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Miller Electric Big Blue 600D manual

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Table of contents for the manual

  • Page 1

    Big Blue 600D Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMA W) W elding MIG (GMA W) W elding Flux Cored (FCA W) W elding Submerged Arc (SA W) W elding Engine Driven Welding Generator OM-481 132 366T July 2002 Stud W elding  Visit our website at www.MillerWelds.com[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog orindividual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW elds[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: Stick = SMAW MIG = GMAW CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other reproductive harm. T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING [...]

  • Page 4

    [...]

  • Page 5

    OM-481 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_4/02 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means W arning! Wat[...]

  • Page 6

    OM-481 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks c an fly of f from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and b e sure the a[...]

  • Page 7

    OM-481 Page 3 MOVING P ARTS can cause injury .  Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards closed and securely in place.  Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .  T o prevent acci[...]

  • Page 8

    OM-481 Page 4 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

  • Page 9

    OM-481 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 4/02 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.  Identifie un message de s é curit é particu[...]

  • Page 10

    OM-481 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

  • Page 11

    OM-481 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement.  Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

  • Page 12

    OM-481 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences.  Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.  Demander seulement à des personnes qualifi ?[...]

  • Page 13

    OM-481 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Start Engine Engine Check engine belt Oil Pressure Battery Hourmeter (HM) Do Not Switch Under Load Read Operator ’ s Manual Certified/T rained Mechanic Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Engine Oil T emper - ature Pos[...]

  • Page 14

    OM-481 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 58 (1473 mm) A C Width 32 (813 mm) A B C  Depth 68 in (1727 mm) D  Do not exceed operating angles while running or engine damage will A 1-1/16 in (27 mm) D E F while running or engine damage will occur .  B 29-7/8 in (759 mm) G  Do not move or operate unit w[...]

  • Page 15

    OM-481 Page 1 1 3-4. Duty Cycle And Overheating sb1.1 8/93 SB-134 397-C Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . Continuous W elding 100% Duty Cycle At 600 Amperes 10 100 15 20 25 30 40 50 60 80 100 150 200 250 300 400 500 600 800 100[...]

  • Page 16

    OM-481 Page 12 3-6. V olt-Ampere Curves SB-133 004-A / SB-133 003-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. For Constant Current (CC) Mode B. For Constant V oltage (CV) Mode[...]

  • Page 17

    OM-481 Page 13 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 7/02 – Ref. ST-800 652 / Ref. ST -800 477-A / ST-158 936-A / S-0854 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 1 2  Always securely fasten welding generator onto transport vehicle or trailer an d comply with all DOT [...]

  • Page 18

    OM-481 Page 14 4-3. Installing Exhaust Pipe And Rain Cap  Stop engine, and let cool. 1 Exhaust Pipe 2 Muf fler Pipe Install exhaust pipe over muffler pipe. Secure exhaust pipe to top cover using supplied hardware. 3 Rain Cap Install so cap opens toward front of unit.  Do not blow exhaust toward air cleaner or air intake. Ref. ST-156 467-C 1/2[...]

  • Page 19

    OM-481 Page 15 4-5. Connecting T o Weld Output T erminals 1 Positive (+) W eld Output T erminals 2 Negative ( – ) W eld Output T erminals For Direct Current Electrode Positive (DCEP), connect work cable to Negative ( – ) terminal and electrode holder cable to Positive (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable con[...]

  • Page 20

    OM-481 Page 16 4-7. Remote 14 Receptacle RC3 Information Socket* Socket Information AJ B K I A 24 volts ac. Protected by circuit breaker CB4. B C L NH D M G E F B Contact closure to A completes 24 volts ac contactor control circuit. I 1 1 5 volts ac. Protected by circuit breaker CB3. J Contact closure to I completes 1 15 volts ac contactor control [...]

  • Page 21

    OM-481 Page 17 4-8. T erminal Strip 3T Connections Ref. ST-131 784-A / Ref. ST -121 578-D / Ref. S-184 781  Stop engine. If remote control plug does not fit in receptacle RC3, wire cord directly to terminal strip 3T .  Do not connect to Remote 14 receptacle RC3 and terminal strip 3 T at the same time. Use only one remote control method. Open [...]

  • Page 22

    OM-481 Page 18 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Front Panel Controls ST-134 687-B 12 4 5 6 7 8 9 10 11 12 15 14 13 3 1 V oltmeter 2 Ammeter 3 Ampere Range Switch  Do not switch under load. Use switch to select weld amperage range. For most welding applications, use lowest amperage range possible to help prevent arc outages. 4[...]

  • Page 23

    OM-481 Page 19 5-2. Example Of Remote Amperage Control Set Switches Adjust Remote Control Set Percentage Min = 55 A DC/CC Percentage Of Range = 50% Max = 90 A DC/CC (50% of 55 to 125) In Example: S-0774 / S-0769 Set Range Min ( 5 5 A DC/CC) Max (90 A DC/CC) 2 3 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt Duplex GFCI Receptacles Ref[...]

  • Page 24

    OM-481 Page 20 6-2. 240 V olt Duplex Receptacle (Optional) Ref. ST-174 733 / ST -174 757  If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. 1 240 V 15 A AC Duplex Receptacle RC1 Receptacle supplies 60 Hz single-phase power at weld/power speed. Maximum out- put from this receptacle is 3 kV A/kW . 2 120 V 20 A AC Duple[...]

  • Page 25

    OM-481 Page 21 100 h Change Oil. See Section 7-4. Change Oil Filter . S e e Section 7-4. Check air cleaner hoses for cracks and loose clamps. Clean And T ighten Battery Connections. 200 h Replace Unreadable Labels. 250 h Check An d Clean Spark Arrestor . Se e Section 7-8. 500 h Repair Or Replace Cracked Cables. 1000 h Blow Out Or V acuum Inside. Du[...]

  • Page 26

    OM-481 Page 22 7-2. Maintenance Label[...]

  • Page 27

    OM-481 Page 23 7-3. Servicing Air Cleaner aircleaner1 2/01 – ST -153 929-B / ST-153 585 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding capac- [...]

  • Page 28

    OM-481 Page 24 7-4. Servicing Fuel And Lubrication Systems Ref. ST-153 653-A / Ref. SD-131 784  Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Secondary Fuel Filter 4 Primary Fuel Filter/W ater Separator 5 Petcock 6 Sludge Drain Plug T o change oil and filter: See engine manual. T o drain water from fuel system: Open petcock and drain[...]

  • Page 29

    OM-481 Page 25 7-5. Adjusting Engine Speed  Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer . See table for proper no load speeds. If necessary , adjust speeds as follows: 1 Speed Adjustment Screw 2 Locknut Loosen nut. Start engine. T urn screw until[...]

  • Page 30

    OM-481 Page 26 7-7. Checking And Replacing Engine Belt Ref. ST-134 730-B / SD-131 784-A  Stop engine, and let cool. A V -belt drives the engine cooling fan and alternator . T o check tight- ness of belt, proceed as follows: Remove rear panel. 1 Fan Pulley 2 Alternator Pulley 3 Engine Belt Place straight edge along top of pul- leys. Push down bel[...]

  • Page 31

    OM-481 Page 27 7-9. Adjusting Overspeed Shutdown V alve Drawing #  Stop engine, and let cool. The overspeed shutdown valve protects the engine from damage du e to high engine speed. If the en- gine stops, the valve may be closed. Shutdown speed is between 1950 an d 2100 rpm. Use a tachometer t o check shutdown speed as follows: Open right side d[...]

  • Page 32

    OM-481 Page 28 7-10. T roubleshooting A. Welding T rouble Remedy No weld output. Be sure Ampere Range switch is not set between positions. Disconnect equipment from generator power receptacles during start-up. Reset circuit breaker CB3 and/or CB4 (see Section 7-6). Place A/V Control switch in Panel position, or place switch in Remote position and c[...]

  • Page 33

    OM-481 Page 29 B. Generator Power T rouble T rouble Remedy No output at 120 volt ac receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 6-1). Check fuse F6, and replace if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes and slip rings. Low or high generator power output voltage at 120 volt ac receptacles.[...]

  • Page 34

    OM-481 Page 30 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator[...]

  • Page 35

    OM-481 Page 31 194 139-B[...]

  • Page 36

    OM-481 Page 32 SECTION 9 – RUN-IN PROCEDURE run_in1 8/01 9-1. W etstacking  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Welding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wet[...]

  • Page 37

    OM-481 Page 33 9-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Load Bank T urn all lo[...]

  • Page 38

    OM-481 Page 34 9-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Resistance Grid [...]

  • Page 39

    OM-481 Page 35 SECTION 10 – GENERA TOR POWER GUIDELINES 10-1. Selecting Equipment gen_pwr 6/02 – Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment  Do not use 2-prong plug un- less equipment is double in- sulated.[...]

  • Page 40

    OM-481 Page 36 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electric[...]

  • Page 41

    OM-481 Page 37 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850 [...]

  • Page 42

    OM-481 Page 38 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 39[...]

  • Page 43

    OM-481 Page 39 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

  • Page 44

    OM-481 Page 40 10-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.  Customer -supplied equipment is re- quire[...]

  • Page 45

    OM-481 Page 41 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

  • Page 46

    OM-481 Page 42 SECTION 1 1 – P ARTS LIST 12 3 4 5 6 89 1 0 1 1 12 13 14 15 16 17 18 19 21 22 65 93 65 66 69 70 71 65 66 72 73 72 77 5 78 80 82 73 67 66 83 84 85 87 88 89 90 92 Fig 1 1-2 Fig 1 1-4 Fig 1 1-3 7 20 68 79 81 5 74 64 75 76 94 95 96 97 65 98 99  Hardware is common and not available unless listed. Figure 1 1-1. Main Assembly[...]

  • Page 47

    OM-481 Page 43 ST-134 499-H 23 24 25 26 27 28 29 30 31 30 32 33 34 47 48 49 50 51 52 53* 54 55 56 57 58 59 47 48 60(Fig. 1 1 – 5) 61 62 63 35 36 38 39 40 41 42 43 44 45 46 37 100[...]

  • Page 48

    OM-481 Page 44 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 Fig 1 1-2 P ANEL, front w/components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fig 1 1-4 CONTROL BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 49

    OM-481 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 48 071 731 W ASHER, flat stl .656 ID x 2.250 OD x .187thk 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1 16 707 SUPPORT , front engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 50

    OM-481 Page 46 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 99 1 18 790 ANGLE, strain relief 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 089 256 CLAMP , stl cush 1.750dia x .531mtg hole 1 . . . . . . . . . . . . . . . .[...]

  • Page 51

    OM-481 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Fig 1 1-1 Item 1) Quantity 1 S3 131 213 SWITCH, range/changeover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 18 340 P ANEL, front upper 1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 52

    OM-481 Page 48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 18 9 1 ST-134 501-B  Hardware is common and not available unless listed. Figure 1 1-3. Panel, Front Lower w/Components[...]

  • Page 53

    OM-481 Page 49 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Panel, Front Lower w/Components (Fig 1 1-1 Item 90) 1 038 612 TERMINAL ASSEMBL Y , pwr output (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 601 840 NUT , brs hex .500-13 jam 4 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 54

    OM-481 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 1 1-4. Control Box (Fig 1 1-1 Item 2) Quantity 1 2T 129 939 BLOCK, term 10A 19P 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 187 013 ENCLOSURE, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 55

    OM-481 Page 51 Description Part No. Item No. Figure 1 1-5. Generator (Fig 1 1-1 Item 60) Quantity 1 *151 299 BRUSH, contact elect clrg .375 x .750 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 188 387 BRUSHHOLDER/BRACKET ASSEMBL Y (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 56

    OM-481 Page 52 Notes[...]

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  • Page 59

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/02 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 60

    PRINTED IN USA  2002 Miller Electric Mfg. Co. 5/02 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters – US A USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headqua rters –[...]