Miller-electric 600 X User Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorOM-4428 215 932K2007−10Visit our website at

OM-4428 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les

OM-4428 Page 96 Hardware is common andnot available unless listed.803 6631154535251464749256555758176810935412134548504244394041383736354334311430272

OM-4428 Page 97DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity6 S6 193 234 SWITCH, rotary

OM-4428 Page 98DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity36 PC4, PC5 189 744 CIRCUIT

OM-4428 Page 99802 404-C Hardware is common andnot available unless listed.56892227282930317242510263433321243231718111314121519202116Figure 15-6. Ge

OM-4428 Page 100DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-6. Generator (Continued)Quantity21 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . .

OM-4428 Page 101 Hardware is common andnot available unless listed.802 279-A123465789Figure 15-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.I

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-4428 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refr

OM-4428 Page 8LES CHAMPS MAGNETIQUES peuv-ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à d

OM-4428 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde

OM-4428 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.

OM-4428 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen

OM-4428 Page 12SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/961 Remove unit from shippingcrate. Remove Owner’sManual f

OM-4428 Page 133-2. Manufacturer’s Rating LabelsCC Models CC/CV Models

OM-4428 Page 143-3. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStart

OM-4428 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRated WeldingOutputMaximumOpen-CircuitVo

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4428 Page 164-3. Volt-Ampere Curves For CC Models203 412The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

OM-4428 Page 174-4. Volt-Ampere Curves For CC/CV Models217 811 / 203 415 / 217 810The volt-ampere curves show theminimum and maximum voltageand ampera

OM-4428 Page 184-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.193 0930 50 100 150 200 250 300 350 400 450 500DC WELD A

OM-4428 Page 19Continuous Welding4-6. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overhe

OM-4428 Page 204-8. Optional Three-Phase Generator Curves197 472 / 197 473The ac power curves show the gen-erator power available in amperesat the sin

OM-4428 Page 21SECTION 5 − INSTALLATIONinstall3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712! Always securely fasten weld-ing generator

OM-4428 Page 225-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye when not

OM-4428 Page 235-3. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on base

OM-4428 Page 245-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 803 604 / Ref. 215 664! Stop engine and let cool. Point exhaust pipe in desired di

OM-4428 Page 255-6. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-4428 Page 265-8. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4428 Page 275-9. Connecting To Weld Output Terminals803 602 / 803 778-ATools Needed:23/4 in1MIG and FCAW WeldingFor MIG and FCAW welding Direct Cur

OM-4428 Page 285-10. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less

OM-4428 Page 295-12. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-pleme

OM-4428 Page 30SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)12215 663 / 803 6021121813

OM-4428 Page 316-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4428 Page 326-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4428 Page 33NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-4428 Page 34SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)215 664 / 802 6022191

OM-4428 Page 357-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

TABLE OF CONTENTSSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel

OM-4428 Page 367-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswi

OM-4428 Page 377-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4428 Page 38SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 3

OM-4428 Page 398-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-B / 803 655 Place Process/Contactor switch

OM-4428 Page 408-3. Optional Generator Power Receptacles (Standard Models)21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC1

OM-4428 Page 418-4. Generator Power Receptacles (Export Models) Generator power is not affected by weldoutput.1 130 V 32 A AC Receptacle RC12 220 Vo

OM-4428 Page 42SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS)9-1. Maintenance Label (Deutz F4L2011-Powered Units)

OM-4428 Page 439-2. Routine Maintenance (Deutz F4L2011-Powered Units)! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor i

OM-4428 Page 449-3. Checking Generator BrushesRef 215 158! Stop engine and let cool.1 Generator BrushMark and disconnect leads at brush hold-er cap. R

OM-4428 Page 459-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units)aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B! Stop engine.NOTIC

OM-4428 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions

OM-4428 Page 469-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)803 656 / Ref. 215 664! Stop engine and let cool.1 Spark

OM-4428 Page 479-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units)803 657! Stop engine and let cool.Engine speed is factory set andshould not re

OM-4428 Page 489-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)803 657! Stop engine and let cool.! After servicing, start eng

OM-4428 Page 499-8. Overload Protection (Deutz F4L2011-Powered Units)Ref. 803 657219874! Stop engine. When a supplementary protector,circuit breaker

OM-4428 Page 50SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS)10-1. Maintenance Label (Deutz F3L912-Powered Units)

OM-4428 Page 5110-2. Routine Maintenance (Deutz F3L912-Powered Units)! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor im

OM-4428 Page 5210-3. Checking Generator BrushesRef 215 158! Stop engine and let cool.1 Generator BrushMark and disconnect leads at brush hold-er cap.

OM-4428 Page 5310-4. Servicing Air Cleaner (Deutz F3L912-Powered Units)aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B! Stop engine.NOTIC

OM-4428 Page 5410-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)803 656 / Ref. 215 664! Stop engine and let cool.1 Spark

OM-4428 Page 5510-6. Adjusting Engine Speed (Deutz F3L912-Powered Units)803 658 / 134 730-C! Stop engine.Engine speeds have been factoryset and should

OM-4428 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4428 Page 5610-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)803 658! Stop engine and let cool.! After servicing, start eng

OM-4428 Page 5710-9. Overload Protection (Deutz F3L912-Powered Units)Ref. 803 658219874! Stop engine. When a supplementary protector, cir-cuit breake

OM-4428 Page 58SECTION 11 − TROUBLESHOOTING11-1. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac r

OM-4428 Page 59B. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-4428 Page 60Trouble RemedyLow CV weld output. Set Ampere Range switch to highest range.Increase Voltage/Amperage Adjust Control setting.Min or max

OM-4428 Page 61E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4428 Page 62SECTION 12 − ELECTRICAL DIAGRAMSFigure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 63215 221-E

OM-4428 Page 64Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units) (Export Models)

OM-4428 Page 65235 275-A

OM-4428 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt

OM-4428 Page 66Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 67215 806-E

OM-4428 Page 68Figure 12-4. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units) (Export Models)

OM-4428 Page 69235 276-A

OM-4428 Page 70Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 71215 807-D

OM-4428 Page 72Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 73215 808-D

OM-4428 Page 74SECTION 13 − RUN-IN PROCEDURErun_in1 2007−0413-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri

OM-4428 Page 7513-2. Run-In Procedure Using Load BankS-06831 Load BankTurn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall

OM-4428 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4428 Page 7613-3. Run-In Procedure Using Resistance GridS-06841 Resistance GridUse grid sized for generator ratedoutput.Turn Off grid.2 Welding Gen

OM-4428 Page 77SECTION 14 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4428 Page 7814-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4428 Page 7914-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4428 Page 8014-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4428 Page 8114-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4428 Page 8214-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4428 Page 8314-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4428 Page 84SECTION 15 − PARTS LIST Hardware is common and notavailable unless listed. A Deutz F4L2011 engine-pow-ered unit is shown below. Seein

OM-4428 Page 85803 659 / 803 665Deutz F3L912 Engine A Deutz F4L2011 en-gine-powered unit isshown below. See in-sert for parts specific toa Deutz F3L9

OM-4428 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni

OM-4428 Page 86DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4428 Page 87DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly (Continued)Quantity♦174 064 IDLE, solenoid assy 1. . . . . . . . . . . .

OM-4428 Page 88DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly (Continued)Quantity88 189 908 VALVE, drain fuel 180deg 1. . . . . . . . .

OM-4428 Page 89803 660-C2111196371422131612515920181784212324102526Figure 15-2. Control Box Assembly − CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figu

OM-4428 Page 90DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-2. Control Box Assembly − CC Models (Continued)Quantity215 013 HARNESS, unit weld control (

OM-4428 Page 91803 661-C23123111621182017141315591084761219222524Figure 15-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Fig

OM-4428 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-3. Control Box Assembly − CC/CV Models (Continued)Quantity23 CB11, 12, 13 139 266 SUPPLEMEN

OM-4428 Page 93 Hardware is common andnot available unless listed.803 662111098722131239373638343532202125272624232830181915161714240414216354293133F

OM-4428 Page 94DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-4. Panel, Front w/Components − CC Models (Continued)Quantity192 558 HARNESS, range (consist

OM-4428 Page 95DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-4. Panel, Front w/Components − CC Models (Continued)Quantity35 HM 210 424 METER, hour 12-24