Miller Electric Big Blue 600 X Owner's Manual

Big Blue 600DProcessesDescriptionAir Carbon Arc (CAC-A) Cuttingand GougingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW) WeldingSubmerged Arc

OM-481 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-481 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-481 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-481 Page 9SECTION 2 – DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Start Engine EngineCheck engine belt Oil Pressure Bat

OM-481 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 58 (1473 mm)ACWidth 32 (813 mm)ABCDepth 68 in (1727 mm)D Do not exceed

OM-481 Page 113-4. Duty Cycle And Overheatingsb1.1 8/93 SB-134 397-CDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout ov

OM-481 Page 123-6. Volt-Ampere Curves SB-133 004-A / SB-133 003-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabil

OM-481 Page 13SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854Elec

OM-481 Page 144-3. Installing Exhaust Pipe And Rain Cap Stop engine, and let cool.1 Exhaust Pipe2 Muffler PipeInstall exhaust pipe over mufflerpipe.

OM-481 Page 154-5. Connecting To Weld Output Terminals1 Positive (+) Weld Output Terminals2 Negative (–) Weld Output TerminalsFor Direct Current Elect

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

OM-481 Page 164-7. Remote 14 Receptacle RC3 InformationSocket* Socket InformationAJBKIA 24 volts ac. Protected by circuitbreaker CB4.BCLNHDMGEFB Conta

OM-481 Page 174-8. Terminal Strip 3T ConnectionsRef. ST-131 784-A / Ref. ST-121 578-D / Ref. S-184 781 Stop engine.If remote control plug does not fi

OM-481 Page 18SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Front Panel ControlsST-134 687-B12 4 5678910111215 14 1331 Voltmeter2 Ammeter3 Ampere Ra

OM-481 Page 195-2. Example Of Remote Amperage ControlSet SwitchesAdjust Remote ControlSet PercentageMin = 55 A DC/CCPercentage Of Range = 50%Max = 90

OM-481 Page 206-2. 240 Volt Duplex Receptacle (Optional)Ref. ST-174 733 / ST-174 757 If unit does not have GFCI recep-tacles, use GFCI-protected exte

OM-481 Page 21100 hChange Oil. SeeSection 7-4.Change OilFilter. SeeSection 7-4.Check aircleaner hosesfor cracks andloose clamps.Clean AndTightenBatter

OM-481 Page 227-2. Maintenance Label

OM-481 Page 237-3. Servicing Air Cleaneraircleaner1 2/01 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without airclean

OM-481 Page 247-4. Servicing Fuel And Lubrication SystemsRef. ST-153 653-A / Ref. SD-131 784 Stop engine and let cool.1 Oil Filter2 Oil Drain Plug3 S

OM-481 Page 257-5. Adjusting Engine Speed Stop engine.Engine speeds have been factoryset and should not require adjust-ment. After tuning engine, che

The following terms areused interchangeablythroughout this manual:Stick = SMAWMIG = GMAWCALIFORNIAProposition 65WarningDiesel engine exhaust andsome o

OM-481 Page 267-7. Checking And Replacing Engine BeltRef. ST-134 730-B / SD-131 784-A Stop engine, and let cool.A V-belt drives the engine coolingfan

OM-481 Page 277-9. Adjusting Overspeed Shutdown ValveDrawing # Stop engine, and let cool.The overspeed shutdown valveprotects the engine from damaged

OM-481 Page 287-10. TroubleshootingA. WeldingTrouble RemedyNo weld output. Be sure Ampere Range switch is not set between positions.Disconnect equipme

OM-481 Page 29B. Generator Power TroubleTrouble RemedyNo output at 120 volt ac receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 6-1).Che

OM-481 Page 30SECTION 8 – ELECTRICAL DIAGRAMFigure 8-1. Circuit Diagram For Welding Generator

OM-481 Page 31194 139-B

OM-481 Page 32SECTION 9 – RUN-IN PROCEDURErun_in1 8/019-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexce

OM-481 Page 339-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust a

OM-481 Page 349-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exh

OM-481 Page 35SECTION 10 – GENERATOR POWER GUIDELINES10-1. Selecting Equipmentgen_pwr 6/02 – Ref. ST-159 730 / ST-800 5771 Generator Power Receptacles

OM-481 Page 3610-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-481 Page 3710-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-481 Page 3810-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-481 Page 3910-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-481 Page 4010-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-481 Page 4110-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-481 Page 42SECTION 11 – PARTS LIST12345689 10 11121314151617181921226593656669707165667273 727757880827367668384858788899092Fig 11-2Fig 11-4Fig 11-

OM-481 Page 43ST-134 499-H2324252627282930313032333447484950515253*545556575859474860(Fig. 11–5)616263353638394041424344454637100

OM-481 Page 44DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 Fig 11-2 PANEL, front w/components 1. . . . . . . . . . . . . . .

OM-481 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity48 071 731 WASHER, flat stl .656 ID x 2.250 OD x .187thk

OM-481 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_4/021-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-481 Page 46DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity99 118 790 ANGLE, strain relief 1. . . . . . . . . . .

OM-481 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 1)Quantity1 S3 131 213 SWITCH, range/changeover

OM-481 Page 48123456789101112131415161718192021222324251891ST-134 501-B Hardware is common andnot available unless listed.Figure 11-3. Panel, Front L

OM-481 Page 49QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Panel, Front Lower w/Components (Fig 11-1 Item 90)1 038 612 TERMINAL ASSEMBLY, pw

OM-481 Page 50DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-4. Control Box (Fig 11-1 Item 2)Quantity1 2T 129 939 BLOCK, term 10A 19P 1. . . . . . . .

OM-481 Page 51DescriptionPartNo.ItemNo.Figure 11-5. Generator (Fig 11-1 Item 60)Quantity1 *151 299 BRUSH, contact elect clrg .375 x .750 1. . . . . .

OM-481 Page 52Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

OM-481 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

PRINTED IN USA  2002 Miller Electric Mfg. Co. 5/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-481 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-481 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-481 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 4/021-1. Signification des symbolesSignifie Mise en garde ! Soyez v