OM-499, Processes, Description | Miller Electric 6000 instruction

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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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Miller Electric 6000 manual OM-499, Processes, Description

Contents

Processes OM-499Description From Miller to You Table of Contents Page Arc Welding Hazards Symbol Usage Engine 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 dangereux DES 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’ouïe DES 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 blessures Information sur les champs électromagnétiques Principales normes de sécurité Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications Welding Weld Output Rated Maximum Generator Power Fuel Consumption Kohler-Powered Units Dimensions, Weights, And Operating AnglesDo not move or operate unit where it Be damaged or unit could tip Exceeding duty cycle can damage unit and void warranty Fuel Consumption Honda-Powered UnitsDuty Cycle Continuous Welding Hz Model Generator Power Curves MAX MID MIN Volt-Ampere Curves Installing Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Engine Prestart Checks Kohler-Powered Units Grounding Generator When Supplying Building SystemsFuel Oil Connecting The Battery Electric-Start Models Only Engine Prestart Checks Honda-Powered Units+ − Connect negative − cable last Selecting 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 Asia It exceeds 5500W Generator Power Panel Ratings Maintenance Label − Maintenance 20 h Routine Maintenance50 h 100 h Adjusting Engine Speed Kohler-Powered Units Overload Protection Honda-Powered UnitsWeld/Power Speed Adjustment Idle Speed Adjustment Throttle Control Lever Adjustment Screw Adjusting Engine Speed Honda-Powered UnitsPilot Screw Throttle Stop Screw Stop engine. Close fuel valve Troubleshooting − TroubleshootingGenerator Power Welding Viscosity oil for operating temperature Check battery voltage electric-start models onlyEngine Circuit board PC1 Circuit Diagram For Welding Generator 1 − Electrical Diagrams Circuit Diagram For Welding Generator 2 Wiring Diagram For Auxiliary Power Panels 1 Wiring Diagram For Auxiliary Power Panels 2 Selecting Equipment − Generator Power Guidelines How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Volts 115 Amps Resistive Load Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x Work like a Pro Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible Weld 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 Angle Electrode Movement During Welding Conditions That Affect Weld Bead Shape Lap Joint Butt JointsTee Joint 16 in 1.6 mm Tack Welds Troubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Main Assembly − Parts List Dia 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