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Engine-Driven
Welder/Generator
Miller Electric Mfg. Co. Equipment Sales US and Canada Web Site
An Illinois Tool Works Company Phone: 866-931-9730 www.MillerWelds.com
1635 West Spencer Street FAX: 800-637-2315
Appleton, WI 54914 USA International Phone: 920-735-4554
International FAX: 920-735-4125
Big Blue 500 X and 600 X CC Specifications
® (Subject to change without notice.)
Welding Weld Output Weld Output Rated at Max. Open- Generator Output Weight
Model Mode Range 40˚C (104˚F) Circuit Voltage Rated at 40˚C (104˚F) Dimensions** (without fuel)***
Big Blue CC/DC 55 – 500 A 400 A at 36 V (14.4 kW),* 95 Peak: 5500 watts H: 1092 mm Perkins 404D.22:
500 X CC 100% Duty Cycle Continuous: 4000 watts, (43 in) 701 kg (1545 lb)
450 A at 38 V (17.1 kW),* 1-phase, 34/17 A, W: 724 mm Deutz D2011L03i:
60% Duty Cycle 120/240 VAC, 50/60 Hz (28-1/2 in) 751 kg (1655 lb)
while welding D: 1654 mm
500 A at 30 V (15 kW),
40% Duty Cycle (65-1/8 in)
Big Blue 55 – 600 A 500 A at 40 V (20 kW),* Deutz D2011L04i:
600 X CC 100% Duty Cycle 769 kg (1695 lb)
550 A at 34 V (18.7 kW), Deutz D912L03:
60% Duty Cycle 810 kg (1785 lb)
600 A at 30 V (18 kW),
40% Duty Cycle
*Perkins powered models are approved — meet NEMA and IEC output ratings. Deutz powered models meet NEMA and IEC output ratings.
**Additional 178 mm (7 in) to top of exhaust. ***Additional 86 kg (190 lb) when fuel tank is full.
1. DC Ammeter*
1
2. DC Voltmeter*
9
2 3. Amperage Adjust Control
10
11 4. Amperage Range Switch
3
5. Amperage Adjust Switch and
4 12
Remote Amperage Adjust Receptacle
6. Stick/TIG Selector Switch
7. Earth Leakage Circuit Breaker
OFF
8. 230 VAC, 16 A Pin and Sleeve Receptacle
9. Fuel Gauge/Hour Meter/Oil Change
RUN/IDLE
RUN
5 START
Interval/Engine Shutdown Indicator
13
6 14 10. Engine Oil Pressure Gauge
11. Battery/Voltmeter*
12. Engine Coolant Temperature Gauge
13. Engine Control Switch
7 14. Starting Aid Switch
15
8 (standard on Perkins model)
15. 120 VAC, 20 A GFCI Duplex Receptacle
16. Polarity Switch*
16 *Optional.
Additional Features
Proven, rugged rheostat control technology A Stick/TIG switch optimizes open-circuit Provisions are provided to plug a RHC3GD34A
that has been in Miller engine drives for over voltage for Stick welding and allows the open- remote control that will allow precise adjust-
60 years. Contains no printed control boards. circuit voltage to be lowered for scratch start ment of amperage without walking back to
TIG welding. the machine.
2
Big Blue 500 X and 600 X CC/CV Specifications
® (Subject to change without notice.)
Welding Weld Output Weld Output Rated at Max. Open- Generator Output Weight
Model Mode Range 40˚C (104˚F) Circuit Voltage Rated at 40˚C (104˚F) Dimensions** (without fuel)***
Big Blue CC/DC 15 – 550 A 400 A at 36 V (14.4 kW),* 95 Peak: 5500 watts H: 1092 mm Perkins 404D.22:
500 X CC/CV CV/DC 14 – 40 V 100% Duty Cycle Continuous: 4000 watts, (43 in) 701 kg (1545 lb)
450 A at 38 V (17.1 kW),* 1-phase, 34/17 A, W: 724 mm Deutz D2011L03i:
60% Duty Cycle 120/240 VAC, 50/60 Hz (28-1/2 in) 751 kg (1655 lb)
while welding D: 1654 mm
500 A at 34 V (17 kW),
40% Duty Cycle (65-1/8 in)
Big Blue 20 – 600 A 500 A at 40 V (20 kW),* Deutz D2011L04i:
600 X CC/CV 14 – 40 V 100% Duty Cycle 769 kg (1695 lb)
550 A at 42 V (23.1 kW), Deutz D912L03:
60% Duty Cycle 810 kg (1785 lb)
600 A at 34 V (20.4 kW),
40% Duty Cycle
*Perkins powered models are approved — meet NEMA and IEC output ratings. Deutz powered models meet NEMA and IEC output ratings.
**Additional 178 mm (7 in) to top of exhaust. ***Additional 86 kg (190 lb) when fuel tank is full.
1 1. DC Ammeter
9 2. DC Voltmeter
2 10 3. Amperage/Voltage Adjust Control
3 11 4. Amperage Range Switch
4 12 5. Amperage/Voltage Adjust Switch and
Remote Amperage/Voltage Adjust Receptacle
6. Process/Contactor Selector Switch
7. Earth Leakage Circuit Breaker
8. 230 VAC, 16 A Pin and Sleeve Receptacle
6 5 OFF
RUN
START
Additional Features
One MIG welding range allows precise voltage boards carry high power and high heat, making
control for welding with 0.6 – 3.2 mm them more vulnerable to failure.
(.023 –.120 in) wires.
“The Vault” Makes Upgrading to Miller CC/CV
A multi-colored process selector control Units Worry-Free
allows quick and easy process changes without Concerns with circuit board reliability have
having to use multiple switches. resulted in some operators steering clear of
CC/CV welder/generators — even though
14-pin remote control allows precise adjustment they offer a superior arc and multiple welding
of amperage or voltage, along with contactor processes. Miller’s circuit board reliability
control, without walking back to the machine. isn’t a concern since all Big Blue multiprocess and controlling output — in heavy industrial
industrial engine drives feature the Vault. applications. No other competitor protects their
The Vault — Superior Circuit Board Design
Miller’s critical circuit boards are engineered Created out of two aluminum halves sealed electronics with a sealed vault, leaving critical
to carry low power and low heat to reduce with silicone, as well as watertight harness circuit boards exposed to harsh elements that
thermal stress and minimize expansion and connections, the Vault provides a clean circuit can disrupt the machine’s electronics, and
contraction. In contrast, our competitor’s board environment, protecting the electronics— therefore, its operation.
3
Big Blue 500 X and 600 X CC Performance Data
®
500 X CC 600 X CC
VOLT/AMP CURVES – STICK MODE VOLT/AMP CURVES – STICK MODE GENERATOR POWER CURVE
100 100 150 300
Ranges Ranges
80 230 – Max 80 300 – Max 125 250 4 kW 5.5 kW
170 – 365 185 – 425
AC VOLTS
110 – 225 125 – 320 100 200
DC VOLTS
DC VOLTS
60 70 – 130 60 85 – 190
55 – 85 65 – 90
75 150
40 40
50 100
20 20
25 50
0 0 0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 0 5 10 15 20 25 30
DC AMPERES DC AMPERES AC AMPERES IN 240 V MODE
0 10 20 30 40 50 60
FUEL CONSUMPTION CURVE DUTY CYCLE CURVE AC AMPERES IN 120 V MODE
7.57 1000
6.62 800
WELD AMPERES
600 600 X
5.69
LITERS/HR.
500
4.73 400
500 X
3.79 600 X 300
1800 RPM 250
2.84
500 X 200
1.90
600 X IDLE 150
0.95 500 X IDLE
0.00 100
0 50 100 150 200 250 300 350 400 450 500 10 15 20 25 30 40 50 60 80 100
DC WELD AMPERES AT 100% DUTY CYCLE % DUTY CYCLE
0 0 100
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 10 15 20 25 30 40 50 60 80 100
DC AMPERES DC AMPERES % DUTY CYCLE
LITERS/HR.
DC VOLTS
60 60 4.73
MAX
3.79 600 X
40 40 1800 RPM
MAX 2.84
500 X
20 20 1.90
MIN MIN
600 X IDLE
0.95 500 X IDLE
0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 0.00
0 50 100 150 200 250 300 350 400 450 500
DC AMPERES DC AMPERES
DC WELD AMPERES AT 100% DUTY CYCLE
500 X CC/CV 600 X CC/CV
VOLT/AMP CURVES – TIG MODE VOLT/AMP CURVES – TIG MODE
100 100
Ranges Ranges
80 60 – 365 80 50 – 440
35 – 250 35 – 320
DC VOLTS
DC VOLTS
25 – 155 25 – 215
60 15 – 75 60 15 – 115
40 40
20 20
0 0
0 100 200 300 400 500 0 100 200 300 400 500
DC AMPERES DC AMPERES
4
Engine Specifications (Subject to change without notice.)
Engine Automatic
Engine Speeds Engine
Model Brand Features HP Type (RPM) Capacities Shutdowns
Big Perkins EPA Tier 4i compliant, indirect-injected, liquid-cooled engine 32.6 4-cylinder, Weld: 1850 Fuel: 95 L (25 gal) Low Oil Pressure,
Blue 404D.22 with full load sound levels of 73.2 dB @ 7 m (98 Lwa). industrial, Oil: 8.5 L (9 qt) High Coolant
500 X Right-side service access with intervals of 500 hours for oil liquid-cooled Coolant: 8.5 L (9 qt) Temperature,
and filters. diesel Low Fuel Level
Deutz EPA Tier 4i compliant, direct-injected, air/oil-cooled engine 32.0 3-cylinder, Weld: 1850 Fuel: 95 L (25 gal) Low Oil Pressure,
D2011L03i with full load sound levels of 76.8 dB @ 7 m (101.7 Lwa). industrial, Oil: 5.9 L (6.2 qt) High Coolant
Right-side service access with intervals of 1000 hours for air/oil-cooled Coolant: Temperature,
oil and filters. Approved underground operation with the diesel Integrated oil Low Fuel Level
purchase of a MSHA (30 CFR part 7) certificate.
Big Deutz EPA Tier 4i compliant, direct-injected, air/oil-cooled engine 48.6 4-cylinder, Weld: 1850 Fuel: 95 L (25 gal) Low Oil Pressure,
Blue D2011L04i with full load sound levels of 76 dB @ 7 m (101 Lwa). industrial, Oil: 8.5 L (9 qt) High Coolant
600 X Right-side service access with intervals of 1000 hours for air/oil-cooled Coolant: Temperature,
oil and filters. diesel Integrated oil Low Fuel Level
Deutz The legendary Tier I, EPA-certified, direct-injected, air-cooled 41.5 3-cylinder, Weld: 1850 Fuel: 95 L (25 gal) Low Oil Pressure,
D912L03 engine with full load sound levels of 81 dB @ 7 m (106 Lwa). industrial, Oil: 8.5 L (9 qt) High Coolant
Right-side service access with intervals of 500 hours for oil air-cooled Coolant: Air Temperature,
and filters. diesel Low Fuel Level
RUN/IDLE
RUN
Perkins. 120 volt block heater.
Installation time: 35 minutes START
5
Genuine Miller Accessories
Engine Filter Kits Stick (SMAW) Welding
#246 988 Field. For Deutz D2011
#246 989 Field. For Deutz D912 Weld Leads
#246 985 Field. For Perkins 404 2/0 Stick Cable Set, 15 m (50 ft)
Includes all filters required for proper #173 851
engine maintenance. Oil filter, primary and Consists of 15 m (50 ft) 2/0 electrode cable
secondary fuel filter, and primary air filter. with holder, and 15 m (50 ft) work cable
with clamp. 350 A, 100% duty cycle.
Spark Arrestor SuitCase® 8RC Wire Feeder #300 660
Muffler Kit 2/0 Stick Cable Set, 30.5/15 m (100/50 ft) SuitCase® 12RC Wire Feeder #300 663
#195 012 Field #043 952 Lightweight and flexible enough to run a
Prevents particles Consists of 30.5 m (100 ft) 2/0 electrode variety of wires up to 1.6 mm diameter.
from leaving the muffler that could cable with holder, and 15 m (50 ft) work Includes remote voltage control. Requires
potentially start a fire. Mandatory when cable with clamp. 300 A, 100% duty cycle. drive roll kit. See Lit. Index No. M/6.5.
operating on California grasslands, brush,
or forest-covered land, and in all National MIG (GMAW)/Flux Cored (FCAW) Guns
Forests. For other areas, check your state Plasma Cutting Miller produces a complete line of
and local laws. Meets US Forest Service dependable MIG guns. See Lit. Index Nos.
standard 5100-1B. AY/15.0, AY/16.0 and AY/17.0.
6
Genuine Miller Accessories (Continued)
A B Front Panel
C
HWY-224 Trailer
D E
4 West Four-Wheel Steerable #043 805 For highway use. F
Off-Road Trailer #042 801 OFR-224 Trailer G
A heavy-duty 1166 kg (2570 lb) capacity #043 802 For off-road use. A. 757 mm (29-13/16 in)
trailer designed for use in mines, quarries, B. 699 mm (27-1/2 in)
A 1202 kg (2650 lb) capacity trailer. Welded
and other rough terrain. Has narrow C. 25 mm (1 in)
steel tubing frame, heavy-duty axle with roller
6.7 m (22 ft) turning radius. Includes D. 244 mm (9-5/8 in)*
bearing hubs and leaf-spring suspension.
76 mm (3 in) lunette eye, universal hitch E. 1181 mm (46-1/2 in)*
Includes jack stand, 50 mm (2 in) ball hitch.
and safety chains. F. 1422 mm (56 in)*
HWY-224 also includes fenders and lights.
Note: Trailer is shipped unassembled.
Note: Trailer is shipped unassembled. G. 1654 mm (65-1/8 in)
Cable Tree #043 826 H. 14 mm (9/16 in) dia.
Provides an area to conveniently wrap weld Height: 1270 mm (50 in) (to top of exhaust)
cables and extension cords. Width: 724 mm (28-1/2 in)
Dual Hitch #300 831
(mounting brackets turned in)
781 mm (30-3/4 in)
2 in (50 mm) ball hitch
and 3 in (76 mm)
(mounting brackets turned out)
Depth: 1654 mm (65-1/8 in)
lunette eye in one
reversible assembly. *With mounting brackets in center position.
Dimensions vary with location of mounting brackets.
7
Ordering Information
Equipment and Factory Options Stock No. Description Qty. Price
Big Blue 500 X CC
® #907 185 Deutz D2011L03i with Engine Gauges and Dry Battery
#907 187 Perkins 404D.22 with Engine Gauges and Dry Battery
#907 187-02-1 Perkins 404D.22 with Engine Gauges and Dry Battery, Weld Meters
and Polarity Switch
Big Blue® 500 X CC/CV #907 184 Deutz D2011L03i with Engine Gauges and Dry Battery
#907 186 Perkins 404D.22 with Engine Gauges and Dry Battery
#907 186-02-1 Perkins 404D.22 with Engine Gauges and Dry Battery, Weld Meters
and Polarity Switch
Big Blue® 600 X CC #907 193 Deutz D2011L04i with Engine Gauges and Dry Battery
#907 189 Deutz D912L03 with Engine Gauges and Dry Battery
#907 189-01-2 Deutz D912L03 with Engine Gauges and Wet Battery
Big Blue® 600 X CC/CV #907 192 Deutz D2011L04i with Engine Gauges and Dry Battery
#907 188 Deutz D912L03 with Engine Gauges and Dry Battery
Field Accessories
Weld Ammeter and Voltmeter Kit #195 131 For all models. Analog welding meters
Polarity Reversing Switch Kit #043 942 For all models. DC polarity switch
#195 095 For all models. AC/DC polarity switch
Battery Voltmeter #195 454 For all models. Analog
Cold Weather Starting Aid Kit #195 056 Perkins. 120 volt block heater
#195 307 Deutz D2011L03i and D2011L04i. 12 volt intake manifold heater
#195 086 Deutz D2011L03i and D2011L04i. 120 volt oil pan heater
Engine Filter Kit #246 988 Deutz D2011. Includes air, oil and fuel filters
#246 989 Deutz D912. Includes air, oil and fuel filters
#246 985 Perkins 404. Includes air, oil and fuel filters
Spark Arrestor Muffler Kit #195 012 For all models. Horizontal externally mounted
Lockable Flame Arrestor Fuel Cap #043 947 For all models. Padlock not included
Vandalism Lockout Kit #195 118 For all models. Lockable front control panel and engine compartment
Cable Holder #043 946 For all models. Stores up to 61 m (200 ft) of 2/0 weld cable
Protective Cover #194 683 For all models. Will not work with cable holder accessory
Stick Welding Leads See page 6
MIG/Flux Cored Welding
SuitCase® X-TREME™ 8VS and 12VS #300 656 /#300 659 See Lit Index No. M/6.41
SuitCase® 8RC and 12RC #300 660/#300 663 See Lit Index No. M/6.5
MIG (GMAW)/Flux Cored (FCAW) Guns See Lit Index Nos. AY/15.0, AY/16.0 and AY/17.0
Spoolmatic® 30A Spool Gun #130 831 Requires WC-24 Control. See Lit. Index No. M/1.73
WC-24 Control #137 549 See Lit. Index No. M/1.5
XR™ Wire Feeder Control and Guns See Lit. Index No. M/1.7, M/1.71, and M/1.73
TIG Welding
Dynasty® 200 Series See Lit Index No. AD/4.8
High Frequency Arc Starters See Lit. Index No. AY/5.0
Remote Controls and Switches See page 7
Trailers and Hitches
4-West Trailer #042 801 4-wheel steerable implement trailer
HWY-224 Trailer #043 805 Trailer with lights, fenders and 50 mm (2 in) ball hitch
OFR-224 Trailer #043 802 Trailer with 50 mm (2 in) ball hitch
Cable Tree #043 826 Trailer mounted cable holder for HWY-224, OFR-224 or HWY-430
Dual Hitch #300 831 Combination 50 mm (2 in) ball hitch and 76 mm (3 in) lunette eye in one
reversible assembly. For HWY-224 or OFR-224
Distributed by:
Litho in USA