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Miller Electric Big Blue 600D Owner's Manual

Miller electric owner's manual welding engine driven welding generator big blue 600d
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Big Blue 600D
OM-481
July 2002
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Submerged Arc (SAW) Welding
Stud Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
R
132 366T

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Summary of Contents for Miller Electric Big Blue 600D

  • Page 1 Big Blue 600D Visit our website at www.MillerWelds.com OM-481 132 366T July 2002 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Submerged Arc (SAW) Welding Stud Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog orindividual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used for welding or cutting, produces fumes or gases which contain SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION chemicals known to the State of California to cause birth defects and, in some cases, cancer.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Check engine belt Do Not Switch Under Load Check Injectors/ Pump Positive Amperes Stick (SMAW) Welding Circuit Breaker Time SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Weld Welding Rated Welding Output...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 58 (1473 mm) Width 32 (813 mm) Depth 68 in (1727 mm) 1-1/16 in (27 mm) 29-7/8 in (759 mm) 6-1/8 in (156 mm) 9-3/4 in (248 mm) 13-3/4 in (349 mm) 28-3/16 in (716 mm) 36 in (914 mm) 46-1/2 in (1181 mm)

  • Page 15: Duty Cycle And Overheating

    3-4. Duty Cycle And Overheating 1000 3-5. AC Generator Power 100% Duty Cycle At 600 Amperes Continuous Welding % DUTY CYCLE Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void...

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves A. For Constant Current (CC) Mode B. For Constant Voltage (CV) Mode OM-481 Page 12 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.

  • Page 17: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Y Do Not Lift Unit From End Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. 4-2. Connecting The Battery START Tools Needed: 1/2 in Airflow Clearance 18 in (460 mm) (460 mm) 18 in...

  • Page 18: Installing Exhaust Pipe And Rain Cap

    4-3. Installing Exhaust Pipe And Rain Cap START Tools Needed: 1/2 in 4-4. Engine Prestart Checks 1/2 in (13 mm) Full Diesel OM-481 Page 14 Full Tools Needed: 3/8 in Y Stop engine, and let cool. Exhaust Pipe Muffler Pipe Install exhaust pipe over muffler pipe.

  • Page 19: Connecting To Weld Output Terminals

    4-5. Connecting To Weld Output Terminals 4-6. Selecting Weld Cable Sizes* Weld Output Terminals Y Turn off power before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. 1000 hart is a guideline and may not suit all applications.

  • Page 20: Remote 14 Receptacle Rc3 Information

    4-7. Remote 14 Receptacle RC3 Information C L N *The remaining sockets are not used. OM-481 Page 16 Socket* Ref. ST-800 907-A Socket Information 24 volts ac. Protected by circuit breaker CB4. Contact closure to A completes 24 volts ac contactor control circuit. 115 volts ac.

  • Page 21: Terminal Strip 3T Connections

    4-8. Terminal Strip 3T Connections REMOTE CONNECTIONS 24 VAC NEUTRAL 115 VAC EQUIPMENT GROUND S-138 042-A START Y Stop engine. If remote control plug does not fit in receptacle RC3, wire cord directly to terminal strip 3T. Y Do not connect to Remote 14 receptacle RC3 and terminal strip 3T at the same time.

  • Page 22: Section 5 - Operating The Welding Generator

    SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls Voltmeter Ammeter Ampere Range Switch Y Do not switch under load. Use switch to select weld amperage range. For most welding applications, use lowest amperage range possible to help prevent arc outages.

  • Page 23: Example Of Remote Amperage Control

    5-2. Example Of Remote Amperage Control Set Range Min (55 A DC/CC) Max (90 A DC/CC) Adjust Remote Control SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt Duplex GFCI Receptacles Y If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.

  • Page 24: Volt Duplex Receptacle (Optional)

    6-2. 240 Volt Duplex Receptacle (Optional) Y If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. 240 V 15 A AC Duplex Receptacle RC1 Receptacle supplies 60 Hz single-phase power at weld/power speed. Maximum out- put from this receptacle is 3 kVA/kW. SECTION 7 –...
  • Page 25 Change Oil. See Section 7-4. Clean And Tighten Battery Connections. Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. 1/2 in. Change Fuel (13 mm) Filters. See Section 7-4. 100 h Change Oil Filter. See Section 7-4. Check cleaner hoses for cracks and loose clamps.

  • Page 26: Maintenance Label

    7-2. Maintenance Label OM-481 Page 22...

  • Page 27: Servicing Air Cleaner

    7-3. Servicing Air Cleaner START Keep nozzle 2 in (51 mm) from element. Blow Optional Inspect Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty.

  • Page 28: Servicing Fuel And Lubrication Systems

    7-4. Servicing Fuel And Lubrication Systems Tools Needed: 7/16 in OM-481 Page 24 START Y Stop engine and let cool. Oil Filter Oil Drain Plug Secondary Fuel Filter Primary Fuel Filter/Water Separator Petcock Sludge Drain Plug To change oil and filter: See engine manual.

  • Page 29: Adjusting Engine Speed

    7-5. Adjusting Engine Speed 7-6. Overload Protection Engine Speed Weld/Power START Y Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer. 1850 See table for proper no load speeds.

  • Page 30: Checking And Replacing Engine Belt

    7-7. Checking And Replacing Engine Belt Tools Needed: 1/2 in, 13 mm 7-8. Servicing Optional Spark Arrestor Tools Needed: 3/8 in OM-481 Page 26 1/2 in (13 mm) Maximum Y Stop engine, and let cool. A V-belt drives the engine cooling fan and alternator.

  • Page 31: Adjusting Overspeed Shutdown Valve

    7-9. Adjusting Overspeed Shutdown Valve Tools Needed: 3/8 in Y Stop engine, and let cool. The overspeed shutdown valve protects the engine from damage due to high engine speed. If the en- gine stops, the valve may be closed. Shutdown speed is between 1950 and 2100 rpm.

  • Page 32: Troubleshooting

    7-10. Troubleshooting A. Welding Trouble No weld output. Be sure Ampere Range switch is not set between positions. Disconnect equipment from generator power receptacles during start-up. Reset circuit breaker CB3 and/or CB4 (see Section 7-6). Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control to Remote A/V Control receptacle RC3 (see Sections 4-7 and 4-8).
  • Page 33 B. Generator Power Trouble Trouble No output at 120 volt ac receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 6-1). Check fuse F6, and replace if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes and slip rings. Low or high generator power output Check engine speed, and adjust if necessary (see Section 7-5).

  • Page 34: Section 8 - Electrical Diagram

    SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator OM-481 Page 30...
  • Page 35 194 139-B OM-481 Page 31...

  • Page 36: Section 9 - Run-In Procedure

    SECTION 9 – RUN-IN PROCEDURE 9-1. Wetstacking OM-481 Page 32 run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 37: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 38: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid OM-481 Page 34 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 39: Grounding Generator To Truck Or Trailer Frame

    SECTION 10 – GENERATOR POWER GUIDELINES 10-1. Selecting Equipment 0-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact. Be sure equipment has this symbol and/or wording. GND/PE Generator Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...

  • Page 40: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 41 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 42 10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 43 10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 44 10-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 45 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 46: Section 11 - Parts List

    SECTION 11 – PARTS LIST Fig 11-2 Fig 11-4 Fig 11-3 OM-481 Page 42 73 72 Figure 11-1. Main Assembly Hardware is common and not available unless listed.
  • Page 47 60(Fig. 11–5) ST-134 499-H OM-481 Page 43...
  • Page 48 Item Dia. Part Mkgs....Fig 11-2 ....Fig 11-4 .
  • Page 49 Item Dia. Part Mkgs....071 731 ....116 707 .
  • Page 50 Item Dia. Part Mkgs....118 790 ....089 256 .
  • Page 51 Item Dia. Part Mkgs... . . 131 213 ....118 340 ..
  • Page 52 Figure 11-3. Panel, Front Lower w/Components OM-481 Page 48 Hardware is common and not available unless listed. ST-134 501-B...
  • Page 53 Item Dia. Part Mkgs....038 612 ....601 840 .
  • Page 54 Item Dia. Part Mkgs... . . 129 939 ....187 013 ..
  • Page 55 Item Part Figure 11-5. Generator (Fig 11-1 Item 60) ..*151 299 BRUSH, contact elect clrg .375 x .750 ..188 387 BRUSHHOLDER/BRACKET ASSEMBLY (consisting of) ..
  • Page 56 Notes OM-481 Page 52...
  • Page 59 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 60: Options And Accessories

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2002 Miller Electric Mfg. Co. 5/02 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 &...

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