Miller BIG BLUE 600DX Owner's manual

Miller
Brand
Miller
Model
BIG BLUE 600DX
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
October
1996
Form:
OM-133929L
Effective
With
Serial
No.
KG1
91348
OWNERS
MANUAL
*
~T@
~
Big
Bluefi
600DX
CC/DC
Welding
Generator
For
SMAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-Ci~uit
Voltage
DC
Auxiliary
Power
Rating
Engine
Fuel
Capacity
.
600
A,
40
Volts
DC,
40%
Duty
Cycle
45600
95
Single-Phase,
3
kVA/kW,
25
A,
120
V
AC,
60
Hz
Deulz
F3L-912
Air-Cooled,
Three-Cylinder,
41.5
HP
Diesel
Engine
23
gal
(87
L)
cover_om
4/95
-
ST-048
720-J
'
1996
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
Ni
J
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warrenty
supersedes
all
previous
MILLER
wsrrsnties
and
is
exclusive
with
no
other
guerentees
or
warrenties
expressed
or
implied.
LIMITED
WARRANTY
Subjecttothe
terms
snd
conditions
below,
MILLER
Electric
Mfg.
Co..
Appleton,
Wisconsin,
wsrrsnta
to
its
originsl
retail
purchsser
thst
new
MILLER
equipment
sold
sfter
the
effective
dste
of
this
limited
werrenty
is
free
of
de
fects
in
material
end
wortcmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRAN11ES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
wsrrsnty
periods
listed
below,
MILLER
will
mpsir
or
replsce
sny
wsr
rented
pens
orcomponents
thst
fsil
due
to
such
defects
in
meteriel
orworlrmenship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
dsys
of
such
defect
orfailure,
st
which
time
MILLER
will
provide
instructions
on
the
wsrrenty
cleim
procedures
to
be
followed.
MILLER
shell
honor
wsrrenty
clsims
on
wenented
equipment
listed
below
in
the
event
01
such
s
feilum
within
the
werrenty
time
periods.
All
werranty
time
periods
atsrt
on
the
dete
thst
the
equipment
was
delivered
to
the
oflginsl
retsil
purchaser,
or
one
yesr
sfter
the
equipment
is
sent
to
e
North
Americsn
distributor
or
eighteen
months
etter
the
equipment
is
sent
to
en
Intemetionel
distributor.
1.
5YeemPerta3YesmLabor
Original
mein
power
rectifiers
*
Invertem
(input
end
output
mctitiers
only)
2.
3
Yeem
Perle
end
Labor
*
Trenstormer/Rectifier
Power
Sources
*
Pleeme
Arc
Cutting
Power
Sources
*
Semi-Automatic
end
Autometic
Wire
Feeders
Inverter
Power
Supplies
*
Intellitig
Robots
(1
yeer
Isbor)
3.
2
Yeem
Perle
end
Labor
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
ere
warrented
eepemtely
by
the
engine
menufectumr.)
*
Air
Compressors
4.
1
Yesr
Pens
end
Labor
*
Motor
Driven
Guns
Process
Controllers
lHP5PowerSources
Weter
Coolent
Systems
*
HFUnite
Grids
Spot
Welders
*
Loed
Benks
*
SDX
Tmneforrnem
Miller
Cyclometic
Equipment
*
Running
Geer/Treilem
*
Pleame
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumseh
Engines
*
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
em
covered
under
True
Bluefi
for
the
mmeining
warrsnty
period
of
the
product
they
ere
installed
in,
or
fore
minimum
of
one
yeerwhicheveris
greeter.)
5.
6
Months
Betterlee
6.
90
Deys
Perle
end
Labor
*
MIG
GuneiIlG
lbrches
APT,
ZIPCUT
&
PLAZCUT
Model
Plseme
Cutting
Torches
*
Remote
Controls
*
Accessory
Kits
Replscement
Pens
MILLERS
True
Bluefi
LImited
Warrenty
shell
not
epply
to:
1.
Items
fumiehed
by
MILLER,
but
menufectured
by
others,
such
se
engines
or
trade
ecceseoriee.
These
items
em
covered
by
the
menufecturers
werrenty,
if
any.
2.
Consumeble
components;
such
es
contect
tips,
cutting
nozzles,
contectom
end
releys
or
pens
thet
feil
due
to
normal
weer.
3.
Equipment
thet
hes
been
modified
by
eny
petty
other
then
MILLER,
or
equip
ment
that
hes
been
improperly
instelled,
improperly
operated
or
misused
besed
upon
industry
etenderds,
or
equipment
which
hes
not
hsd
meeoneble
end
necesaary
meintenence,
or
equipment
which
hes
been
used
for
operstion
outside
of
the
epecficetions
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
In
the
event
01
e
warranty
claim
covered
by
this
werrenly,
the
exclusive
remedies
shell
be,
st
MILLERS
option:
(t)
repei~
or
(2)
replscement;
o
where
euthorized
in
writing
by
MILLER
in
eppropriete
cases,
(3)
the
reesoneble
cost
of
repeir
or
replece
ment
et
en
euthorized
MILLER
service
stetion;
or
(4)
peyment
of
or
credit
forthe
pur
chase
price
(less
reasoneble
deprecietion
besed
upon
ectuel
use)
upon
mtum
of
the
goode
et
customers
risk
end
expense.
MILLERS
option
of
repeir
or
replecement
will
be
FOB.,
Fectoryet
Appleton,
Wisconsin,
or
FOB.
et
e
MILLER
euthorized
ser
vice
fecility
se
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
trenaporletion
costs
of
eny
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT
SPECIAL,
INCIDENTALOR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTAT1ON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPUCA11ON,
OPERA11ON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PAR11CULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EGUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
en
implied
warranty
lasts,
or
the
exclusion
of
incidentel,
indirect,
specisl
or
consequentiel
demages,
so
the
ebove
limitetion
or
exclusion
mey
not
epply
to
you.
This
werrenty
provides
ape
cfic
legel
rights,
end
other
rights
mey
be
aveileble,
but
mey
very
from
stste
to
stste.
In
Cenada,
legieletion
in
some
provinces
provideeforcertein
edditionel
werrentiee
or
remedies
other
then
as
stated
herein,
end
to
the
extent
thet
they
mey
not
be
waived,
the
limitstione
end
exclusions
set out
ebove
may
not
epply.
This
Umited
Werrenty
provides
specific
legel
rights,
end
other
rights
may
be
available,
but
mey
very
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(Service
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process
Handbooks
To
file
a
claim
for
loss
or
damage
during
shipment,
U
contact
the
deliVering
canier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
anwor
equipment
manufacturers
Transportation
Department
L~T1
Miller
Electric
Mfg.
Co.
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Users
Guides
Distributor
Directories
contact
your
distributor
1e
=
WRITE:
Mi)ler
Electric
Mfg.
Co.
P0.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Seriai
or
Styie
Number
u
miller_wan
3/96
TABLE
OF
CONTENTS
SECTION
1
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Engine
Hazards
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
3
1-5.
Principal
Safety
Standards
3
1-6.
EMF
Information
3
SECTION
2
DEFINITIONS
4
2-1.
Symbols
And
Definitions
4
SECTION
3
INSTALLATION
5
3-1.
Installing
Welding
Generator
5
3-2.
Dimensions,
Weights,
And
Operating
Angles
5
3-3.
Activating
The
Dry
Charge
Battery
6
3-4.
Connecting
The
Battery
7
3-5.
Installing
Exhaust
Pipe
7
3-6.
Fuel
Consumption
7
3-7.
Engine
Prestart
Checks
8
3-8.
Weld
Output
Terminals
And
Cable
Sizes
9
3-9.
Installing
Ether
Cylinder
(Optional
Ether
Starting
Aid)
9
SECTION
4OPERATING
THE
WELDING
GENERATOR
10
4-1.
Duty.Cycle
And
Overheating
10
4-2.
Front
Panel
Controls
11
4-3.
Remote
NV
Control
12
SECTION
5-
OPERATING
AUXILIARY
EQUIPMENT
13
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
13
5-2.
Optional
Auxiliary
Power
Receptacles
14
5-3.
Connecting
Optional
Auxiliary
Power
Plant
15
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
16
6-1.
Routine
Maintenance
16
6-2.
Maintenance
Label
17
6-3.
Servicing
Air
Cleaner
18
6-4.
Servicing
Fuel
And
Lubrication
Systems
19
6-5.
Adjusting
Engine
Speed
20
6-6.
Servicing
Optional
Ether
Starting
Aid
20
6-7.
Checking
And
Replacing
Alternator
Belt
21
6-8.
Resetting
Fan
Belt
Safety
Shutdown
22
6-9.
Inspecting
And
Cleaning
Optional
Spark
Arrestor
Muffler
23
6-10.
Troubleshooting
23
SECTION
7
ELECTRICAL
DIAGRAM
25
SECTION
8
RUN-IN
PROCEDURE
26
8-1.
Wetstacking
26
8-2.
Run-In
Procedure
Using
Load
Bank
27
8-3.
Run-In
Procedure
Using
Resistance
Grid
28
SECTION
9
PARTS
LIST
30
OM-133
929L-
10i96
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
safety_romi
4/95
1-1.
Symbol
Usage
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
This
group
of
symbols
means
Waming!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
________________________________
actions
to
avoid
the
hazards.
1-2.
Arc
Welding
Hazards
a
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-5.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
oower
cord
ground
wire
is
properly
connected
to
ground
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
powercord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
yourface
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
3.
Wear
approved
safety
glasses
with
side
shields.
4.
Use
protective
screens
or
bamers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
NOISE
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
I
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
OM-133
929
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.i
(see
Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
oft
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leathergloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Engine
Hazards
a
WARNING
A
~!
1.
2.
3.
ENGINE
Engines
pr
EXHAUST
GASES
can
kill.
oduce
harmful
exhaust
gases.
1.
2.
Use
equipment
outside
in
open,
well-ventilated
areas.
away
from
any
building
air
intakes.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
.~
f
A
-
ENGINE
FUEL
can
cause
fire
or
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
explosion,
open
flames.
Engine
fuel
is
highly
flammable.
3.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
I
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
1.
Stop
engine
and
let
it
cool
off
before
checking
or
adding
fuel,
engine.
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
Moving
parts,
such
as
fans,
rotors,
and
belts
can
maintenance
and
troubleshooting
as
necessary.
cut
fingers
and
hands
and
catch
loose
clothing.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
parts.
securely
in
place.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
engine
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on
a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop
engine
before
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
Batteries
contain
acid
and
generate
explosive
3.
4.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
gases.
5.
Observe
correct
polarity
(-I-
and
)
on
batteries.
.
~
&~IgW
STEAM
AND
PRESSURIZED
COOLANT
can
burn
face,
eyes,
skin.
it
is
best
to
check
coolant
level
when
eng
cold
to
avoid
scalding.
HOT
and
me
is
1.
2.
3.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and
3.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
Turn
cap
slightly
and
let
pressure
escape
slowly
before
completely
removing
cap.
OM-133
929
Page
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
a
WARNING
MOVING
PARTS
can
cause
injury.
1.
Before
working
of
generator,
remove
spark
plugs
or
injectors
to
keep
engine
from
kicking
back
or
starting.
Block
flywheel
so
that
it
will
not
tum
while
working
___________
_____________________________________________
on
generator
components.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
_______
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
___________
_______________________________________________
move,
or
ship
PC
boards.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
___________
_____________________________________________
operations.
HOT
PARTS
can
cause
severe
burns.
1.
Allow
cooling
period
before
maintaining.
2.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
BATItRY
ACID
can
BURN
SKIN
AND
FALLING
EQUIPMENT
can
cause
serious
EYES
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
1.
Do
not
tin.
gas
cylinders,
or
any
other
accessories.
2.
Replace
damaged
battery.
Use
equipment
of
adequate
capacity
to
lift
unit.
3.
Flush
eyes
and
skin
immediately
with
water.
READ
INSTRUCTIONS.
1.
Use
only
genuine
MILLER
replacement
parts.
2.
Reinstall
injectors
and
bleed
air
from
fuel
system
according
to
engine
manual.
DO
NOT
LET
ENGINE
EXHAUST
SPARKS
1~
CAUSE
FIRE.
.
1.
Use
approved
engine
exhaust
spark
arrestor
in
required
areas
see
applicable
codes.
,
LOW
VOLTAGE
AND
FREQUENCY
CAN
DAMAGE
electrical
equipment
such
as
c~j~
J
MOTORS.
1.
Tum
oft
or
unplug
equipment
before
starting
or
stopping
engine.
~
~
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
startingtoweldagain.
3.
Follow
rated
duty
cycle.
I
TILTING
OF
TRAILER
can
cause
injury.
1.
Use
tongue
jack
or
blocks
to
support
weight.
2.
Properly
install
welding
generator
onto
trailer.
according
to
instructions
supplied
with
trailer.
1-5.
Principal
Safety
Standards
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1
,from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safely
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Govemment
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-6.
EMF
Information
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
forSafety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.i
,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cuffing
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Considerations
About
Welding
And The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Papei
OTA-BP-E-53
(Washington,
DC:
U.S.
Govemment
Printing
Office,
May
1989):..
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
nut
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information~
OM-133
929
Page
3
SECTION
2-
DEFINITIONS
2-1.
Symbols
And
Definitions
fi
~
Stop
Engine
Start
Engine
Ether
Starting
Aid
Engine
fi
/
..
Do
Not
Switch
While
Welding
I
+
I
Battery
(Engine)
Circuit
Breaker
Engine
Oil
Check
lnjectors/
Pump
Check
Valve
Clearance
j~
Fuel
Protective
Earth
(Ground)
f.
Positive
Negative
CertifiediTrained
Mechanic
/
..
.
Welding
Arc
A
Amperes
~(
Volts
Panel/Local
~j
Remote
Read
Operators
Manual
Temperature
c~3~-).
Output
/\~,
Alte
mating
Current
Q~
Time
Hours
Seconds
1
\..,
Single
Phase
3
/\4/
Three
Phase
OM-133
929
Page
4
SECTION
3-
INSTALLATION
Height
Width
Depth
A
B
C
D
E
F
G
H
J
K
L
Dimensions
47-5/8
in
(1210
mm)
31-1/4
in
(794
mm)
60-1/2
in
(1537
mm)
59-1/8
in
(1502
mm)
47-1/4
in
(1200
mm)
43-1/4
in
(1099
mm)
32-3/4
in
(832
mm)
24-15/16
in
(633
mm)
10-1/2
in
(267
mm)
6-1/2
in
(165
mm)
2-7/8
in
(73
mm)
29-7/8
in
(759
mm)
11/16
in
(24
mm)
21/32
in
(17
mm)
Dia.
16
Holes
Weight
1898
lb
(861
kg)
3-1.
Installing
Welding
Generator
Movement
A
Do
Not
Lift
Unit
From
End
Airflow
Clearance
OR
Location
18
in
l8in
(460
mm)
Grounding
18
in
(460
mm)
18
in
OR
1
Generator
Base
2
Metal
Vehicle
Frame
3
Equipment
Grounding
Terminal
4
Grounding
Cable
Use
#10
AWG
or
larger
insulated
copper
wire.
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI
protected
extension
cord.
Electrical!ybondgeneratorframe
to
vehicle
frame
by
metal-to-metal
contact.
3-2.
Dimensions,
Weights,
And
Operating
Angles
instafil
3/96
Ref.
ST-800
652
I
Ref.
ST-800
477-A
/
ST-i
58 936-A
/
S-0854
I
Do
not
move
or
operate
unit
where
it
could
tip.
A
Do
not
exceed
operating
angles
while
run
fling
or
engin
e
damage
will
occur.
A
ST-158
699
angles_i
3196
OM-1
33929
Page
5
3-4.
Connecting
The
Battery
3-6.
Fuel
Consumption
3-5~
Installing
Exhaust
Pipe
~L!i
A
Stop
engine
and
let
cool.
A
Do
not
blow
exhaust
toward
air
cleaner
or
air
intake.
Top
View
Tools
Needed:
~
1/2in
exhpipe2
4/96
ST-i
54
089-A
/
ST-154
611
/
ST-i
80
933
The
curve
shows
typical
fuel
use
under
weld
or
power
loads.
a.
~
7.57
1.70
2.00
6.82
1.46
1.75
5.67
1.25
1.50
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.62
0.75
1.98
0.40
0.50
0.95
0.21
0.25
0
200
250
300
350
400
450
500
DC
WELD
AMPERES
AT
bOX
DUTY
CYCLE
Ref.
ST-047
094-B
OM-1
33929
Page
7
3-7.
Engine
Prestart
Checks
Check
all
fluids
daily.
Engine
must
be
cold
and
on
a
level
surface.
Follow
run-in
procedure
in
engine
manual.
If
unburned
fuel
and
oil
collect
in
exhaust
pipe
during
run-in,
see
Section
8.
OM-133
929
Page
8
3-8.
Weld
Output
Terminals
And
Cable
Sizes
3-9.
Installing
Ether
Cylinder
(Optional
Ether
Starting
Aid)
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
To reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
electronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
0
L
150ft
200ft
250ft
300ft
350ft 400ft
100
ft
(30m)
r
ess
(45
m)
(60
m)
(70
m)
(90
m)
(105
m)
(120
m)
1060%
Duty
Cycle
60
100%
Duty
Cycle
10100%
Duty
Cycle
4
4
4
3
2
1
3
3
2
1
1/0
2/0
3
2
1
1/0
2/0
3/0
2
1
1/0
210
3/0
4/0
1
1/0
2/0
3/0
4/0
2-2/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2/0
3/0
4/0
2-2/0
Weld
cable
size
(AWG)
is
based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
at
least
300
circular
mils
per
ampere
2-3/0
2-4/0
A
Stop
engine.
A
Improper
handling
or
expo
sure
to
ether
can
harm
your
health.
Follow
manufactur
ers
safety
instructions
on
cylinder.
A
Do
not
use
Ether
Starting
Aid
while
engine
is
running.
Open
side
door(s).
1
Ether
Cylinder
2
Nozzle
Remove
cover
and
clean
cylinder
nozzle.
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove
cap
and
clean
fitting.
Install
cylinder
on
fitting.
flghten
clamp.
UT
After
inst
ailing
cylindei
wait
at
least
10
minutes
before
using
to
let
ether
particles
settle
and
prevent
atomizer
plugging.
Put
cap
on
flthng
when
cylinder
is
removed.
etheri
7/96-ST-i
53
382-A
/
ST-i
80933
5
3
.4
6
OM-133
929
Page
9
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
4-1.
Duty
Cycle
And
Overheating
40%
Duty
Cycle
At
600
Amperes
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
-*
4
Minutes
Welding
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
6
Minutes
Resting
000
REED
400
cwP~
-
0,
Ui
U
a
IC
C
-J
Ui
150
w
0
2550
X
DUTY
40
50S0~5000t0
CYCLE
rdutyl
5/95
SB-069
697-B
OM-133
929
Page
10
4-2.
Front
Panel
Controls
1
Ampere
Range
Switch
A
Do
not
switch
under
load.
2
AmperageNoltage
Control
Control
adjusts
amperage
within
range
se
lected
by
Ampere
Range
switch.
Control
ad
justs
amperage
only
when
welding,
and
does
not
adjust
open-circuit
voltage.
Weld
output
would
be
233
A
DC
with
controls
set
as
shown
(50%
of
140
to
325
A).
3
Remote
AN
Control
Receptacle
And
Switch
(See
Section
4-3)
Manual
Stop
Control
4
5
EngineStartButton
6
Ether
Starting
Aid
Switch
(Optional)
Push
switch
up
and
release
while
cranking
engine
to
release
ether.
A
Do
not
use
Ether
if
engine
is
running.
To
Start:
Press
button
and
use
Ether
switch
(if
necessary).
Release
button
when
engine
starts.
Do
not
crank
engine
while
engine
is
tuming.
To
Stop:
Pull
control
out
and
hold.
Release
control
when
engine
stops.
7
DC
Ammeter
(Optional)
ST-158
630-B
/
Ref.
ST-158
631
/
ST-i
80
933
8
DC
Voltmeter
(Optional)
9
Oil
Pressure
Waming
Light
Light
goes
oft
if
oil
pressure
is
too
low.
If
light
goes
off,
stop
engine
and
check
oil
level.
10
Battery
Charging
Waming
Light
Light
goes
on
when
battery
is
not
charging.
Stop
engine
and
check
engine
belt.
A
Stop
engine
and
fix
trouble
if
either
light
goes
on.
11
Engine
Hour
Meter
12
Polarity
Switch
(Optional)
OM-133
929
Page
11
4-3.
Remote
NV
Control
ZNv
Example:
Combination
Remote
Amperage
Control
0
1
AN
Control
Switch
Use
switch
to
select
front
panel
or
remote
amperage
control.
2
Remote
A/V
Control
Receptacle
RC3
Connect
optional
remote
control
to
RC3.
In
Example:
Range
=
140
to
325
A
Percentage
Of
Range
=
50%
Max
=
233
A
DC
(50%
of
140
to
325)
Max
(233ADC)
Mm
(100
A
DC)
A/V
Set
Switches
Set
Range
Set
Percentage
Adjust
Optional
Remote
Control
S-0774
I
Ret.
ST.18O
933
OM-133
929
Page
12
SECTION
5-
OPERATING
AUXILIARY
EQUIPMENT
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
r
i
I
L
(~
j~
A
If
unit
does
not
have
GFCI
~
411111
receptacles,
use
GFCI-pro
______________________________
tected
extension
cord.
1
120
V
15
A
AC
Receptacle
RC2
2
240
V
15
A
AC
Receptacle
RC1
Receptacles
supply
60
Hz
single-
phase
power
at
weld/power
speed.
3
Circuit
Breakers
CB1
And
CB2
CB1
and
CB2
protect
RC1
and
RC2
from
overload.
If
CB1
or
CB2
opens,
RC1
and
one
half
of
RC2
does
not
work.
120
volts
may
still
be
present
at
RC1.
Press
button
to
reset
breaker.
U?
If
a
circuit
breaker
continues
to
open,
contact
Factory
Autho
rized
Se,vice
Agent.
Maximum
output
from
each
duplex
receptacle
is
1.8
kVA/kW,
and
3
kVNkW
from
all
receptacles.
ItT
Auxiliary
power
is
not
affected
by
weld
output.
EXAMPLE:
If
10
A
is
drawn
from
RC1,
only
5
A
is
available
at
RC2:
(240
V
x
10
A)
+
(120
V
x
5
A)
=
3.0
kVA/kW
Rof.
ST-iso
933
OM-133
929
Page
13
5-2.
Optional
Auxiliary
Power
Receptacles
I(~n~2
240V
13A
Auxiliary
power
is
not
affected
by
weld
output.
If
a
circ
ult
breaker
continues
to
open,
contact
Factory
Aulho
rized
Se,vice
Agent.
GFCI
Receptacle
Option
1
120V15AACGFCI
Receptacle
GFCI1
Auxiliary
power
output
and
circuit
breaker
protection
is
the
same
as
standard
receptacles
(see
Section
5-1)
If
a
ground
fault
is
detected,
GFCI
Reset
button
pops
out
and
receptacle
does
not
work.
Check
for
faulty
tools
plugged
in
receptacle.
Press
button
to
reset.
~
At
least
once
a
month,
run
en
gine
at
weld/power
speed
and
press
test
button
to
verify
GFCI
is
working
properly.
Australian
And
South
African
Receptacle
Options
2
240
V
10
A
AC
Australian
Receptacle
RC1
3
24OVoltl3AACSouth
African
Receptacle
RC1
RC1
supplies
60
Hz
single-phase
power
at
weld/power
speed.
Maxi
mum
output
from
receptacle
is
3
kVAIkW.
4
Circuit
Breaker
CB1
CB1
protects
RC1
from
overload.
If
CB1
opens,
RC1
does
not
work.
Press
button
to
reset
breaker.
British
Receptacle
Option
5
240
Volt
13
A
AC
British
Receptacles
RC1
And
RC2
RC1
and
RC2
supply
60Hz
single-
phase
power
at
weld/power
speed.
Maximum
combined
output
of
both
receptacle
is
3
kVNkW.
6
Circuit
Breaker
CB1
CB1
protects
RC1
and
RC2
from
overload.
If
CB1
opens,
the
recep
tacles
do
not
work.
Press
button
to
reset
breaker.
Ref.
ST-leo
933
/
Ref.
ST-182
266
4~
6.
OM-133
929
Page
14
5-3.
Connecting
Optional
Auxiliary
Power
Plant.
93
91
90
92
A
Stop
engine.
A
Power
and
weld
outputs
are
live
at
the
same
time.
Discon
nect
or
insulate
unused
cables.
Have
qualified
person
install
according
to
circuit
diagram
and
Auxiliary
Power
Guidelines
Booklet
(M176
712).
Remove
junction
box
cover.
1
Lead
93
2
Lead
92
3
Lead
91
4
Lead
90
(Neutral)
5
Lead
42
(Circuit
Grounding
Lead)
Lead
42
connects
to
front
panel
Ground
stud.
6
Grounding
Terminal
7
JumperLead42
8
Isolated
Neutral
Terminal
Jumper
42
is
connected
to
lead
90
at
factory.
Jumper
42
may
be
dis
connected
from
neutral
to
meet
applicable
electrical
codes.
9
User-Supplied
Leads
10
Load
Terminals
Connect
leads
to
terminals.
11
Fuses
Fl,
F2,
And
F3
Fl
F2,
and
F3
protect
each
load
line
from
overload.
Tools
Needed:
Ref.
S-iSO
187
(
AC
~
Output
Single
Phase
1
~-~i
Three
Phase
3
(\J
Volts
120/240
240
Amps
31
24
KVNKW
7.5
10
Frequency
60
Hz
Engine
Speed
1850
RPM
Max.
Fuse
Size
35
Amperes
OM-133
929
Page
15
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
fi8h
Recycle
engine
fluids.
A
Stop
engine
before
maintaining.
See
also
Engine
Manual
and
Mainte
nance
LabeL
Senace
engine
more
often
during
severe
conditions.
50h
Change
Oil.
See
Section
6-4.
500h
4
1000
h
250h
OM-133
929
Page
16
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Miller BIG BLUE 600DX Owner's manual

Miller
Brand
Miller
Model
BIG BLUE 600DX
Category
Welding System
Type
Owner's manual
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