Miller Electric Blue Star 3500 manual Dia Part

Page 53

Item

Dia.

 

Part

 

 

 

 

No.

 

Mkgs.

No.

Description

 

Quantity

 

 

 

 

 

 

Figure 13-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

 

. . .

1

. . .

. . . . . . .

. .

. . +495 247

. . TOP, control box (specify color)

. . . 1

. . .

2

. . .

. . . . . . .

. .

. . . Deleted

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . .

3

. . CR1, CR2

. . . 035 704

. . RECTIFIER, integ bridge 40 amp 800 v

. . . . . . . . . . . . . . . . . . . . . . . .

. . . 2

. . .

4

. . .

. . . . . . .

. .

. . . 134 201

. . STAND-OFF, support

. . . 4

. . .

5

. . .

. . . . . . .

. .

. . . 495 236

. . BASE, control box

. . . 1

. . .

6

. . . . . L3 .

. .

. . . 495 200

. . REACTOR, stabilizing

. . . 1

. . .

7

. . .

. . . . . . .

. .

. . . 211 297

. . LABEL, warning general precautionary

. . . 1

. . . 8

. . .

. . . . . . .

. .

. . . 493 509

. . BRUSHHOLDER, assembly

. . . 1

. . .

9

. . .

. . . . . . .

. .

. . . 204 138

. . LABEL, warning fuel (also supplied with engine)

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +195 557

. . ENGINE, gas Kohler 8.5HP (recoil start)

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 952

. . FILTER, air Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 954

. . FILTER, air pre Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 955

. . CAP, fuel Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 956

. . TANK, fuel Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 957

. . STRAINER, fuel Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 958

. . MUFFLER, exhaust engine Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 959

. . GASKET, muffler Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 960

. . SPARK PLUG, Kohler cs 8.5 & 12

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +184 556

. . ENGINE, Honda 9HP (recoil start)

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +184 555

. . ENGINE, Honda 9HP (electric start)

. . . 1

. . . 11

. . .

. . . . . . .

. .

. . . 494 606

. . ADAPTER, engine

. . . 1

. . . 12

. . .

. . . . . . .

. .

. . . 494 629

. . GUARD, generator

. . . 1

. . . 13

. . .

. . . . . . .

. .

. . . 194 509

. . FAN, generator (Kohler)

. . . 1

. . . 13

. . .

. . . . . . .

. .

. . . 493 868

. . FAN, generator (Honda)

. . . 1

. . . 14

. . .

. . . . . . .

. .

. . . 209 320

. . GENERATOR, w/stator assembly

. . . 1

. . . 15

. . .

. L1-D

. .

. . . 494 574

. . ROTOR, assembly

. . . 1

. . . 16

. . .

. . . . . . .

. .

. . . 495 349

. . SCREW, 1/4-20 HWH

. . . 4

. . . 17

. . .

. . . . . . .

. .

. . . 494 587

. . CARRIER, bearing

. . . 1

. . . 18

. . .

. . . . . . .

. .

. . . 495 348

. . SCREW, 5/16-24 HWH

. . . 1

. . . 19

. . .

. . . . . . .

. .

. . +494 628

. . PANEL, end generator

. . . 1

. . . 20

. . .

. . . . . . .

. .

. . . Deleted

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . 21

. . .

. . . . . . .

. .

. . . 495 257

. . MOUNT, shock w/bushing

. . . 2

. . . 22

. . .

. . . . . . .

. .

. . . 495 256

. . MOUNT, shock generator

. . . 1

. . . 23

. . .

. . . . . . .

. .

. . . 194 504

. . FRAME, mtg assembly (Kohler)

. . . 1

. . . 23

. . .

. . . . . . .

. .

. . . 495 132

. . FRAME, mtg assembly (Honda)

. . . 1

. . . 24

. . .

. PC1

. . . . . 148 608

. . BOARD, PC filter (CSA only)

. . . 1

. . . 25

. . .

. . . . . . .

. .

. . . 494 613

. . TERMINAL, output

. . . 2

. . . 26

. . .

. . R1 .

. .

. . . 494 618

. . RHEOSTAT, 35 ohm 100W

. . . 1

. . . 27

. . .

. . . . . . .

. .

. . . 495 214

. . SEAL, air duct

. . . 1

. . . 28

. . .

. . . . . . .

. .

. . . 495 255

. . DUCT, air

. . . 1

. . . 29

. . .

. . . . . . .

. .

. . . 097 924

. . KNOB, pointer

. . . 1

. . . 30

. . .

. . . . . . .

. .

. . . . . . . . . . . .

. . NAMEPLATE, overlay (order by model and serial number)

. . . 1

. . . 31

. . .

. . . . . . .

. .

Figure 13-2

. . PANEL, aux power assembly (CSA)

. . . 1

. . . 32

. . .

. . 1T .

. .

. . . 172 661

. . BLOCK, terminal

. . . 1

. . . 33

. . .

. . . . . . .

. .

. . . 495 193

. . BRACKET, mtg terminal block

. . . 1

. . . 34

. . .

. . L2 .

. .

. . . 495 202

. . REACTOR, weld assembly

. . . 1

. . . 35

. . .

R2/VR1 .

. . . 046 819

. . SUPPRESSOR, assembly

. . . 1

. . . 36

. . .

. CR3

. . . . . 495 188

. . RECTIFIER, assembly

. . . 1

. . . 37

. . .

. . . . . . .

. .

. . . 201 223

. . LABEL, warning electric shock power still present

. . . 1

. . . 38

. . .

. . . . . . .

. .

. . . 494 976

. . LABEL, current selection

. . . 1

. . . 39

. . .

. . . . . . .

. .

. . . 495 112

. . LEAD, battery neg (electric start)

. . . 1

. . . 40

. . .

. . . . . . .

. .

. . . . . . . . . . . .

. . BATTERY, 12V (electric start)

. . . 1

. . . 41

. . .

. . . . . . .

. .

. . . 494 604

. . BOLT, hold down (electric start)

. . . 1

. . . 42

. . .

. . . . . . .

. .

. . . 493 057

. . CLAMP, battery (electric start)

. . . 1

. . . 43

. . .

. . . . . . .

. .

. . . 495 111

. . LEAD, battery pos (electric start)

. . . 1

. . . 44

. . .

. . . . . . .

. .

. . . 494 039

. . COVER, battery cable (electric start)

. . . 1

+When ordering a part displaying a precautionary label, order label also.

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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OM-498 Page 49

Page 52 Page 54
Image 53
Page 52 Page 54
Contents Description OM-498Processes From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéSymbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsFuel Consumption Kohler-Powered Units Dimensions, Weights, And Operating AnglesDimensions Weight Kohler-Powered UnitsExceeding duty cycle can damage unit and void warranty Fuel Consumption Honda-Powered UnitsDuty Cycle 100% Duty Cycle at 80 Amperes CC/DCVolt-Ampere Curves Generator Power CurveGrounding Generator To Truck Or Trailer Frame − InstallationInstalling Welding Generator Use ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsConnecting The Battery Honda Electric-Start Models Only Engine Prestart Checks Honda-Powered Units+ − OilSelecting Weld Cable Sizes Connecting To Weld Output Terminals− Operating the Welding Generator Controls Kohler-Powered Units60 Hz Choke Control LeverRecoil-Start 2Electric-Start Controls Honda-Powered Units See SectionWork like a Pro Description Of Controls Honda-Powered Units See Section120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 218 USA− Operating Auxiliary Equipment Generator Power Panel 495 Optional Generator Power PanelsCanada South Africa South America Australia Europe AsiaIt exceeds 3500W Generator Power Panel RatingsWire Load Plug Wired For 120/240Plex receptacle shares a load with One half of the 240 V receptacle− Maintenance Overload Protection Honda-Powered Units Only Maintenance LabelWeld/Power Speed Adjustment Adjusting Engine Speed Kohler-Powered UnitsTop View Idle Speed Adjustment Stop engine. Close fuel valve Top ViewThrottle Control Lever Adjustment Screw Adjusting Engine Speed Honda-Powered UnitsStop engine. Close fuel valve Tools Needed 3/8Troubleshooting − TroubleshootingGenerator Power WeldingViscosity oil for operating temperature Check battery voltage Honda electric-start models onlyEngine Make starting difficultCircuit Diagram For Welding Generator − Electrical DiagramsWiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 OM-491 − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Volts 115 Amps Resistive LoadApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible− Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead 31−Fig − Parts ListDia Part Generator Power Panel 495 South Africa Australia Generator Power Panel 495 Generator Power Panel 495 315 USACanada Europe AmericaGenerator Power Panel 495 279 Canada Generator Power Panel 495 218 USAGenerator Power Panel 495 253 South Africa Generator Power Panel 495 289 AustraliaWork like a Pro Page TM-188 304 Invision 354MP Material Thickness Reference ChartSupport ServiceYour distributor also gives For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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