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Welding System
Miller Electric
Big Blue 600D
manual
Models:
Big Blue 600D
1
57
60
60
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60 pages
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Troubleshooting
Specification
Install
Parts list
Electrical Diagram
Symbol Usage
Warranty
Maintenance
Battery Explosion can Blind
RUN-IN Procedure
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Contents
OM-481
Processes
Description
From Miller to You
Table of Contents
Page
Arc Welding Hazards
Symbol Usage
Electric Shock can kill
ARC Rays can burn eyes and skin
Engine Hazards
Moving Parts can cause injury
Battery Explosion can Blind
Engine Exhaust Gases can kill
Engine Heat can cause fire
EMF Information
Principal Safety Standards
Radiation can cause interference
ARC Welding can cause interference
Consignes DE SÉ Curité Lire Avant Utilisation
Signification des symboles
UN Choc É Lectrique peut tuer
LES Fumé ES ET LES GAZ peuvent ê tre dangereux
DES Particules Volantes peuvent blesser les yeux
LE Soudage peut provoquer un in- cendie ou une explosion
DES PIÈ CES Chaudes peuvent provoquer des brû lures graves
LE Bruit peut affecter l’ouïe
’EXPLOSION DE LA Batterie peut
DES Organes Mobiles peuvent provoquer des blessures
LA Chaleur DU Moteur peut pro- voquer un incendie
LA Chute DE L’APPAREIL peut blesser
Information sur les champs é lectromagné tiques
Principales normes de sé curité
LE Soudage À L’ARC risque de provoquer des interfé rences
Consignes relatives aux stimulateurs cardiaques
Symbols And Definitions
Specifications
Weld, Power, And Engine Specifications
Definitions
Do not move or operate unit where it could tip
Dimensions, Weights, And Operating Angles
Fuel Consumption
Do not exceed operating angles
Exceeding duty cycle can damage unit and void warranty
AC Generator Power
Duty Cycle And Overheating
100% Duty Cycle At 600 Amperes
Volt-Ampere Curves
For Constant Current CC Mode For Constant Voltage CV Mode
Installation
Installing Welding Generator
Connecting The Battery
Engine Prestart Checks
Installing Exhaust Pipe And Rain Cap
Selecting Weld Cable Sizes
Connecting To Weld Output Terminals
Socket
Remote 14 Receptacle RC3 Information
Terminal Strip 3T Connections
Stop engine
Open right side door Terminal Strip 3T Strain Relief
Do not run engine until problem is fixed
Do not switch under load
Operating the Welding Generator
Front Panel Controls
Operating Auxiliary Equipment
Example Of Remote Amperage Control
Volt Duplex Gfci Receptacles
Routine Maintenance
Maintenance & Troubleshooting
Volt Duplex Receptacle Optional
50 h
200 h
100 h
250 h
500 h
Maintenance Label
By the warranty
Servicing Air Cleaner
To clean air filter
Do not clean housing with air hose
Servicing Fuel And Lubrication Systems
Overload Protection
Adjusting Engine Speed
Checking And Replacing Engine Belt
To adjust belt tension
Servicing Optional Spark Arrestor
To replace belt
Speed Control Lever Overspeed Shutdown Valve
Adjusting Overspeed Shutdown Valve
Welding
Troubleshooting
Engine
Generator Power Trouble
Circuit Diagram For Welding Generator
Electrical Diagram
194 139-B
RUN-IN Procedure
Wetstacking
Welding Generator
Procedure at less than
Run-In Procedure Using Load Bank
Stop engine Do not touch hot exhaust
From flammables Do not Perform
Bank/grid
Run-In Procedure Using Resistance Grid
From flammables
Do not perform run-in
Generator Power Guidelines
Selecting Equipment
Grounding Generator To Truck Or Trailer Frame
How Much Power Does Equipment Require?
Grounding When Supplying Building Systems
Earth ground if supplying
Amperes x Volts = Watts
Approximate Power Requirements For Farm/Home Equipment
Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Contractor Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
How Much Power Can Generator Supply?
Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x
Work like a Pro
Typical Connections To Supply Standby Power
Current Load Watts Amperes
Selecting Extension Cord Use Shortest Cord Possible
66 71 74 73
Parts List
60Fig
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/Components
Panel, Front Lower w/Components -1 Item
Control Box -1 Item
Generator -1 Item
OM-481
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