Miller Electric 6000 manual OM-499, Processes, Description

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OM-499

197 850H

March 2004

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Blue StarR 6000

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Contents Processes OM-499Description 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 Welding Weld Output Rated Maximum Generator PowerFuel Consumption Kohler-Powered Units Dimensions, Weights, And Operating AnglesDo not move or operate unit where it Be damaged or unit could tipExceeding duty cycle can damage unit and void warranty Fuel Consumption Honda-Powered UnitsDuty Cycle Continuous WeldingHz Model Generator Power CurvesMAX MID MIN Volt-Ampere CurvesInstalling Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Engine Prestart Checks Kohler-Powered Units Grounding Generator When Supplying Building SystemsFuel OilConnecting The Battery Electric-Start Models Only Engine Prestart Checks Honda-Powered Units+ − Connect negative − cable lastSelecting Weld Cable Sizes Connecting To Weld Output Terminals− Operating the Welding Generator Controls Kohler-Powered Units50 Hz 60 Hz Recoil-Start 2Electric-Start Controls Honda-Powered Units See Section60 Hz 50 Hz 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 Generator Power Panel 495 Optional Generator Power PanelsSouth Africa South America Australia Europe AsiaIt exceeds 5500W Generator Power Panel RatingsMaintenance Label − Maintenance20 h Routine Maintenance50 h 100 hAdjusting Engine Speed Kohler-Powered Units Overload Protection Honda-Powered UnitsWeld/Power Speed Adjustment Idle Speed AdjustmentThrottle Control Lever Adjustment Screw Adjusting Engine Speed Honda-Powered UnitsPilot Screw Throttle Stop Screw Stop engine. Close fuel valveTroubleshooting − TroubleshootingGenerator Power WeldingViscosity oil for operating temperature Check battery voltage electric-start models onlyEngine Circuit board PC1Circuit Diagram For Welding Generator 1 − Electrical DiagramsCircuit Diagram For Welding Generator 2 Wiring Diagram For Auxiliary Power Panels 1 Wiring Diagram For Auxiliary Power Panels 2 Selecting Equipment − Generator Power GuidelinesHow 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 xWork like a Pro Typical Connections To Supply Standby PowerCurrent 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 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 − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Main Assembly − Parts ListDia Part Dia Part Mkgs Description Quantity Generator Power Panels Item Dia Part Mkgs Description Quantity Work like a Pro Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department