) TO PLG100 (22)
120A PLG11 (C2) TO PLG10 (4) 210A PLG106 (2) TO PLG100 (21)
121A PLG11 (F2) TO PLG20 (4) 211A PLG106 (3) TO PLG100 (20)
122A PLG11 (D3) TO PLG10 (3) 212A CB10 (BATT) TO STARTER
123A PLG11 (D2) TO PLG20 (3) 212B CB10 TO CB16
124A PLG11 (E2) TO PLG10 (2) 212C STARTER TO ALT
125A PLG11 (F1) TO PLG20 (2) 220A PLG211 (C2) TO PLG210 (4)
126A PLG11 (E3) TO PLG10 (1) 221A PLG211 (F2) TO PLG220 (4)
127A PLG11 (F3) TO PLG20 (1) 222A PLG211 (D3) TO PLG210 (3)
130A PLG11 (A2) TO PLG20 (5) 224A PLG211 (E2) TO PLG210 (2)
131A PLG11 (A1) TO PLG20 (6) 225A PLG211 (F1) TO PLG220 (2)
132 PC6−132 − CB8 226A PLG211 (E3) TO PLG210 (1)
133A PLG11 (B1) TO PLG10 (6) 227A PLG211 (F3) TO PLG220 (1)
134A PLG11 (B3) TO PLG10 (7) 229A PLG211 (A3) TO PLG220 (7)
135 PC6−135 TO RC2−6 230A PLG211 (A2) TO PLG220 (5)
135A PC6−135A TO RC13 (1) 231A PLG211 (A1) TO PLG220 (6)
135A PLG6 (G2) TO PLG8 (6) 233A PLG211 (B1) TO PLG210 (6)
136A PC6−136A TO RC13 (3) 235A PLG26 (G2) TO PLG28 (6)
136A PLG6 (J3) TO PLG8 (8) 236A PLG26 (J3) TO PLG28 (8)
137 PC6−137 TO RC2−9 237A PLG26 (H2) TO PLG28 (9)
137A PLG6 (H2) TO PLG8 (9) 240A PLG27 (F3) TO TE2
140 PC6−140 TO RC2−10 240B PLG28 (10) TO TE2
140A PLG7 (F3) TO PLG8 (10) 240C PLG7 (E2) TO TE2
141 PC6−141 TO RC2−4 241A PLG26 (F2) TO PLG28 (4)
141A PLG6 (F2) TO PLG8 (4) 243A PLG211 (B2) TO PLG210 (5)
143A PLG11 (B2) TO PLG10 (5) 250A PLG27 (B3) TO PLG28 (7)
148 PC6−148 TO RC2−2 260A PLG27 (B1) TO RC23 (6)
148A PC6−148A TO RC13 (2) 261A PLG27 (A1) TO RC23 (5)
150 PC6−150 TO RC2−7 262A PLG26 (K1) TO RC23 (4)
150A PLG7 (B3) TO PLG8 (7) 265A PLG26 (C2) TO PLG22 (1)
160A PLG7 (B1) TO RC3 (6) 266A PLG26 (B2) TO PLG22 (2)
161A PLG7 (A1) TO RC3 (5) 267A PLG26 (A2) TO PLG22 (3)
162A PLG6 (K1) TO RC3 (4) 270A PLG26 (D3) TO PLG29 (1)
163A TE3 TO HAT SWITCH (S12) 271A PLG26 (A3) TO PLG29 (2)
163B TE3 TO CR10 (A) 272A PLG27 (A3) TO PLG29 (3)
163D TE3 TO CR15 (2) 274A PLG27 (C3) TO PLG17 (CR24)(86)
164A S10 (5) TO S10 (2) 282A EXCITER STATOR TO PLG99 (4)
164B CR10 (9) TO S10 (5) 282A RC99 (4) TO SR23 (AC)
165A D10 (CATHODE) TO COMPRESSOR (CLUTCH) 283A EXCITER STATOR TO PLG99 (5)
283A PLG211 (D1) TO RC99 (5) 311A CB14 TO CR14 (30)
286A EXCITER STATOR TO PLG99 (6) 311B CR14 (30) TO CR15 (4)
286A RC99 (6) TO SR23 (AC) 435A PLG101 (12) TO R6 (TWISTED PAIR WITH 436A)
287A PLG211 (E1) TO SR23 (+) 435B R6 TO PLG4 (2) (TWISTED PAIR WITH 436B)
288A PLG211 (C1) TO SR23 (−) 435C R6 TO PLG102 (H) (TWISTED PAIR WITH 436C)
300A CB1 (TOP−LEFT) TO RC5 (X) 436A PLG101 (13) TO R6 (TWISTED PAIR WITH 435A)
300B CB1 (TOP−LEFT) TO RC4 (X) 436B R6 TO PLG4 (3) (TWISTED PAIR WITH 435B)
301A CB1 (TOP−CENTER) TO RC5 (Y) 436C R6 TO PLG102 (G) (TWISTED PAIR WITH 435C)
301B CB1 (TOP−CENTER) TO RC4 (Y)
302A CB1 (TOP−RIGHT) TO RC4 (Z)
SECTION 14 − TORQUE SPECIFICATIONS
14-1. Torque Specifications
All tolerances +10% unless specified.

267 602-C
Part Description Qty. Where Used Torque

No. Required
Engine
183915 Screw,M10−1.5X100 Hex Hd−Pln 8.8 Pld) 1 Fan/Alt Bkt To Engine 30 ft lb

208423 Screw,M 8−1.25X 100 Hex Hd−Pln 8.8 Full Thd Din933 1 Fan/Alt Bkt To Engine 20 ft lb
208422 Screw,M 8−1.25X 90 Hex Hd−Pln 8.8 Full Thd Din933 1 Fan/Alt Bkt To Engine 20 ft lb
198447 Screw,M10−1.5X 20 Hex Hd−Pln 8.8 Pln 1 Idler Pulley To Engine 30 ft lb
605579 Screw,M 8−1.2X 20 Hex Hd−Pln 8.8 Pld 1 Alternator Tension Bkt To Fan/Alt Bkt 20 ft lb
208421 Screw,M20−2.5X110 Soc Hd Cap Din 912 12.9 Pln 1 Fan Pulley To Bkt 100 ft lb
605579 Screw,M 8−1.2X 20 Hex Hd−Pln 8.8 Pld 4 Fan Blade To Water Pump Pulley 20 ft lb
172555 Screw,M10−1.5X 50 Hex Hd−Pln 8.8 Pld 4 Crankshaft Pulley To Engine 30 ft lb
208426 Screw,M12−1.75X 45 12Pt Flange Screw 12.9 1 Muffler Bkt To Comp Bkt 60 ft lbs
208497 Nut,M08−1.2 13 mmhex 8.3 mm T Stl Pld Sem Con Washer 3 Muffler To Turbo 20 ft lb
070008 Screw,M14−2.0X 30 Hex Hd−Pln 8.8 Pln 4 Engine Mounts To Engine 100 ft lb
232889 Screw,312−18X .50 Hexwhd.66D Stl Tap−R W/Ann Ring 5 Starter Hole Covers To Barrel 15 ft lb
223287 Screw,M 6−1.0X 16 Pan Hd−Torx Slffmg 1 Mag Pickup To Bkt 69 in lb
199849 Screw,625−11X4.00 Hex Hd−Pln Gr5 Pld 2 Engine Mounts To Base (Left & Right) 100 ft lb
198447 Screw,M10−1.5X 20 Hex Hd−Pln 8.8 Pln 1 Grnd Cable To Engine 30 ft lbs
602154 Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw 5 Air Cleaner Bkt To Weld Control Bkt 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 3 Control Boxes To Frame 85 in lb
108941 Screw,250−20X1.00 Hexwhd.61D Gr5 Pld 4 Engine Ecu To Bkt 85 in lb
080389 Screw,312−18X1.00 Hexwhd.66D Stl Pld Slffmg Tap−Rw 11 Engine Oil Cooler To Rear Upright And 15 ft lb
Shroud
080389 Screw,312−18X1.00 Hexwhd.66D Stl Pld Slffmg Tap−Rw 5 Fan Shroud To Cooler 15 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Cushion Clamp For Left Side Engine Oil 85 in lb
Tube
604534 Screw,312−18X1.25 Hex Hd−Pln Gr5 Pld 2 Air Cleaner To Air Cleaner Bkt 15 ft lb
210821 Screw,M10−1.5X 60 Soc Hd−Pln 8.8 Pld 1 Belt Tensioner 35 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 4 Fan Guard To Fan Shroud (Left And Right) 15 ft lb
Fuel
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Top Fuel Tank Bkt 10 ft lb
602154 Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Rear Fuel Tank Bkt 10 ft lb
108941 Screw,250−20X1.00 Hexwhd.61D Gr5 Pld 1 Fuel Line Clamp To Engine Adapter 85 in lb
601948 Screw,312−18X1.00 Hex Hd−Pln Gr5 Pld 2 Base,Fuel Filter Assy To Bkt 15 ft lb
Frame
179635 Screw,250−20X .1.00 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Ground Wires On Left Engine Mount Tower 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Cush Clamp, Right Eng Mt Tower 85 in lb
(+ Bat Cable)
232889 Screw,312−18X .50 Hexwhd.66D Stl Tap−R W/Ann Ring 2 Hose Bkt To Base 10 ft lb
232889 Screw,312−18X .50 Hexwhd.66D Stl Tap−R W/Ann Ring 4 Hole Cover,Base To Base 10 ft lb
199849 Screw,625−11X4.00 Hex Hd−Pln Gr5 Pld 2 Generator Mounts To Base 100 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 8 Stab Bkt To Base 10 ft lb
004454 Screw,625−11X1.00 Hex Hd−Pln Gr5 Pld 4 Center Upright To Base 140 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Switch Bkt To Base 85 in lb
602085 Screw,008−32X .75 Hexwhd.34D Stl Pld Slffmg Tap−Rw 1 Switch Bkt To Base 30 in lb
191914 Screw,375−16X1.00 Hexwhd.66D Stl Pld Slffmg 6 Front Upright To Base 30 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 4 Braces To Front & Center Uprights 15 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 4 Box Cover To Front Upright 10 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 4 Front Top Cover To Front Upright 85 in lb
No. Required
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Ground Wires On Right Frame 85 in lb
134711 Nut, 312−18 .50Hex .28H Stl Pld Ser Flange .68D 2 Battery Bracket To Base 10 ft lb
191914 Screw,375−16X1.00 Hexwhd.66D Stl Pld Slffmg 6 Rear Upright To Base 30 ft lb
191914 Screw,375−16X1.00 Hexwhd.66D Stl Pld Slffmg 8 Mounting Bkt To Base 30 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 3 Battery Access Door 15 ft lb
172684 Nut, 312−18 .50Hex .27H Stl Pld Sem Cone Wshr.76D 2 Battery Bracket To Base 10 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 6 Front Control Panel To Front Upright 85 in lb
Weld
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 8 Stab To Bkt 10 ft lb
602154 Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw 4 Resistors To Base 85 in lb
108940 Screw,250−20X .75 Hexwhd.61D Gr5 Pld 2 Leads To Stabilizer 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 3 Pan To Rails 85 in lb
136420 Screw,008−32X .37 Hexwhd.34D Stl Pld Slffmg Tap−Rw 2 Resistor To Pan 30 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 4 Bottom Weld Module To Pan 85 in lb
044710 Screw,250−20X3.25 Hex Hd−Pln Stl Pld 4 Bottom Vault To Pan 85 in lb
602085 Screw,008−32X .75 Hexwhd.34D Stl Pld Slffmg Tap−Rw 2 Hd1/Hd2 To Pan/Vault Bkt 30 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Rectifier Bkt To Pan 85 in lb
217283 Bolt,Crg Stl .250−20 X .750 Gr5 Pld 3 Leads To Bottom Cap Ckt 85 in lb
129351 Screw,008−32X .50 Hexwhd.34D W/Spl Gndrng Stl Pld 2 Resistor Vault Bkt 30 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 5 Vault Bkt To Pan/Bottom Weld Module 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 3 Rectifier Bkt To Vault Bkt 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 4 Top Weld Module To Pan 85 in lb
602085 Screw,008−32X .75 Hexwhd.34D Stl Pld Slffmg Tap−Rw 2 Hd1/Hd2 To Pan/Vault Bkt 30 in lb
217283 Bolt,Crg Stl .250−20 X .750 Gr5 Pld 3 Leads To Top Cap Ckt 85 in lb
044710 Screw,250−20X3.25 Hex Hd−Pln Stl Pld 4 Top Vault To Vault Bkt 85 in lb
108940 Screw,250−20X .75 Hexwhd.61D Gr5 Pld 2 Leads To Stabilizer 85 in lb
602154 Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Control Box Assembly (Engine To Weld) 85 in lb
129351 Screw,008−32X .50 Hexwhd.34D W/Spl Gndrng Stl Pld 2 Control Box Assembly (Engine To Weld) 30 in lb
Case
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 4 Weld Output Panel To Front Upright 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 6 Weld Control Panel To Front Upright 85 in lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 14 Side Panels To Base 15 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 3 Support Brace To Top Cover 15 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 2 Latch Bkt To Top Cover 15 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Latch Catch To Latch Bkt 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 12 Supports To Lift Off Door 85 in lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Latch To Lift Off Door 85 in lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 5 Top Cover To Uprights 15 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 15 Panels To Uprights And Top Cover 15 ft lb
Generator
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 6 Air Baffle To Barrel 15 ft lb
132053 Screw,375−16X1.50 Hex Hd−Pln Gr5 Pld Blk 6 Endbell To Barrel 30 ft lb
049026 Screw,M10−1.5X 25 Hex Hd−Pln 8.8 Pln 4 Rotor To Engine 30 ft lb
172555 Screw,M10−1.5X 50 Hex Hd−Pln 8.8 Pld 6 Barrel To Engine Adapter 30 ft lb
604534 Screw,312−18X1.25 Hex Hd−Pln Gr5 Pld 2 Brushholder To Endbell 12 ft lb
232889 Screw,312−18X .50 Hexwhd.66D Stl Tap−R W/Ann Ring 1 Grd Strap To Endbell 15 ft lb
Aux Grp
602154 Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Term Blk Assy To Frame 85 in lb
Compressor
208422 Screw,M 8−1.25X 90 Hex Hd−Pln 8.8 Full Thd Din933 2 Compressor/Muffler Bracket To Engine 20 ft lb
208423 Screw,M 8−1.25X 100 Hex Hd−Pln 8.8 Full Thd Din933 1 Muffler To Compressor/Muffler Bracket 20 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 2 Filter Bkt To Base 85 in lb
No. Required
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 1 Filter Bkt To Base 15 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 4 Air Tank To Base 15 ft lb
198447 Screw,M10−1.5X 20 Hex Hd−Pln 8.8 Pln 2 Compressor Filter To Filter Bkt 30 ft lbs
605579 Screw,M 8−1.2X 20 Hex Hd−Pln 8.8 Pld 1 Comp Rear Bkt To Engine 20 ft lb
192686 Screw,M 8−1.25X 25 Hex Hd−Pln 8.8 Pld Din933 1 Fuel/Comp Brkt To Engine 20 ft lb
602159 Screw,312−18X .75 Hexwhd.66D Stl Pld Slffmg Tap−Rw 4 Box,Valve Ball To Front Upright 10 ft lb
604224 Screw,250−20X .75 Hexwhd.50D Stl Pld Slffmg Tap−Rw 1 Air Tube To Weld Control Brace 85 in lb
192686 Screw,M 8−1.25X 25 Hex Hd−Pln 8.8 Pld Din933 4 Inlet Valve To Comp 20 ft lb
218558 Screw,M 8−1.2X 50 Hex Hd−Pln 8.8 Pld 4 Manifold To Comp 20 ft lb
080389 Screw,312−18X1.00 Hexwhd.66D Stl Pld Slffmg Tap−Rw 2 Bkt To Fan Shroud 15 ft lb
220439 Stud,Stl 12 mm−1.75 X 80 mm Pld Full Thrd 2 Compressor To Compressor Bkt 60 ft lbs
208424 Screw,M 6−1.0X 90 Soc Hd−Hex Pln 12.9 Din 912 2 Comp Rear Bkt To Comp 12 ft lb
044772 Screw,M12−1.75X 30 Hex Hd−Pln 8.8 Pln 1 Compressor To Compressor Bkt 80 ft lbs
044772 Screw,M12−1.75X 30 Hex Hd−Pln 8.8 Pln 4 Plate,Mtg Compressor To Alternerator Bkt 80 ft lbs
604535 Screw,312−18X1.50 Hex Hd−Pln Gr5 Pld 2 Air Cleaner To Comp Bkt 15 ft lb
Misc.
Rectifi- Rectifier Nuts 6 Rectifiers To Brkt 10 ft lb

er
Deutz Long Alternator Bolt (Reuse) 1 Alternator 20 ft lb
Deutz Short Alternator Bolt (Reuse) 1 Alternator 20 ft lb
173336 Ftg,Adapter Oil Drain 1 Engine Oil Drain Connection To Oil Pan 50 ft lb
267180 Clamp,Hose .500 − .906 Clp Dia W/Sst Screw 2 Fuel Line Clamps (1/2in. Line) 40 in lb
209635 Hose,Tubing Oil Assy W/Fittings 42.360Lg 1 Tube To Valve Box Only 80 ft lb
239507 Hose,Tubing Oil Assy W/Fittings 22.380Lg 1 Connection To Engine Only 80 ft lb
209762 Ftg,Pipe Stl Elbow Adapter 90Dg 3/4 Sae−Jic− 1 Connect To Engine Cooler 80 ft lb
209623 Ftg,Stl Adapter Long 3/4 Sae−3/4 Jic 1 Connect To Engine Cooler 80 ft lb
209764 Ftg,Pipe Stl Tee Branch Sae−12 X Jic−12 1 Connect To Engine Cooler 80 ft lb
209756 Ftg,Pipe Stl Elbow M 90Dg 1/2 Jic X 3/4 Sae 1 Connect To Engine Cooler 80 ft lb
210251 Ftg,Stl Swivel Straight Thread Conn 3/4 O−Ring 2 Connect To Engine Cooler 80 ft lb
209825 Ftg,Stl Adapter Swivel 12M X Jic−12 F 1 Connect To Engine Cooler 80 ft lb
210250 Hose Assy,Oil W/Fittings 3/4 X 15.500 Lg 1 Connect To Engine Cooler 80 ft lb
209633 Hose,Tubing Oil Assy W/Fittings 20.000Lg 1 To Radiator Assembly 80 ft lb
1 Use Loctite 242 (Miller Part No. 009 425).
SECTION 15 − ENGINE INFORMATION DISPLAY
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
15-1. Display Layout And Controls

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

1 pause Engine Control switch in
Run or Run/Idle position for
several seconds. The engine
controller initiation sequence
must occur. If glow plugs are on
4 5
(automatically determined by
ambient temperature), also
wait until the initial Wait to Start
3 2 message on the display is
cleared (see Section 15-4).
Function buttons are used to navi-
gate through menus, increment/
decrement, and select (see Section
15-2).
The yellow LED lights as part of se-
quences used to alert the operator
to errors or conditions that will affect
operation, such as low fuel.
The red LED lights as part of a shut-
down sequence, such as when fuel
is too low or oil pressure is too low
to continue operation without dam-
aging the engine.
MurphyDisplay 2014−03 / 258 833-D
15-2. Function Buttons
Function Button Previous Next Menu/Cancel View Enter/Diagnostic

6-Up Display None None Menu Go to 1-Up Engine Diagnostics
1-Up Display Previous Next Menu Go to 6-Up Engine Diagnostics
15-3. RPM Signal Failed Display
1 RPM Signal Failed Display
If the operator places the Engine
Control switch in the Run/Idle or
Run position and does not start the
engine, a timer starts. If this condi-
tion exists for 5 minutes or longer,
the RPM signal failed message ap-
1 pears. Place Engine Control switch
in Off position to reset.
RPM SIGNAL FAILED
Hide
15-4. Service Reminder Screen
Wait to Start/Preheating 2
1
Service Reminder Remaining Service Reminder Remaining

Engine Oil 0 Engine Oil 480
Compressor Oil 0 Compressor Oil 495
Glow plugs turn on automatically as de- switch position while the engine controller
goes through the preheat sequence. Once
a few seconds. It can also be found as a
1-up screen (see Section 15-7).
termined by ambient temperature.
this message clears, the engine can be The 6-Up Display then appears as the de-
Compressor oil information appears
only on models with air compressor. started. fault. The engine can be started when the
1 Wait to Start/Preheating Display 2 Service Reminder Display 6-Up Display appears.
The Wait to Start display appears when the The Service Reminder display shows ser- If the Enter/Diagnostic function button is
Engine Control switch is in the Run or Run/ vicing intervals in hours counting down pressed while in this display, the DM2 dia-
Idle position and glow plugs are functioning. from engine manufacturer recommended gnostic screen appears. (see Section
The operator needs to pause at either service intervals. This display appears for 15-11).
15-5. 6-Up Display
1
0 PSI 0.0 H 0 PSI 0.0 H
9
3
32 F 0% 32 F 0%
8
4
0 RPM 0 VDC 0 PSI 0 VDC

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

1 View Function Button
From 6-Up Display, press the
View function button to go to 1-Up
Display.
2 1-Up Oil Pressure Display
0 PSI 0.0 H 45 60 To increment to the next display,
press the Next function button. To
30 75 return to the 6-Up Display, press
0%
32 F
15 90 the View function button.
0 105
0 RPM 0 VDC
0 PSI
n/min
2
Oil Pressure
15-7. 1-Up Displays
1 1-Up Machine Hours Display
To increment to the next display,
return to previous display, press
1 the Previous function button. To
return to the 6-Up Display, press
the View function button.
0H
Machine Hours
15 18
12
9
125 6
100 150 3
75
50
175
200 0 0V
25 225
250 Battery Potential
0F
Coolant Temperature
125
100
75
100 50
75 25
50 0 0%
25 Percent Load@RPM
0 0%
Fuel Level
Engine Oil
1000 1500
500 2000
0H
n/min
2500 Service Reminders

0 RPM
Engine Speed
15-8. 1-Up Compressor Displays (Models With Compressor Only)
1 Air Compressor Pressure
1-Up Display
To increment to the next display,
1 return to previous display, press the
Previous function button. To return
to the 6-Up Display, press the View
function button.
80 120
Air Pressure display does not
40 160 appear if the air pressure input
is less than 50 PSI.
200
0 PSI
Air Pressure
0H
Compressor Oil Compressor Hours
0H
Engine Oil
0H
Service Reminders
15-9. Fuel Level Warnings
Fuel level warnings are generat-
ed by sensors at the fuel tank. All
engine warnings that are dis-
played are generated by the en-
gine controller (see Sections
0 PSI 0.0 H 15-10 and 15-11).
1 6-Up Display
2 1-Up Fuel Level Display
1 3 Low Fuel Warning
32 F 0% The low fuel warning indicator ap-

pears and begins to flash when fuel
level reaches 10%. It continues to
flash until fuel level falls to 0%.
4 Yellow LED
0 RPM 0 VDC The yellow LED begins to flash when
the low fuel warning appears. It con-
tinues to flash until 0% is reached.
5 Red LED
The red LED turns on and stays lit
when fuel level reaches 0%. The en-
gine will shut down.
6 No Fuel Display
This display appears at engine shut-
down. Turn Engine Control switch to
3 Off, refuel, and restart.
100
2
75
50
25
0
Fuel Level
4 5
NO FUEL
Hide
15-10. Warning or Shutdown Display
1 Oil Pressure Display
2 Fault Warning Indicator
The warning symbol appears on the
display when an engine condition
approaches a shutdown condition.
45 60 3 Fault Shutdown Indicator
30 75 The shutdown symbol appears on
the display when a severe engine
1 15 90 2 fault can cause shutdown.
3
105 The 6-up or 1-up screen with fault
0 PSI indicator is shown briefly and
automatically advances to the
fault display.
Oil Pressure 4 Fault Display
5 Level Of Fault
6 Indicates Number Of Faults
7 Suspect Parameter Number
8 Failure Mode Identifier
The SPN and FMI numbers are
generated by the engine controller
according to the J1939 standard.
4
Typical faults are listed in
Table 15-1.
5 9 Diagnostic Description
6
10 Occurrence Count
For non−critical faults, the number
0 of 0 Warning of occurrences can accumulate
8
7 11 Previous Function Button
SPN: 0 FMI 0
12 Next Function Button
9 13 Hide Function Button
Dm1. DiagnosticString
Non−critical faults can be hidden.
14 Acknowledge Function Button
To acknowledge the fault and ad-
10 vance the display to the 1-up or
OC: 0 6-up display, press the Ack function
button and then the Hide function
button.
Prev Next Hide Ack The condition that caused the

warning or shutdown must be
remedied before operation can
11 14 continue.
12 13
1 of 1 Warning
SPN: 100 FMI 1

Low oil pressure warning threshold
exceeded
OC: 1
Prev Next Hide Ack
Table 15-1. Fault Descriptions
This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized
Service Agent.
SPN FMI Description of Fault
Tier 3 or Tier 4 Interim Engines
100 2 Low oil pressure; warning threshold exceeded
110 2 High coolant temperature; warning threshold exceeded
Tier 4 Final Engines
94 1 Low fuel pressure; warning threshold exceeded
100 1 Low oil pressure; warning threshold exceeded
110 0 High coolant temperature; warning threshold exceeded
111 1 Coolant level too low
168 2 High battery voltage; warning threshold exceeded
174 0 High low fuel temperature; warning threshold exceeded
175 0 High oil temperature; warning threshold exceeded
15-11. Engine Diagnostic Display

Engine diagnostic codes are
for use by the engine Factory
Authorized Service Agent only.
Attempting engine repair may
1 void engine warranty.
2
1 Diagnostic Display
2 Indicates Number Of Faults
0 of 0 Engine Diagnostics
4 3 Suspect Parameter Number
3 4 Failure Mode Identifier
SPN: 0 FMI 0
The SPN and FMI numbers are
5 generated by the engine controller
Dm2. DiagnosticString according to the J1939 standard.
5 Diagnostic Description
6 Requesting/Ok
6 7 Requesting appears on the display
Ok OC: 0 as the display communicates with
the engine controller. Once all diag-
nostic codes are available, Ok ap-
Get pears on the display.
Prev Next Hide Faults 7 Occurrence Count
For non−critical faults, the num-
8 11 ber of occurrences of each fault
can accumulate.
8 Previous Function Button
9 Next Function Button
9 10 10 Hide Function Button
Non−critical faults can be hidden.
11 Get Faults Function Button
15-12. Main Menu Access Code
1 Access Code Display
An access code is required to gain
access to the main menu. This dis-
play appears whenever the Menu/
Cancel function button is pressed
while in the 1-Up or 6-Up display
1 ENTER PASSWORD 2 Access Code (Password)
The factory set access code is
2 1000. This access code is not pro-
grammable and cannot be
0000 changed.
3 Increase Number Function
Button
4 Go to Next Number Function
Button
Use the increase function button to
increase the value underlined. Use
4
the > function button to move to the
+ > Cancel Enter next digit.
3 5
5 Cancel Function Button
6 6 Enter Function Button
15-13. Main Menu Options − Resetting Hours At Oil Change

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

Engine Oil 500 0
Compressor Oil 1000 490
Modify Reset Cancel

6
15-14. Main Menu Options: Brightness, Contrast, And Units
1 Main Menu
2 Cursor
2 Use scroll function buttons to move
1 cursor.
4 Select Function Button
When the cursor is in desired posi-
Brightness 0% tion, press Select function button to
go to sub-menu.
Contrast 0
5 Brightness Menu Display
Units English Use scroll function buttons to in-
Reminders crease or decrease display
brightness. When desired per-
OEM centage is reached, press Select
function button.
Version
6 Contrast Menu Display
Stored Codes Use scroll function buttons to in-
Language English crease or decrease display con-
trast (lightness/darkness). Con-
4 trast range is 0 to 175. Viewing
angle affects appearance of dis-
play. When desired contrast is
reached, press Select function
button.
7 Units Menu Display
Use scroll function buttons to scroll
through choices:
3 English (PSI, F)
5
Bar (Bar, C)
Kpa (Kpa, C)
Brightness 0%
When desired units configuration
is reached, press Select function
button.
Contrast 0 7
Units English
15-15. Main Menu Options − Reminders
1 Main Menu
2 Cursor
Use scroll function buttons to move
1 2 cursor.
4 Select Function Button
tion, press Select function button to
Brightness 0% go to sub-menu.
Contrast 0 5 Service Reminders Display
Units English Move cursor to select engine or
compressor and press Select func-
Reminders tion button. The appropriate
Change Oil display appears.
OEM
6 Reset Function Button
Version
Press the Reset function button to
Stored Codes reset Remaining Hours after chan-
ging oil.
Language English
7 Modify Function Button
4 NOTICE − The service interval can
be modified. Shorter service inter-
vals may be appropriate during
heavy use or in certain environ-
ments (such as dusty or extreme
temperatures). Lengthening ser-
vice intervals is not recommended
and could result in voiding engine
5 warranty.
3
8 Increase Number Function
Button
9 Go to Next Number Function
Button
Service Reminder IntervalRemaining Use the increase function button to
Engine Oil 500 0 increase the value underlined. Use
the > function button to move to the
Compressor Oil 1000 490 next digit.
10 Cancel Function Button
11 Enter Function Button
Change Engine Oil
Change Engine Oil

000000H
+ > Cancel Enter 11

8
Modify Reset Cancel

6
7
9 10
15-16. Main Menu Options − OEM, Version, Stored Codes, And Language
1 Main Menu
2 Cursor
Use scroll function buttons to move
cursor.
1 2 4 Select Function Button
tion, press Select function button to
go to sub-menu.
Brightness 0% 5 OEM Menu Option
Contrast 0 This menu option is for Factory Au-
thorized Service Agents only and is
Units English password protected.
Reminders 6 Version Menu Display
OEM The information in this display may
5 be requested by a Factory Author-
Version ized Service Agent during
troubleshooting.
Stored Codes
7 Stored Codes
7 Language English
Stored codes can also be accessed
4 when the initial Service Reminder
8 display appears as the engine con-
troller is initiating (see Sections
15-4 and 15-11).
8 Language Menu Display
Use scroll function buttons to
scroll through choices: English,
French, Italian, Spanish, and
3 Brazilian Portuguese. When de-
sired language is reached, press
Select function button.
Configuration 0.0.0.0
Bootloader 00.00. 00.00
Firmware 00.00. 00.00
Part Number XX−XX−XXXX
Version
SECTION 16 − RUN-IN PROCEDURE
run_in2 2014−10
NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
16-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welder/Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
2
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.
1
16-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
1
+
3 6
S-0683 / S-0684
! Stop engine. Connect load bank or resistor grid to For Resistance Grid
! Do not touch hot exhaust pipe, en- generator Side A weld output terminals Set grid switches and then adjust gen-
gine parts, or load bank/grid. using proper size weld cables with correct erator A/V control so load equals rated
connectors. Observe correct polarity. voltage and current of the generator
! Keep exhaust and pipe away from
4 Resistance Grid (see nameplate, rating label, or the
flammables.
specifications section in this manual).
NOTICE − Do not perform run-in Use grid sized for generator rated output.
Check generator and meters after first five
procedure at less than 20 volts weld output Turn Off grid. minutes then every fifteen minutes to be
and do not exceed duty cycle or equipment sure generator is loaded properly.
damage may occur. 5 Voltmeter
NOTICE − Check oil level frequently during
1 Load Bank 6 Clamp-On Ammeter run-in; add oil if needed.
Turn all load bank switches Off. If needed, Connect voltmeter and ammeter as It is recommended to run the welder/gener-
connect load bank to 115 volts ac wall shown, if not provided on generator. ator for two hours minimum and up to four
receptacle or generator auxiliary power hours under load. Place A/V control in
receptacle. Start engine and run for several minutes. minimum position, then shut down load
2 Welder/Generator For Load Bank bank or grid to remove load. Run engine
Place Welder Selector switch in the A several minutes at no load.
Set load bank switches and then adjust
position (Single Operator) and rotate A/V ! Stop engine and let cool.
generator A/V control so load equals
control to minimum. Place Process Select- rated voltage and current of generator 7 Engine Exhaust Pipe
or switch in Stick position. (see nameplate, rating label, or the Repeat procedure if wetstacking is pres-
3 Weld Cables specifications section in this manual). ent.
TM-267 603A 2015−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Engine Driven Welder/Generator And

Air Compressor
)
Big Blue 800X / 800CA

Duo Air Pak
)

And Following
For OM-267 603 Revision A Thru D
File: Engine Drive
Visit our website at

www.MillerWelds.com
SECTION 17 − PARTS LIST
EFF W/SERIAL NO. ME200183E AND FOLLOWING
Hardware is common and not
available unless listed. 30
29
28
27
26
25
24
31
32
14
23 33
15
22
16
34
35
13 21
19
17 20
18
12
9
102
103
10
11
8
6
7
5 104
108
4 105
109 106
3
2 107
110
1
111
116 115 114 113 112
117 118
119
120
121
122
Figure 13-1. Main Assembly
Eff w/Serial No. ME200183E And Following
62
61 63
60
64
59
58
57
45 56
55
46 65
47 54
44 53 66
48
52 67
41 51
50
42 49
72 68
43
73 69
74 70
71
75
76
79 80
77 81
40
39 37 78
38 82
36
101
99
100
91
90 89
92 88
93
94 83
84
95
85
96
97 86
98 87
Ref. 907 634−3
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Weld Output Panel see Figure 13-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Power Panel see Figure 13-5 thru Figure 13-7 . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . Engine & Weld Control Front Panel see Figure 13-3 . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . TE1 . . . . 255682 . . Block, Term Assy Standard W/Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT1 . . . . 105370 . . Xfmr. Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 254117 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 209683 . . Label, Warning Safety Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . HD1, HD21 . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . 256487 . . Pan, Vault & Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 259039 . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . SR6, SR26 . 248933 . . Rectifier, Si 3ph 300 Amp 600 Piv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 260581 . . Panel, Generator Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . R10, R210 . 188067 . . Resistor, Ww Fxd 100 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 259533 . . Panel, Engine Extension Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . PC1, PC21 . 258544 . . Module, Main Control/Igbt Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . . . . . . . . . . Weld Output Module see Figure 13-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 256489 . . Bracket, Mtg Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 269943 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 218086 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 260961 . . Bracket, Mtg Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 209094 . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . +255669 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269515 . . Label, Warning Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . +266513 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 254678 . . Cap, Tank Screw-on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 269515 . . Label, Warning Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 206604 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 191354 . . Support, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 254108 . . Tank, Fuel (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 189912 . . . . Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189913 . . . . Fitting, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259499 . . Ftg, Stand Pipe Hose .500 X 9.265 Lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 084173 . . Clamp, Hose .460 - .545 Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 264196 . . . . Sender, Fuel Gauge Reed Switch 9in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189910 . . . . Fitting, Stand Pipe Hose .3125 X 9.260 Lg 90deg Zinc . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 254678 . . . . Cap, Tank Screw−On 3.500 In W/Vent W/Lanyard 8in . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 228054 . . . . Gasket, Fuel Sender/Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . Generator see Figure 13-8
. . . 37 . . . . . . . . . . . . . . 010862 . . Clamp, Hose 1.562 - 2.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 266520 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 023313 . . Clamp, Hose 1.312 - 3.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 265397 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 255768 . . Air Cleaner, Intake (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . *192938 . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine Lh Hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 267435 . . Engine, Deutz Dsl Elec Td2011l04 (T4i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259883 . . Heater,Block Engine 120v 530w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . . . . . . . . . . Compressor Assembly see Figure 13-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 266515 . . Muffler, Exhaust W/Manifold Deutz 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 206613 . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 602243 . . Washer, Flat .438idx1.000odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 218609 . . Belt, Micro V 21mm X 1485mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 207808 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 208024 . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 208042 . . Spacer, Stl .800 Id X 1.188 Od X .090 Thk . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 239507 . . Hose, Tubing Oil Assy W/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 240354 . . Ftg, Stl Adapter 3/4 Sae-3/4 Jic 45 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 267977 . . Guard, Fan Lh W/Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . +239503 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210229 . . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 239501 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 265398 . . Plate, Cover Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 260226 . . Extrusion, Rubber W/Adhesive .750 X .750 X 27.000 . . . . . . . . . . . . . . . . . 2
. . . 62 . . . . . . . . . . . . . . 254275 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 210229 . . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 239505 . . Guard, Fan Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 209623 . . Ftg, Stl Adapter Long 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 209633 . . Hose, Tubing Oil Assy W/Fittings 20.000lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 239515 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 8 Blade Suction . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley available from engine manufacturer . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 206800 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 208040 . . Tensioner, Belt W/Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 209611 . . Switch,Disc Battery 2p 6-36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 209612 . . Lever,Switch Lockout Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8-18nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 176529 . . . . Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xc Oil (Order By Ft) . . . . . . . . . . . . . . . . . . 2ft
. . . 79 . . . . . . . . . . . . . . 209093 . . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 209092 . . Bracket, Mtg Saftey Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 209090 . . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 82 . . . . . . . . . . . . . +259532 . . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 209667 . . Latch, Paddle w/ Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 210681 . . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 259402 . . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 260658 . . Label, Maintenance Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257145 . . Label, Suggested Arc Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 209059 . . Schematic, Air System (Big Blue Air Pak) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . . 206464 . . Label, Maintenance Big Blue Air Pak Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 86 . . . . . . . . . . . . . . 191626 . . Bumper, Door Access Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 87 . . . . . . . . . . . . . . 259406 . . Panel, Generator Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 257139 . . Fuel Line Assy, W/Clamps 11.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . *192744 . . Filter, Fuel Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 267764 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 239542 . . Bracket, Fuel Filter Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 93 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 2
. . . 94 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 96 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 97 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 2
. . . 98 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 2
. . . 99 . . . . . . . . . . . . . . 176528 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 173336 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 066298 . . Washer, Seal Oil Cu .722 Id X .937 Od X .056 T . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42.000 No 1 Awg W/Clamp & .400 Rng . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 260236 . . Cable, Bat Pos 24.000 No 1 Awg W/Clamp & .400 Rng . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 266385 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 106 . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 660 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . . . 264924 . . Bracket, Battery Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 109 . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 110 . . . . . . . . . . . . . . . . . . . . . . . Label, Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . . . . . . . . . . . . Control Box Assembly see Figure 13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . R3, R8 . . . 189699 . . Resistor,Ww Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . Z1, Z21 . . . 249772 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 115 . . . . . . . . . . . . . 248940 . . Bracket,Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 116 . . . . . . . . . . . . . 207096 . . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . . 265249 . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 259265 . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . . 259268 . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . . 259266 . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . . 265250 . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
♦OPTIONAL
*Recommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
Hardware is common and not available unless listed.
12
13
8
16
15
4 5
3 6 14
2 7
1
11
10
19
9
18
8
23
24 17
20
6
22
5
21
268 617
Figure 13-2. Control Box Assembly
Item Dia. Part

Figure 13-2. Control Box Assembly (Figure 13-1 Item 112)
. . . 1 . . . . . . . . . . . . . . 021385 .. Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 202209 .. Spacer, Nylon .805 Od X .510 Id X .220 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 258549 .. Label, VRD On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S5 . . . . . 028111 .. Switch, Tgl Dpst 20a 250v Spd Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 190323 .. Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 6 . CB2, CB3, CB4 . 139266 .. Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . . . . . . . . . . 258577 .. Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . TE2, TE3 . . 190210 .. Block, Term 5−3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 SR1−SR4,SR23 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 10 . CR4, CR24 . 173069 .. Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . CR10 . . . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 201078 .. Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB15 . . . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR8 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR5 . . . . 252053 .. Relay,Encl 12vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 C10/D10, C12/D12 189701 .. Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . R6 . . . . . 262019 .. Resistor Board, 120 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . CB10, CB16 . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 258582 .. Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 13-2. Control Box Assembly (Continued)
. . . 20 . . . . . . . . . . . . . . 223710 . . Relay, Encl 12vdc Dpst−No 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . C6 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 204737 . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 23 . . . F1−F2 . . . 256852 . . Holder, Fuse Mintr W/10a Slo−Blo Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . *085874 . . . . Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CR15 . . ♦172015 . . Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR14 . . ♦090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB14 . . ♦139266 . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 1
♦OPTIONAL
Hardware is common and 6

not available unless listed.
5
2
3
1
19
8
10
9
18 11
17
12
16
14 13
15 259 461
Figure 13-3. Panel, Front Engine & Weld Controls
Item Dia. Part
Figure 13-3. Panel, Front Engine & Weld Controls (Figure 13-1, Item 3)
. . . 1 . . . . . . . . . . . . . . 258833 . . Label, Nameplate Engine/Weld Control Airpak . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 258684 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . R1, R21 . . 246961 . . Switch, Rotary 8 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . . . 2
. . . 4 R2,R5,R22,R25 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . PC2, PC22 . 251527 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 258683 . . Enclosure, Dual Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . PC5, PC25 . 242263 . . Circuit Card Assy, Connector/Receptacle (R) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . CB9, CB29 . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .805 Od X .510 Id X .220 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S10 . . . . 206624 . . Switch, Tgl Sptt 6a 125vac (On)−On−(On)Spd Term . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . DISPLAY . . 256689 . . Display, Lcd Alphanumeric Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 218764 . . Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 242579 . . Screw, K40x 10 Pan Hd−Phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 134201 . . Stand−Off Support, Pc Card .312/.375w/Post&Lock .43 . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . 5

10
10 12
9
7
6 8
5
14
4
13
3
2
1
15
16
17 259 364
Figure 13-4. Panel, Weld Output
Item Dia. Part

Figure 13-4. Panel, Weld Output (Figure 13-1, Item 1)
. . . 1 . . . . . . . . . . . . . . 005107 . . Bolt, Crg Stl .250−20 X .750 Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 2 . . . . . . . . . . . . . . 108941 . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 6 . . . . . . . . . . . . . . 258836 . . Label, Output Panel W/Parallel Airpak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 258685 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . C4, 5, 24, 25 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . 108940 . . Screw, 250−20x .75 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . . . . . . . . . 152461 . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . . 14
. . . 13 . . . . . S3 . . . . . 259356 . . Switch, Paralleling W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . . . . . 602208 . . Washer, Tooth.256idx0.510odx.028t Stl Pld Ext.250 A . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 189445 . . Screw, 250−20x .50 Pan Hd−Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 230339 . . Switch Handle W/Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10
9
8
7
18
5 12
11
13
4
6
14
3
15
1 2
17
16
259 666
Figure 13-5. Panel, Auxiliary Power North America (Prior To ME260126E)
Item Dia. Part

Figure 13-5. Panel, Auxiliary Power (Figure 13-1, Item 2)
. . . 1 . . . . . . . . . . . . . . 209056 . . Cover,Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

. . . 2 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . RC5 . . . . 182954 . . Rcpt,Str 3p4w 50a 125/250v Flush Mtg *14-50 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 259528 . . Label, Auxillary Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 248894 . . Panel,Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . GFCI1, 2 . . 246614 . . Receptacle, GFCI 15/20a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . 025248 . . Stand-off,Insul .250-20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 214927 . . Boot,Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . C1−C2 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CB1 . . . . 214926 . . Supplementary Protector,Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . . 1
. . . 11 . . RC1, RC2 . . 147632 . . Receptacle, Tw Lk Grd 2p3w 30a 250v L6-30r . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . RC4 . . . . 254094 . . Rcpt,Str 3p4w 50a 250v Flush Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . CB7, CB8 . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 190861 . . Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB6 . . . . 201083 . . Supplementary Protector,Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 190323 . . Boot,Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 263778 . . Guard, Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7
17
11
14
4 10
5
3
16
12
8
15 6
13
1
9
18
264 277
Figure 13-6. Panel, Auxiliary Power North America (Eff w/ME260126E)
Item Dia. Part

Figure 13-6. Panel, Auxiliary Power North America (Figure 13-1, Item 2)
... 1 .............. 264275 .. Panel, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 264773 .. Label, Aux Power W/In Use Cover (Bw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 GFCI1−GFCI2 246614 .. Receptacle, Gfci 15/20a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . RC4 . . . . 254094 .. Rcpt, Str 3p4w 50a 250v Flush Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . RC1−RC2 . . 147632 .. Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . RC5 . . . . 182954 .. Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CB1 . . . . 214926 .. Supplementary Protector, Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . 1
... 8 . . CB7−CB8 . . 093996 .. Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 9 . . . . CB6 . . . . 201083 .. Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . 1
... 10 . . . C1−C2 . . . 217054 .. Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 11 .............. 214927 .. Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 201553 .. Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 209056 .. Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 14 .............. 207560 .. Insulator, Stand−Off With Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 197203 .. Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 190861 .. Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
... 17 .............. 263778 .. Guard, Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 .............. 263905 .. Cover, Receptacle Weatherproof Duplex Dual . . . . . . . . . . . . . . . . . . . . . . . 1
3
15 12
6
1 13
7
2
14
10 8
9
16
11
5
4
264 996
Figure 13-7. Panel, Auxiliary Power Export Deluxe
Item Dia. Part

Figure 13-7. Panel, Auxiliary Power Export Deluxe
... 1 .............. 264997 .. Panel, Aux Power (Ex) Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 264998 .. Label, Aux Power (Ex) Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 GFCI1−GFCI2 246614 .. Receptacle, Gfci 15/20a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . C1−C2 . . . 217054 .. Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . 2
. . . 4 . . RC1−RC2 . . 173555 .. Rcpt, Str 2p3w 16a 130v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . RC3−RC4 . . 176355 .. Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . CB7−CB8 . . 093996 .. Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . CB5 . . . . 266567 .. Supplementary Protector, Man Reset 2p 40a 240vac . . . . . . . . . . . . . . . . . 1
. . . 8 . . . ELCB1 . . . 222991 .. Circuit Breaker, Elcb 16a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 144844 .. Stand−Off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 209056 .. Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 11 . . . . RC5 . . . . 251972 .. Rcpt ,Str 4p5w 32a 400v 3ph Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . . 254884 .. Supplementary Protector, Man Reset 3p 30a 480vac . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 214927 .. Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 203016 .. Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 207560 .. Insulator, Stand−Off With Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 197203 .. Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hardware is common and 13 14

12
9 11
10
8
6
7
5 15
4 28
3 16
2 17
1
18
19
20
24 21
22
26 25
27 23 255 861 / Ref. 907 634−3
Figure 13-8. Generator

Item Dia. Part
Figure 13-8. Generator (Figure 13-1, Item 36)
. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−Pln Gr5 Pld Blk . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 264057 . . Endbell W/Exciter Stator (Includes) (Prior To XXXXXXXXX) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 270955 . . Endbell, W/Exciter Stator (Eff w/XXXXXXXXX) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257974 . . . . Kit, Endbell w/O−ring (Includes)
. . . . . . . . . . . . . . . . . . . . 203635 . . . . . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 143220 . . . . . . O−Ring, 2.859 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 264060 . . . . Stator, Exciter/Aux Power (Prior To XXXXXXXXX) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 270956 . . . . Stator, Exciter/Aux Power (Eff w/XXXXXXXXX) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 604538 . . . . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 172684 . . . . Nut, 312−18 .50hex .27h Stl Pld Sem Cone Wshr.76d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 604537 . . Nut, 312-18 .50hex .28h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 604538 . . Washer, Flat .344idx0.688odx.065t Stl Pld Ansi.312 . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 261463 . . Screw, 312-18x4.50 Hex Hd-pln Stl Gr5 Pld Full . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . +260669 . . Stator, Weld/Power Assy Complete (CA Models) . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . +252897 . . Stator, Weld/Power Assy Complete (Export Models) . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−Pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . . . . . . . . . . . 024617 . . Ring,Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 053390 . . Bearing,Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 251855 . . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 080389 . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . 8
. . . 11 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 8
. . . 12 . . . . . . . . . . . . . . 206242 . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Item Dia. Part
Figure 13-8. Generator (Continued)
. . . 13 . . . . . . . . . . . . . . 083883 .. Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 10

. . . 14 . . . . . . . . . . . . . . 049026 .. Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 15 . . . . . . . . . . . . . . 210332 .. Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 259483 .. Bracket, Mtg Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 191579 .. Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 199849 .. Screw, 625-11x4.00 Hex Hd-pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 071731 .. Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 071890 .. Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 071730 .. Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 083476 .. Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 135205 .. Nut, 625-11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 602159 .. Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 189142 .. Brushholder, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *190823 .. Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 208469 .. Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 25 . . . . . . . . . . . . . . 602242 .. Washer, Flat .375idx0.875odx.083t Stl Pld Blk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . 604534 .. Screw, 312−18x1.25 Hex Hd−Pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . 191577 .. Guard, Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
13 14
9
9
10
1 10
15
15
6
7
6 11
8
16
7 5
Included With 12
17 Item 6
252 915-D
Figure 13-9. Weld Output Module
Item Dia. Part

Figure 13-9. Weld Output Module (Figure 13-1, Item 16)
... 1 .............. 247407 .. Heat Sink Assy, Igbt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

not available unless listed. 76
77
79
78
80 74
81
72 72
73
70 71
45
69
68
66
65 67
27 28
26
12
25
24
23 29
13 22
11 21
20
10
14
9
15
19
8 16 18
17
7 49
45
36
45
30
6
31 35
5
34
4
33
32
267 588
Figure 13-10. Air Compressor
64
56
63
57
62
61 58
55
54
59
53
52
33 60
50 51
37
39 38
40
41
49
42
43 48
47
46
44
45
Item Dia. Part
Figure 13-10. Air Compressor (Figure 13-1 Item 45)
... 1 . . . . . . . . . . . . . . 233721 .. Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 206606 .. Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 210523 .. Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 209635 .. Hose, Tubing Oil Assy W/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 087318 .. Clamp, Stl Cush 1.000 Dia X .406 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 209621 .. Ftg, Stl Adapter 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . 210054 .. Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 210040 .. Orifice/Muffler, Blowdown .120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 209854 .. Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . 218601 .. Hose, Nylon Red 1/4 Id X 3/8 Od X 36 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 218602 .. Hose, Nylon Blue 1/4 Id X 3/8 Od X 44 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 071270 .. Ftg, Pipe Brs Tee St 1/4 Npt 071269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . 210053 .. Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 117826 .. Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 16 . . . . . . . . . . . . . . 084999 .. Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 151662 .. Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 206937 .. Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 209787 .. Ftg, Pipe Stl Nipple Close 3/4 Npt Schedual 80 . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 209754 .. Ftg, Stl Elbow 45 Deg 3/4 Npt (M) X 3/4 Jic (M) . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . 206743 .. Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . . . . 209767 .. Ftg, Pipe Stl Connector M 3/4 Sae-npt Adapter . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 210051 .. Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 210040 .. Orifice/Muffler, Blowdown .120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 26 . . . . . . . . . . . . . . 206746 .. Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . . . . . . . . . . 602965 .. Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . . . . . . . . . . . . 206615 .. Sender, Pressure Oil 0- 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 073655 .. Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 . . . . . . . . . . . . . . 206939 .. Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 209457 .. Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 209638 .. Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . . 209639 .. Hose, Oil W/Fittings 22.5 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . . 209766 .. Ftg, Pipe Stl Tee Street 3/4 Npt M-f-f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 . . . . . . . . . . . . . . 247624 .. Pointer Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 210058 .. Gauge, Oil Level (Modified) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 37 . . . . . . . . . . . . . . 209641 .. Hose, Nylon White 1/4 Id X 3/8 Od X 36 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
... 38 . . . . . . . . . . . . . . 209646 .. Tubing, Sst .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 39 . . . . . . . . . . . . . . 209856 .. Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1
... 40 . . . . . . . . . . . . . . 210027 .. Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 41 . . . . . . . . . . . . . . 209755 .. Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 43 . . . . . . . . . . . . . . 208029 .. Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 44 . . . . . . . . . . . . . . 214686 .. Ftg, Pipe Stl Elbow 90dg 3/4bspp O-ring X 3/4 Jic M . . . . . . . . . . . . . . . . 1
... 45 . . . . . . . . . . . . . . 210248 .. Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 46 . . . . . . . . . . . . . *206747 .. Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 47 . . . . . . . . . . . . . . 220326 .. Head, Spin On Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 48 . . . . . . . . . . . . . . 214687 .. Ftg, Pipe Stl 3/4bspp X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 49 . . . . . . . . . . . . . . 214685 .. Hose Assy, Air W/Fittings 3/4 X 20.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 50 . . . . . . . . . . . . . . 209756 .. Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1
... 51 . . . . . . . . . . . . . *206745 .. Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 52 . . . . . . . . . . . . . . 210052 .. Valve, Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 53 . . . . . . . . . . . . . . 206744 .. Thermostat, 170f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 54 . . . . . . . . . . . . . . 209825 .. Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 55 . . . . . . . . . . . . . . 209764 .. Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 56 . . . . . . . . . . . . . . 209851 .. Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 13-10. Air Compressor (Continued)
. . . 57 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O-ring . . . . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . 267651 . . Ftg, Pipe Stl Swivel 3/4 Jic (M) X 3/4 Jic (F) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 243794 . . Hose, Tubing Oil Assy W/Fittings 19.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 267531 . . Bracket, Mtg Ftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae-jic- . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 265396 . . Bracket, Mtg Compressor (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 260369 . . Ftg, Pipe Brs Elbow/Adapter M 1/8 Npt X 3/8 Od Line . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae-3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 211904 . . Manifold, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 209853 . . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 602887 . . Ftg, Pipe Brs Plug Hexhd 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 73 . . . . . . . . . . . . . . 225038 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 256685 . . Clutch, Electro Magnetic 12vdc W/8 Groove Pulley . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 260374 . . Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 210001 . . Airend, Gear-driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258419 . . Kit, Compressor Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . 78 . . . . . . . . . . . . . . 260374 . . Ftg, Pipe Brs Elbow/Adapter M 1/4 Npt X 3/8 Od Line . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 254976 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 010862 . . Clamp, Hose 1.562 − 2.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 249657 . . Air Cleaner, Intake 5.250 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.
Item Dia. Part

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

. . . . . . . . . PLG101 . . 240075 .. Conn, Rect Jpt Rcpt 25 Pos R Ang Left Key . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG100 . . 240442 .. Conn, Rect Jpt Rcpt 25 Pos R Ang Right Key . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240076 .. Conn, Rect Jpt Cover 25 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 240074 .. Seal, Plug Single Wire (5mm Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
.................... 240071 .. Plug, Cavity 2.5mm Din72585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . PLG104 . . 240077 .. Conn, Rect Jpt 2 Pos 1 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215192 .. Conn, Rect 2p Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG105 . . 240104 .. Conn, Rect 2 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG12 . . . 215261 .. Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 .. Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 238028 .. Conn, Deutsch 6p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 238029 .. Conn, Deutsch Wedge Lock 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG106 . . 266134 .. Conn, Rect 3 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CLUTCH . . 212116 .. Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212117 .. Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG103 . . 240081 .. Conn, Circ Cpc 7skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240082 .. Conn, Circ Cpc Clamp 90deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG102 . . 240098 .. Conn, Circ Cpc 12skt Size 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240099 .. Conn, Circ Cpc Cap Plg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 240100 .. Conn, Circ Cpc Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG409 . . 177859 .. Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 .. Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB2 . . . . 139266 .. Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR1 . . . . 252053 .. Relay, Encl 12vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S10 . . . . 206624 .. Switch, Tgl Sptt 6a 125vac (On)−On−(On)Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR5 . . . . 223710 .. Relay, Encl 12vdc Dpst−No 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR10 . . . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258581 . . Harness, Weld Air Pak (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . PLG6,PLG26 193184 . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG7,PLG11,
. . . . . PLG27,PLG211 193183 . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . PLG5,PLG10,PLG20,
. . . . . PLG25,PLG210,
. . . . . . . . . PLG220 . . 113751 . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . PLG2,PLG9,PLG22,
. . . . . . . . . PLG29 . . . 150316 .. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . RC3,RC23 . 155129 .. Conn, Rect Univ 039 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 2
. . . . . . PLG8,PLG28 231708 .. Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 2
. . . . . . . . . . RC99 . . . . 158466 .. Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . RC98 . . . . 135133 .. Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC30 . . . . 229933 .. Conn, Rect Univ 039 10p/S 2row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 259207 .. Cable, Lem 7 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 196602 .. Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 214933 .. Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . 214934 .. Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2015 Miller Electric Mfg. Co. 2015−01

BB 800 800X 800CA Duo Pro Air Pak TM

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BB 800 800X 800CA Duo Pro Air Pak TM

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Copyright:

Available Formats

TM-267 603A 2015−05

Eff w/Serial No. ME200183E

Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Engine Driven Welder/Generator And

Big Blue 800X / 800CA

File: Engine Drive

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

7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1-1. Symbol Usage

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

1-2. Servicing Hazards

FLYING METAL or DIRT can injure eyes.

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

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

1-3. California Proposition 65 Warnings

1-4. EMF Information

Big Blue 800X/800CA Duo Air Pak TM-267 603 Page 3

2-1. Additional Safety Symbols And Definitions

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

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

Do not weld on drums or any closed containers.

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

TM-267 603 Page 4 Big Blue 800X/800CA Duo Air Pak

Do not smoke while fueling or if near fuel.

Stop engine before fueling.

Do not fuel a hot engine.

Safe 118 2014−10

Hot muffler and exhaust pipe can cause severe burns.

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

Become trained and read the instructions before working on the

Read Owner’s Manual. Read labels on unit.

2-2. Miscellaneous Symbols And Definitions

Seconds Positive Single Phase

TM-267 603 Page 6 Big Blue 800X/800CA Duo Air Pak

s Welding In An Engine Rated Welding

Lift Arc TIG Air Cleaner

Fuel Filter Cancel Function

Engine Coolant Increase View

Big Blue 800X/800CA Duo Air Pak TM-267 603 Page 7

3-2. Weld, Power, And Engine Specifications

Stick: 400A, 36 Independent of Weld Output

3-3. Air Compressor Specifications

Compressor Model And Air Output At Effective Working Safety Relief

60 scfm (1.7 m3 min−1),

3-4. Environmental Specifications

TM-267 603 Page 8 Big Blue 800X/800CA Duo AirPak

28-1/2 in. (724 mm) G

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

Lifting Eye Weight Rating:

3-6. Duty Cycle And Overheating

1 100% Duty Cycle

This unit is rated for welding at

Big Blue 800X/800CA Duo AirPak TM-267 603 Page 9

Big Blue 800X/800CA Duo AirPak TM-267 603 Page 11

DC WELD AMPERES AT 100% DUTY CYCLE

TM-267 603 Page 12 Big Blue 800X/800CA Duo AirPak

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

Big Blue 800X/800CA Duo AirPak TM-267 603 Page 13

rot_grnd2 2014−11 − 800 652-D