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Portable Generator
Miller Electric
6000
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OM-499 Page 31
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able Of Contents
197 857-E
Figure 10-2. Circuit Diagram For Welding Generator (2 Of 2)
Contents
Main
Blue Star 6000
From Miller to You
TABLE OF CONTENTS
Page
OM-499 Page 1
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage
Marks a special safety message.
1-2. Arc Welding Hazards
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND.
FUEL can cause fire or explosion.
MOVING PARTS can cause injury.
OM-499 Page 3
1-4. Compressed Air Hazards
cause serious injury or death.
COMPRESSED AIR can cause injury
HOSES can cause injury.
HOT METAL from air arc cutting and gouging can cause fire or explosion.
1-6. California Proposition 65 Warnings
1-7. Principal Safety Standards
1-8. EMF Information
OM-499 Page 5 Revenez la table des matires
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.
2-1. Signification des symboles
Identifie un message de scurit particulier.
2-2. Dangers relatifs au soudage larc
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort.
LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU.
OM-499 Page 7 Revenez la table des matires
LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.
2-4. Dangers lis lair comprim
RESPIRER LAIR COMPRIM peut pro
voquer des blessures graves ou cause
la mort.
LAIR COMPRIM peut provoque
2-6. Principales normes de scurit
2-7. Information sur les champs lectromagntiques
SECTION 3 DEFINITIONS
3-1. Symbol Definitions
h
s
SECTION 4 SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
4-2. Dimensions, Weights, And Operating Angles
4-3. Fuel Consumption (Kohler-Powered Units)
Page
OM-499 Page 12 Return To Table Of Contents
4-6. Generator Power Curves
The generator power curves show the ac power available in amperes at the receptacles.
B. 50 Hz Model
A. 60 Hz Model
4-7. Volt-Ampere Curves
A. 60 Hz Model
MID MAX
MIN
B. 50 Hz Model
SECTION 5 INSTALLATION
5-1. Installing Welding Generator
5-2. Grounding Generator To Truck Or Trailer Frame
5-3. Grounding Generator When Supplying Building Systems
5
-4. Engine Prestart Checks (Kohler-Powered Units)
5
-5. Engine Prestart Checks (Honda-Powered Units)
+
5-6. Connecting The Battery (Electric-Start Models Only)
5-7. Connecting To Weld Output Terminals
5-8. Selecting Weld Cable Sizes*
SECTION 6 OPERATING THE WELDING GENERATOR
6-1. Controls (Kohler-Powered Units)
6-2. Controls (Honda-Powered Units) (See Section 6-3)
6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2)
Notes
SECTION 7 OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Panel 495 218 (USA)
7-2. Optional Generator Power Panels
OM-499 Page 23
7-3. Generator Power Panel Ratings
Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles.
Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)
It exceeds 5500W.
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
SECTION 8 MAINTENANCE
200 h
50 h
8-1. Maintenance Label
ENGINE MAINTENANCE
8-2. Routine Maintenance
8 h 20 h
50 h
100 h
200 h
8-3. Overload Protection (Honda-Powered Units)
8-4. Adjusting Engine Speed (Kohler-Powered Units)
8-5. Adjusting Engine Speed (Honda-Powered Units)
SECTION 9 TROUBLESHOOTING
9-1. Troubleshooting
A. Welding
B. Generator Power
C. Engine
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SECTION 11 GENERATOR POWER GUIDELINES
1
11-1. Selecting Equipment
1-2. Grounding Generator To Truck Or Trailer Frame
11-3. Grounding When Supplying Building Systems
11-4. How Much Power Does Equipment Require?
11-5. Approximate Power Requirements For Industrial Motors
11-6. Approximate Power Requirements For Farm/Home Equipment
11-7. Approximate Power Requirements For Contractor Equipment
11-8. Power Required To Start Motor
11-9. How Much Power Can Generator Supply?
11-10.Typical Connections To Supply Standby Power
Notes
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
11-11.Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 12 STICK WELDING (SMAW) GUIDELINES
12-1. Stick Welding Procedure
OM-499 Page 42 Return To Table Of Contents
12-2. Electrode and Amperage Selection Chart
2
3
12-3. Striking an Arc Scratch Start Technique
1 2 3
12-5. Positioning Electrode Holder
12-6. Poor Weld Bead Characteristics
12-7. Good Weld Bead Characteristics
12-8. Conditions That Affect Weld Bead Shape
12-9. Electrode Movement During Welding
12-10.Butt Joints
12-11.Lap Joint
12-12.Tee Joint
12-13.Weld Test
12-14.Troubleshooting Porosity
12-15.Troubleshooting Excessive Spatter
12-16.Troubleshooting Incomplete Fusion
12-17.Troubleshooting Lack Of Penetration
12-18.Troubleshooting Excessive Penetration
12-19.Troubleshooting Burn-Through
12-20.Troubleshooting Waviness Of Bead
12-21.Troubleshooting Distortion
SECTION 13 PARTS LIST
Figure 13-1. Main Assembly
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Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Effective January 1, 2003 (Equipment with a serial number preface of LC or newer)
Please complete and retain with your personal records.
For Service
Always provide Model Name and Serial/Style Number.
Owners Record