Miller Electric Big Blue 600D Owner'S Manual Download Page 1

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Big Blue 600D

Processes

Description

Air Carbon Arc (CAC-A) Cutting
and Gouging

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Submerged Arc (SAW) Welding

Engine Driven Welding Generator

OM-481

132 366T

July 2002

Stud Welding

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www.MillerWelds.com

Summary of Contents for Big Blue 600D

Page 1: ...ir Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Submerged Arc SAW Welding Engine Driven Welding Generator OM 481 132 366T July 2002 Stud Welding Vis...

Page 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself again...

Page 3: ...e Prestart Checks 14 4 5 Connecting To Weld Output Terminals 15 4 6 Selecting Weld Cable Sizes 15 4 7 Remote 14 Receptacle RC3 Information 16 4 8 Terminal Strip 3T Connections 17 SECTION 5 OPERATING T...

Page 4: ......

Page 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Page 6: ...ch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIE...

Page 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...quer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du co...

Page 10: ...pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut...

Page 11: ...ir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquemen...

Page 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 13: ...t Current DC Alternating Current Output Stick SMAW Welding Air Carbon Arc Cutting CAC A MIG GMAW Welding Protective Earth Ground Circuit Breaker Temperature Work Connection Electrode Connection Time h...

Page 14: ...ine damage will occur B 29 7 8 in 759 mm G Do not move or operate unit where it could tip C 6 1 8 in 156 mm H D 9 3 4 in 248 mm J E 13 3 4 in 349 mm K F 28 3 16 in 716 mm G 36 in 914 mm H 46 1 2 in 11...

Page 15: ...ating Exceeding duty cycle can damage unit and void warranty Continuous Welding 100 Duty Cycle At 600 Amperes 10 100 15 20 25 30 40 50 60 80 100 150 200 250 300 400 500 600 800 1000 DUTY CYCLE WELD AM...

Page 16: ...SB 133 003 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A For Cons...

Page 17: ...t electric shock and static electricity hazards If unit does not have GFCI re ceptacles use GFCI protected extension cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3...

Page 18: ...utdown system to monitor oil level Follow run in procedure in engine manual If unburned fuel and oil col lect in exhaust pipe during run in see Section 9 Fuel Do not use gasoline Gaso line will damage...

Page 19: ...1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2...

Page 20: ...I 115 volts ac Protected by circuit breaker CB3 J Contact closure to I completes 115 volts ac contactor control circuit OR G Circuit common for 24 and 115 volts ac circuits C 0 to 10 volts dc output t...

Page 21: ...receptacle RC3 and terminal strip 3T at the same time Use only one remote control method Open right side door 1 Terminal Strip 3T 2 Strain Relief Connect leads to 3T using terminal information shown...

Page 22: ...n maximum position 8 Output Contactor Switch Use switch to control remote contactor con nected to receptacle RC3 or terminal strip 3T see Sections 4 7 and 4 8 9 Check Cooling System Alternator Light S...

Page 23: ...CB2 protects GFCI2 from overload If CB1 or CB2 opens the receptacle does not work If a circuit breaker continues to open contact a Factory Authorized Service Agent If a ground fault is detected the G...

Page 24: ...ntinues to open contact a Factory Authorized Service Agent 4 Total Generator Power Output Combined output of all receptacles limited to 3 kVA kW output of the generator EXAMPLE If 10 A is drawn from t...

Page 25: ...ean Spark Arrestor See Section 7 8 500 h Repair Or Replace Cracked Cables 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Drain Sludge From Fuel Tank See Section 7 4 FUEL SLUDGE...

Page 26: ...OM 481 Page 22 7 2 Maintenance Label...

Page 27: ...otection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place pri...

Page 28: ...ry fuel filter wa ter separator Turn filter counterclockwise Re move filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Bleed air from fuel sys tem according...

Page 29: ...ts Contact a Factory Authorized Service Agent 1 Circuit Breaker CB3 CB3 protects the 115 volts ac out put to Remote 14 receptacle RC3 or terminal strip 3T If CB3 opens the 115 volts ac output stops 2...

Page 30: ...of belt Readjust if necessary To replace belt Replace belt if damaged or cracked Replace belt as follows Loosen hex nuts pivot alternator counterclockwise and remove belt Install new belt pivot altern...

Page 31: ...al turns 7 Speed Control Lever 8 Overspeed Shutdown Valve Start engine and increase speed by moving lever toward high speed stop screw Note engine rpm when valve closes and stops engine If shutdown sp...

Page 32: ...odes Remove excessive coils from weld cables Tighten lead connections to Ampere Range switch Have Factory Authorized Service Agent check circuit boards PC1 and or PC2 High or low weld output voltage C...

Page 33: ...oo high or oil pressure is too low Check fuse F and replace if necessary see Section 7 6 Check engine battery charging system according to engine service manual Engine suddenly stops If Check Cooling...

Page 34: ...OM 481 Page 30 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram For Welding Generator...

Page 35: ...OM 481 Page 31 194 139 B...

Page 36: ...specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris k...

Page 37: ...n 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load ba...

Page 38: ...size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several...

Page 39: ...mbol and or wording 3 1 0 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Gr...

Page 40: ...istive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 10 8 3 Rating Data Rating shows volt...

Page 41: ...ome Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mi...

Page 42: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 43: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 44: ...f required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perm...

Page 45: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 46: ...13 14 15 16 17 18 19 21 22 65 93 65 66 69 70 71 65 66 72 73 72 77 5 78 80 82 73 67 66 83 84 85 87 88 89 90 92 Fig 11 2 Fig 11 4 Fig 11 3 7 20 68 79 81 5 74 64 75 76 94 95 96 97 65 98 99 Hardware is co...

Page 47: ...OM 481 Page 43 ST 134 499 H 23 24 25 26 27 28 29 30 31 30 32 33 34 47 48 49 50 51 52 53 54 55 56 57 58 59 47 48 60 Fig 11 5 61 62 63 35 36 38 39 40 41 42 43 44 45 46 37 100...

Page 48: ...OR strip term 1 23 170 550 PANEL side LH 1 24 131 688 COVER top 1 057 359 BLANK snap in nylon 375 4 190 847 PLUG protective 3 500 rd cover 1 25 117 486 PIPE exhaust 1 26 118 073 CAP rain 3 000 ID 1 27...

Page 49: ...MP hose 520 605clp dia slfttng 7 67 145 282 FITTING hose brs barbed elb M 5 16tbg x 1 4NPT 2 68 117 227 BRACKET mtg fuel filter 1 69 192 744 FILTER fuel spin on 1 70 206 297 BASE fuel filter assy 1 71...

Page 50: ...riginally displaying a precautionary label the label should also be ordered Recommended Spare Parts Part of 042 185 Optional FA 4 Flame Arrestor Strainer Fuel Cap To maintain the factory original perf...

Page 51: ...870 GAUGE pressure oil 25 30 PSI preset 1 128 829 KIT oil line 44 000 in 1 8NPT x 10mm 1 15 129 837 GAUGE SWITCH temp oil mech 250deg setting 1 16 HM 118 058 METER hour 12 24VDC 2 250dia 1 17 082 788...

Page 52: ...OM 481 Page 48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 18 9 1 ST 134 501 B Hardware is common and not available unless listed Figure 11 3 Panel Front Lower w Components...

Page 53: ...976 CONNECTOR w SOCKETS consisting of 1 079 534 CONNECTOR circ skt push in 14 18ga Amp 66358 6 14 134 734 CONNECTOR circ 14 pin plug Amp 213571 2 134 731 CONNECTOR circ pin push in 14 18ga Amp 213603...

Page 54: ...8ga Molex 39 00 0038 8 11 134 201 STAND OFF SUPPORT PC card 8 12 PC1 166 203 CIRCUIT CARD field current regulator 1 PLG1 135 275 CONNECTOR SOCKETS consisting of 1 114 066 CONNECTOR rect skt 20 14ga Am...

Page 55: ...50thk 1 11 053 390 BEARING ball rdl sgl row 1 370 x 2 830 x 600 1 12 083 748 FAN rotor gen 1 13 180 684 STATOR exciter 1 14 601 965 SCREW cap stl hexwhd slflkg 375 16 x 1 000 6 15 173 068 ENDBELL cons...

Page 56: ...OM 481 Page 52 Notes...

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Page 59: ...ols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles cont...

Page 60: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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