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OM-4428AZ 2023-05 215932 Processes Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 600 X ® Deutz OWNER’S MANUAL 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 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
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Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...
� Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.
1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
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� Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.
� If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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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� Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.
� Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).
� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...
L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
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� Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.
� Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
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les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.
Safe Safe8 Safe8 � Complete Parts List is available at www.MillerWelds.com Never use generator inside a home or garage, even if doors Never use generator inside a home or garage, even if doors a SECTION 3 – DEFINITIONS Never use generator inside a home or garage, even if doors a dows are open.
Connect green or green/yellow grounding conductor to ground Connect green or green/yellow grounding conductor to ground terminal. terminal. Hot Parts can burn. Do not touch hot parts bare-handed. Allow cooling period before handling parts or equip- Connect input conductors (L1, L2 And L3) to line terminals. Connect input conductors (L1, L2 And L3) to line terminals.
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� Complete Parts List is available at www.MillerWelds.com Engine Start (En- Spark Arrestor Welding (General) gine RPM) Air Filter Shielded Metal Arc Engine Stop Welding (SMAW) Gas Tungsten Arc Air Flow Welding (GTAW) / Engine Oil Tungsten Inert Gas (TIG) Welding Check Air Cleaner Starting Aid Fuel...
Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...
� Complete Parts List is available at www.MillerWelds.com 4-5. Dimensions Weights And Operating Angles Dimensions Height 50 in. (1270 mm) (to top of muffler) Width 28.5 in. (724 mm) Do not exceed tilt angles or engine (mtg. brackets turned in) could be damaged or unit could tip.
� Complete Parts List is available at www.MillerWelds.com 4-6. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.
� Complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that 100% Duty Cycle At 500 Amperes unit can weld rated load without overheating. � This unit is rated for welding at 500 am- peres continuously.
� Complete Parts List is available at www.MillerWelds.com 4-9. Fuel Consumption The curve shows typical fuel use under weld or power loads. 1800 RPM IDLE 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 193 093 4-10.
� Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator Movement And Airflow Clearance 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) (460 mm) 18 in.
� Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle shock and static electricity hazards.
� Complete Parts List is available at www.MillerWelds.com 5-4. Installing Exhaust Pipe Stop engine and let cool. SECTION 2 INSTALLATION � Point exhaust pipe in desired direction but always away from front panel and direction of travel. 1/2 in. philips head wrench crescent wrench 5-5.
2 Full � Use Starting Aid switch (see Section 6- � Diesel engines in Miller equipment are Add fresh diesel fuel before starting to pre- � Keep battery in good condition. Store meant to operate optimally at moder- vent air from entering the fuel system (see battery in warm area.
� Complete Parts List is available at www.MillerWelds.com 5-7. Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Positive (+) Weld Output Terminal 2 Negative (−) Weld Output Terminal Stick and TIG Welding For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect elec-...
� Complete Parts List is available at www.MillerWelds.com 5-9. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
� Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATING THE WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 238 627-B / 803 602 OM-4428 Page 29...
5 Engine Temperature Gauge 2 Engine Control Switch R1 to maximum when the arc breaks. NOTICE – Diesel engines in MILLER equip- Normal temperature is 212 − 239° F (100 − Also in the Stick position, the arc drive (dig) ment are meant to operate optimally at mod- 115°...
� Complete Parts List is available at www.MillerWelds.com 6-3. Remote Amperage Control (Optional) Example: Combination Remote Amperage Control (Stick) Max (240 A DC) Min (84 A DC) Ref. 154 862-A / Ref. 236 973 / 803 602 Combination Remote Amperage Control Step 4.
� Complete Parts List is available at www.MillerWelds.com 6-4. Weld Control/Arc Condition Information Label � Set weld controls as shown to achieve softer or stiffer arc conditions for differ- ent applications. 212 944-B OM-4428 Page 32...
� Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Export Auxiliary Power Receptacles 805259-A Test GFCI monthly. See Section 7-2 Use GFCI protection when operating � At least once a month, press test but- for GFCI information and for reset- auxiliary equipment.
� Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.
� Complete Parts List is available at www.MillerWelds.com SECTION 8 – DEUTZ D2011L04I MAINTENANCE 8-1. Maintenance Label (Deutz D2011L04i-Powered Units) OM-4428 Page 36...
Hours ouble: Dirty fuel filters. Symptom: Fuel flow to the engine is When servicing a Miller gasoline-powered welder/generator, always perform the following basic stricted. Engine will not run or run well if it is starved for fuel. engine checks before contacting the engine manufacturer.
� Complete Parts List is available at www.MillerWelds.com Every Every 6000 6000 Hours Hours or 5 or 5 Years Years ��Engine Timing Belt � Clean exterior, including stainless steel, frequently to prevent rust and corrosion. *To be done by factory authorized service agent. DEUTZ Service: http://www.deutzamericas.com To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer.
� Complete Parts List is available at www.MillerWelds.com NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 8-5. Servicing Air Cleaner (Deutz D2011L04i-Powered Units) Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty.
� Complete Parts List is available at www.MillerWelds.com 8-6. Inspecting/Cleaning Optional Spark Arrestor (Deutz D2011L04i-Powered Units) Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole.
� Complete Parts List is available at www.MillerWelds.com 8-8. Adjusting Engine Speed (Deutz D2011L04i-Powered Units) Stop engine and let cool. � For operation at high altitude, engine may require adjustments. If adjustment is necessary, contact engine manufac- turer’s Factory Authorized Service Agent.
� Complete Parts List is available at www.MillerWelds.com 8-9. Servicing Fuel And Lubrication Systems (Deutz D2011L04i-Powered Units) 803 657 tools/ maintenance label for oil/filter change To replace secondary fuel filter: Stop engine and let cool. allen_wrench allen_set flathead philips head wrench crescent wrench information.
� Complete Parts List is available at www.MillerWelds.com 8-10. Overload Protection (Deutz D2011L04i-Powered Units) Stop Engine. � When a supplementary protector, cir- cuit breaker or fuse opens, it usually in- dicates a more serious problem exists. Contact Factory Authorized Service Agent.
� Complete Parts List is available at www.MillerWelds.com SECTION 9 – DEUTZ F3L912 MAINTENANCE 9-1. Maintenance Label (Deutz F3L912-Powered Units) OM-4428 Page 44...
Technical Manual. event damage to the EFI fuel pump and injectors. See Section __. � Weld Terminals Complete Parts List available at www.MillerWelds.com When servicing a Miller gasoline-powered welder/generator, always perform the following basic FUEL Every Refer to Complete Parts List is available at www.MillerWelds.com...
� Complete Parts List is available at www.MillerWelds.com Every 3000 Hours � Injectors* � Clean exterior, including stainless steel, frequently to prevent rust and corrosion. *To be done by factory authorized service agent. DEUTZ Service: http://www.deutzamericas.com To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer. They are staffed with highly qualified parts, service and engine specialists to handle your different needs.
� Complete Parts List is available at www.MillerWelds.com NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 9-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty.
� Complete Parts List is available at www.MillerWelds.com 9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole.
� Complete Parts List is available at www.MillerWelds.com 9-7. Adjusting Engine Speed (Deutz F3L912-Powered Units) Stop engine and let cool. � For operation at high altitude, engine may require adjustments. If adjustment is necessary, contact engine manufac- turer’s Factory Authorized Service Agent.
� Complete Parts List is available at www.MillerWelds.com 9-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 803 658 tools/ maintenance label for oil/filter change To replace secondary fuel filter: Stop engine and let cool. allen_wrench allen_set flathead philips head wrench crescent wrench information.
� Complete Parts List is available at www.MillerWelds.com 9-9. Overload Protection (Deutz F3L912-Powered Units) Stop Engine. � When a supplementary protector, cir- cuit breaker or fuse opens, it usually in- dicates a more serious problem exists. Contact Factory Authorized Service Agent.
� Complete Parts List is available at www.MillerWelds.com SECTION 10 – TROUBLESHOOTING 10-1. Troubleshooting A. Welding Trouble Remedy No weld output; generator power out- Check position of Ampere Range switch. put okay at AC receptacles. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect re- mote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).
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� Complete Parts List is available at www.MillerWelds.com Trouble Remedy Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output at generator power AC Check engine speed, and adjust if necessary.
SECTION 11 – PARTS LIST A. Recommended Spare Parts Reccomended Spare Parts Item Part No. Description Quan- Dia. Mkgs. tity F1, F2 085874 Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt 190823 Brush, Contact Elect .250 X.500 X 1.250 Grd Ay ♦192939 Filter, Air Element Safety 246988...
SECTION 13 – RUN-IN PROCEDURE NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended peri- ods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
13-2. Run-In Procedure Using Load Bank Or Resistance Grid Stop engine. Connect load bank or resistor grid to gener- For Resistance Grid ator Side A weld output terminals using Do not touch hot exhaust pipe, en- Set grid switches and then adjust gener- proper size weld cables with correct connec- gine parts, or load bank/grid.
SECTION 14 – 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. 14-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
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14-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (shop,...
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14-5. 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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14-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment 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...
14-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
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14-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
14-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)
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Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � CoolBelt, PAPR Blower, and PAPR Face...
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