Miller Electric Blue Star 3500 manual Compressed Air Hazards

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STEAM AND HOT COOLANT can burn.

DIf possible, check coolant level when engine is cold to avoid scalding.

D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

DIf the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

DWear safety glasses and gloves and put a rag over radiator cap.

DTurn cap slightly and let pressure escape slowly before completely re- moving cap.

ENGINE EXHAUST GASES can kill.

D Use equipment outside in open, well-ventilated ar- eas.

DIf used in a closed area, vent engine exhaust outside

and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flam- mables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in re- quired areas — see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

DDo not use compressed air for breathing.

DUse only for cutting, gouging, and tools.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

DDo not cut or gouge near flammables.

DWatch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury.

DWear approved safety goggles.

DDo not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

DRelease air pressure from tools and system before servicing, adding or changing attachments, or open- ing compressor oil drain or oil fill cap.

HOT PARTS can cause burns and injury.

DDo not touch hot compressor or air system parts.

DLet system cool down before touching or servicing.

READ INSTRUCTIONS.

DRead Owner’s Manual before using or servicing unit.

DStop engine and release air pressure before servicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories.

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stop- ping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

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TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer accord- ing to instructions supplied with trailer.

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Contents Processes OM-498Description From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsWeight Kohler-Powered Units Dimensions, Weights, And Operating AnglesFuel Consumption Kohler-Powered Units Dimensions100% Duty Cycle at 80 Amperes CC/DC Fuel Consumption Honda-Powered UnitsExceeding duty cycle can damage unit and void warranty Duty CycleVolt-Ampere Curves Generator Power CurveInstalling Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsOil Engine Prestart Checks Honda-Powered UnitsConnecting The Battery Honda Electric-Start Models Only + −Selecting Weld Cable Sizes Connecting To Weld Output TerminalsChoke Control Lever Controls Kohler-Powered Units− Operating the Welding Generator 60 HzRecoil-Start 2Electric-Start Controls Honda-Powered Units See SectionWork like a Pro Description Of Controls Honda-Powered Units See Section− Operating Auxiliary Equipment Generator Power Panel 495 218 USA120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Australia Europe Asia Optional Generator Power PanelsGenerator Power Panel 495 Canada South Africa South AmericaIt exceeds 3500W Generator Power Panel RatingsOne half of the 240 V receptacle Plug Wired For 120/240Wire Load Plex receptacle shares a load with− Maintenance Overload Protection Honda-Powered Units Only Maintenance LabelStop engine. Close fuel valve Top View Adjusting Engine Speed Kohler-Powered UnitsWeld/Power Speed Adjustment Top View Idle Speed AdjustmentTools Needed 3/8 Adjusting Engine Speed Honda-Powered UnitsThrottle Control Lever Adjustment Screw Stop engine. Close fuel valveWelding − TroubleshootingTroubleshooting Generator PowerMake starting difficult Check battery voltage Honda electric-start models onlyViscosity oil for operating temperature EngineCircuit Diagram For Welding Generator − Electrical DiagramsWiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 Selecting Equipment − Generator Power GuidelinesOM-491 Volts 115 Amps Resistive Load Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleWeld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion 31−Fig − Parts ListDia Part Europe America Generator Power Panel 495 Generator Power Panel 495 315 USAGenerator Power Panel 495 South Africa Australia CanadaGenerator Power Panel 495 289 Australia Generator Power Panel 495 218 USAGenerator Power Panel 495 279 Canada Generator Power Panel 495 253 South AfricaWork like a Pro Page TM-188 304 Invision 354MP Material Thickness Reference ChartYour distributor also gives ServiceSupport Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s