Summary of Contents for Miller Kubota Big Blue 600 Pro
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OM-272375D 2016−12 Processes 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 Big Blue 600 Pro Kubota File: Engine Drive For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
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We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
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D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —...
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
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BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.
1-6. 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 &...
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
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D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...
D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé...
D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, D Remettre les portes, panneaux, recouvrements ou dispositifs...
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D Réduire le courant ou le facteur de marche avant de poursuivre le LA SORTIE DE RECHARGE et L’EXP- soudage. LOSION DE LA BATTERIE peuvent D Ne pas obstruer les passages d’air du poste. provoquer des blessures. LES CHARGES ÉLECTROSTATI- La recharge de batterie n’existe pas sur tous les QUES peuvent endommager les modèles.
2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.
Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. 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.
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Complete Parts List available at www.MillerWelds.com 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.
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Complete Parts List available at www.MillerWelds.com 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.
Complete Parts List available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Gas Tungsten Arc Rated No−Load Welding (GTAW) / Amperage Voltage (OCV) Tungsten Inert Gas (TIG) Welding Conventional Voltage Load Voltage Flux Cored Arc Welding (FCAW) Rated Welding Hertz...
Complete Parts List available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. 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.
Complete Parts List available at www.MillerWelds.com B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range −40 to 104°F (−40 to 40°C) −40 to 131°F (−40 to 55°C) *Output is derated at temperatures above 104°F (40°C). Temp_2016- 07 4-5. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load...
Complete Parts List available at www.MillerWelds.com 4-7. Volt-Ampere Curves A. Stick The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. DC Amperes B. TIG DC Amperes C.
Complete Parts List available at www.MillerWelds.com 4-8. Generator Power Curves A. Single Phase 4 kW The AC power curves show the generator output in amperes. AC Amperes B. Three Phase 20 kW AC Amperes C. Single Phase 12 kW AC Amperes 272 796-A OM-272375 Page 22...
Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. Movement (460 mm) 18 in. (460 mm) 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) Location/Mounting Bolting Welding Unit In Unit In Place Place...
Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2012−03 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on shock and static electricity hazards.
Complete Parts List available at www.MillerWelds.com 5-4. 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.
Full Diesel Full 907 695 / 255 549 NOTICE − Diesel engines in Miller equip- face. If oil is not up to full mark on dipstick, Check all engine fluids daily. ment are meant to operate optimally at mod- add oil (see maintenance label).
Complete Parts List available at www.MillerWelds.com 5-6. Weld Output Terminals Tools Needed: 3/4 in. 907 695 right. work cable to Negative (−) terminal on Stop engine. right. Use Process/Contactor switch to se- For Stick and TIG Direct Current Electrode Turn off power before connecting to lect type of weld output (see Section 6-4).
**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. ( ) = mm 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-L 2015−02 5-9. Connecting To Remote 14 Receptacle...
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Complete Parts List available at www.MillerWelds.com Notes OM-272375 Page 29...
Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 272 446-B / 907 695 OM-272375 Page 30...
NOTICE − Diesel engines in Miller equipment perage control to the remote control (see Sec- of cable and connections. are meant to operate optimally at moderate to tion 6-9).
Complete Parts List available at www.MillerWelds.com 6-4. Process/Contactor Switch Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot posi- tion and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low).
Complete Parts List available at www.MillerWelds.com 6-5. Arc Control Arc Control Stick Control adjusts Dig when Stick is se- lected on mode switch. When control is set toward minimum, short-circuit amperage at low arc voltage is the same as normal weld- ing amperage.
Complete Parts List available at www.MillerWelds.com 6-6. Low Open-Circuit Voltage (VRD) Switch Mode 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-...
Complete Parts List available at www.MillerWelds.com 6-8. 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.
Complete Parts List available at www.MillerWelds.com 6-9. Remote Voltage/Amperage Control Remote 14 Receptacle Connect optional remote control to receptacle (see Section 5-9). 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- trol.
Complete Parts List available at www.MillerWelds.com 6-10. Engine Block Heater Operation Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater Heater Specifications plug to 120 volts AC receptacle. Do not run engine while en- ±...
Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. North American Auxiliary Power Receptacles 271 858-A Single-Phase Generator Power CB6 protects RC1 and RC2, and the gen- (240 V x 13 A) + (120 V x 7 A) = erator winding from overload.
Complete Parts List available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting And Testing RotGFCI1 2016-12 If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles Use GFCI protection when operat- button pops out, and the circuit opens to ing auxiliary equipment.
Complete Parts List available at www.MillerWelds.com 8-2. 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 lower left side of the center upright.
Complete Parts List available at www.MillerWelds.com 8-4. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each...
Complete Parts List available at www.MillerWelds.com 8-5. Checking Generator Brushes Stop engine and let cool. 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.
Complete Parts List available at www.MillerWelds.com 8-7. 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.
Complete Parts List available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems Tools Needed: 907 695 To replace fuel filters: Once the air has escaped, fuel will begin to Stop engine and let cool. seep out of the spout and from underneath For primary fuel filter, disconnect water sen- the air bleed screw on the secondary fuel fil- After servicing, start engine and...
Complete Parts List available at www.MillerWelds.com 8-11. Engine/Generator Overload Protection 907 695 / Ref. 272388-TP1 CB3 protects the weld control circuit. If CB10 protects the engine battery circuit. If Stop engine. CB3 opens, weld output stops, meters will CB10 opens, the engine will not crank. be blank;...
Complete Parts List available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Help Displays HL.P Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayed normally weld output has stopped but generator power Display Example output may be okay. To reset help displays, stop unit and then restart.
Complete Parts List available at www.MillerWelds.com 8-13. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12). Also see Engine Information Display to assist in troubleshooting engine related problems (see Section 11). A. Welding Trouble Remedy No weld output;...
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Complete Parts List available at www.MillerWelds.com Trouble Remedy Constant speed wire feeder does not Reset supplementary protector CB9 (see Section 8-11). work. Check and secure connections to Remote 14 receptacle (see Section 5-9). Repair or replace wire feeder. Low CV weld output. Increase Voltage/Amperage Adjust Control setting.
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Complete Parts List available at www.MillerWelds.com D. Engine Trouble Remedy Engine will not crank. Supplementary protector CB2 open. Reset CB2. Check fuel level. Check battery connections and tighten if necessary. Check battery, and replace if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-11). Have Factory Authorized Service Agent check engine wiring harness and components.
Complete Parts List available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity ..F1, F2 . . . 085874 Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt .
SECTION 11 − 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. 11-1. Display Layout And Controls Engine Information Display Engine Control Switch Function Buttons Yellow LED Red LED The Engine Information Display...
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11-3. RPM Signal Failed Display 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- pears.
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11-5. 6-Up Display n/min 6-Up Display With Engine RPM 6-Up Display With Air Compressor Engine Coolant Temperature Pressure (Models With Air Engine RPM Compressor) This is the default screen configuration. If Compressor Air Pressure The air compressor must be on and air the operator wants to toggle to the 1-Up Battery Voltage pressure must be available for this display...
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11-7. 1-Up Displays 1-Up Machine Hours Display To increment to the next display, press the Next function button. To return to previous display, press the Previous function button. To return to the 6-Up Display, press the View function button. Machine Hours 15 18 Battery Potential Coolant Temperature...
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11-8. 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 11-9 and 11-10). 6-Up Display 1-Up Fuel Level Display Low Fuel Warning The low fuel warning indicator ap- pears and begins to flash when fuel...
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11-9. Warning or Shutdown Display Oil Pressure Display Fault Warning Indicator The warning symbol appears on the display when an engine condition approaches a shutdown condition. 45 60 Fault Shutdown Indicator The shutdown symbol appears on the display when a severe engine fault can cause shutdown.
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Table 11-1. 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. Description of Fault Tier 3 or Tier 4 Interim Engines Low oil pressure; warning threshold exceeded High coolant temperature;...
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11-11. Main Menu Access Code 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 ENTER PASSWORD Access Code (Password) The factory set access code is 1000.
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11-13. Main Menu Options: Brightness, Contrast, And Units Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- Brightness " tion, press Select function button to go to sub-menu. Contrast Brightness Menu Display Units...
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11-14. Main Menu Options − Reminders Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to Brightness go to sub-menu. Contrast Service Reminders Display Units English...
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11-15. Main Menu Options − OEM, Version, Stored Codes, And Language Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to go to sub-menu.
2014−09 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.
12-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Weld Cables voltage and current of the generator (see nameplate, rating label, or the Resistance Grid Do not touch hot exhaust pipe, en- specifications section in this manual). gine parts, or load bank/grid.
SECTION 13 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 13-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
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13-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
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13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
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13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw 14 in.
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13-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
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13-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- al and national, state, and lo- cal codes.
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13-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes)
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Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
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Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...