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Welding System
Miller Electric
Big Blue 600D
manual
Models:
Big Blue 600D
1
4
60
60
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60 pages
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Troubleshooting
Specs
Install
Parts list
Electrical Diagram
Symbol Usage
Warranty
Maintenance
Battery Explosion can Blind
RUN-IN Procedure
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Contents
Processes
OM-481
Description
From Miller to You
Table of Contents
Page
Symbol Usage
Arc Welding Hazards
Electric Shock can kill
ARC Rays can burn eyes and skin
Engine Hazards
Battery Explosion can Blind
Moving Parts can cause injury
Engine Exhaust Gases can kill
Engine Heat can cause fire
Principal Safety Standards
EMF Information
Radiation can cause interference
ARC Welding can cause interference
Signification des symboles
Consignes DE SÉ Curité Lire Avant Utilisation
UN Choc É Lectrique peut tuer
LES Fumé ES ET LES GAZ peuvent ê tre dangereux
LE Soudage peut provoquer un in- cendie ou une explosion
DES Particules Volantes peuvent blesser les yeux
DES PIÈ CES Chaudes peuvent provoquer des brû lures graves
LE Bruit peut affecter l’ouïe
DES Organes Mobiles peuvent provoquer des blessures
’EXPLOSION DE LA Batterie peut
LA Chaleur DU Moteur peut pro- voquer un incendie
LA Chute DE L’APPAREIL peut blesser
Principales normes de sé curité
Information sur les champs é lectromagné tiques
LE Soudage À L’ARC risque de provoquer des interfé rences
Consignes relatives aux stimulateurs cardiaques
Specifications
Symbols And Definitions
Weld, Power, And Engine Specifications
Definitions
Dimensions, Weights, And Operating Angles
Do not move or operate unit where it could tip
Fuel Consumption
Do not exceed operating angles
AC Generator Power
Exceeding duty cycle can damage unit and void warranty
Duty Cycle And Overheating
100% Duty Cycle At 600 Amperes
For Constant Current CC Mode For Constant Voltage CV Mode
Volt-Ampere Curves
Installing Welding Generator
Installation
Connecting The Battery
Installing Exhaust Pipe And Rain Cap
Engine Prestart Checks
Connecting To Weld Output Terminals
Selecting Weld Cable Sizes
Remote 14 Receptacle RC3 Information
Socket
Stop engine
Terminal Strip 3T Connections
Open right side door Terminal Strip 3T Strain Relief
Do not switch under load
Do not run engine until problem is fixed
Operating the Welding Generator
Front Panel Controls
Example Of Remote Amperage Control
Operating Auxiliary Equipment
Volt Duplex Gfci Receptacles
Maintenance & Troubleshooting
Routine Maintenance
Volt Duplex Receptacle Optional
50 h
100 h
200 h
250 h
500 h
Maintenance Label
Servicing Air Cleaner
By the warranty
To clean air filter
Do not clean housing with air hose
Servicing Fuel And Lubrication Systems
Adjusting Engine Speed
Overload Protection
To adjust belt tension
Checking And Replacing Engine Belt
Servicing Optional Spark Arrestor
To replace belt
Adjusting Overspeed Shutdown Valve
Speed Control Lever Overspeed Shutdown Valve
Troubleshooting
Welding
Generator Power Trouble
Engine
Electrical Diagram
Circuit Diagram For Welding Generator
194 139-B
Wetstacking
RUN-IN Procedure
Welding Generator
Run-In Procedure Using Load Bank
Procedure at less than
Stop engine Do not touch hot exhaust
From flammables Do not Perform
Run-In Procedure Using Resistance Grid
Bank/grid
From flammables
Do not perform run-in
Selecting Equipment
Generator Power Guidelines
Grounding Generator To Truck Or Trailer Frame
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Earth ground if supplying
Amperes x Volts = Watts
Approximate Power Requirements For Industrial Motors
Approximate Power Requirements For Farm/Home Equipment
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Power Required To Start Motor
How Much Power Can Generator Supply?
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x
Typical Connections To Supply Standby Power
Work like a Pro
Selecting Extension Cord Use Shortest Cord Possible
Current Load Watts Amperes
Parts List
66 71 74 73
60Fig
Dia Part Description Mkgs Quantity
Shunt
Panel, Front w/Components
Panel, Front w/Components -1 Item
Panel, Front Lower w/Components
13 14 23 22 21 2524
Panel, Front Lower w/Components -1 Item
Control Box -1 Item
Generator -1 Item
OM-481
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