Miller Electric Big Blue 600D manual Table of Contents

Page 3

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

CALIFORNIA

Proposition 65

Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The following terms are used interchangeably throughout this manual:

Stick = SMAW

MIG = GMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

2

1-4.

Additional Symbols For Installation, Operation, And Maintenance

3

1-5.

Principal Safety Standards

4

1-6.

EMF Information

4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2.

Dangers relatifs au soudage à l’arc

5

1-3. Dangers existant en relation avec le moteur

6

1-4.

Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-5. Principales normes de sécurité

8

1-6.

Information sur les champs électromagnétiques

8

SECTION 2 – DEFINITIONS

9

2-1.

Symbols And Definitions

9

SECTION 3 – SPECIFICATIONS

9

3-1.

Weld, Power, And Engine Specifications

9

3-2. Dimensions, Weights, And Operating Angles

10

3-3.

Fuel Consumption

10

3-4. Duty Cycle And Overheating

11

3-5.

AC Auxiliary Power

11

3-6.

Volt-Ampere Curves

12

SECTION 4 – INSTALLATION

13

4-1.

Installing Welding Generator

13

4-2.

Connecting The Battery

13

4-3. Installing Exhaust Pipe And Rain Cap

14

4-4.

Engine Prestart Checks

14

4-5.

Connecting To Weld Output Terminals

15

4-6.

Selecting Weld Cable Sizes

15

4-7.

Remote 14 Receptacle RC3 Information

16

4-8.

Terminal Strip 3T Connections

17

SECTION 5 – OPERATING THE WELDING GENERATOR

18

5-1.

Front Panel Controls

18

5-2.

Example Of Remote Amperage Control

19

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

19

6-1.

120 Volt Duplex GFCI Receptacles

19

6-2.

240 Volt Duplex Receptacle (Optional)

20

SECTION 7 – MAINTENANCE & TROUBLESHOOTING

20

7-1.

Routine Maintenance

20

7-2.

Maintenance Label

22

7-3.

Servicing Air Cleaner

23

7-4. Servicing Fuel And Lubrication Systems

24

7-5.

Adjusting Engine Speed

25

7-6.

Overload Protection

25

7-7.

Checking And Replacing Engine Belt

26

7-8. Servicing Optional Spark Arrestor

26

7-9. Adjusting Overspeed Shutdown Valve

27

7-10.

Troubleshooting

28

SECTION 8 – ELECTRICAL DIAGRAM

30

SECTION 9 – RUN-IN PROCEDURE

32

9-1.

Wetstacking

32

9-2. Run-In Procedure Using Load Bank

33

9-3. Run-In Procedure Using Resistance Grid

34

SECTION 10 – AUXILIARY POWER GUIDELINES

35

SECTION 11 – PARTS LIST

42

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents
OM-481 ProcessesDescription From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbols And Definitions Weld, Power, And Engine SpecificationsDo not exceed operating angles Dimensions, Weights, And Operating AnglesDo not move or operate unit where it could tip Fuel Consumption100% Duty Cycle At 600 Amperes AC Generator PowerExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingVolt-Ampere Curves For Constant Current CC Mode For Constant Voltage CV ModeInstallation Installing Welding GeneratorConnecting The Battery Engine Prestart Checks Installing Exhaust Pipe And Rain CapSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Remote 14 Receptacle RC3 InformationTerminal Strip 3T Connections Stop engineOpen right side door Terminal Strip 3T Strain Relief Front Panel Controls Do not switch under loadDo not run engine until problem is fixed Operating the Welding GeneratorOperating Auxiliary Equipment Example Of Remote Amperage ControlVolt Duplex Gfci Receptacles 50 h Maintenance & TroubleshootingRoutine Maintenance Volt Duplex Receptacle Optional500 h 100 h200 h 250 hMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterServicing Fuel And Lubrication Systems Overload Protection Adjusting Engine SpeedTo replace belt To adjust belt tensionChecking And Replacing Engine Belt Servicing Optional Spark ArrestorSpeed Control Lever Overspeed Shutdown Valve Adjusting Overspeed Shutdown ValveWelding TroubleshootingEngine Generator Power TroubleCircuit Diagram For Welding Generator Electrical Diagram194 139-B RUN-IN Procedure WetstackingWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesGenerator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible66 71 74 73 Parts List60Fig Dia Part Description Mkgs Quantity Shunt Panel, Front w/Components Panel, Front w/Components -1 Item 13 14 23 22 21 2524 Panel, Front Lower w/ComponentsPanel, Front Lower w/Components -1 Item Control Box -1 Item Generator -1 Item OM-481 Page Page Service Your distributor also givesSupport Miller Electric Mfg. Co Owner’s Record
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