Miller Electric TM-499C manual

Processes

Description

Stick (SMAW) Welding

Engine Driven Welding Generator

TM-499C August 2004

Eff. w/Serial Number LA124002 (Kohler)

Eff. w/Serial Number LB086216 (Honda)

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www.MillerWelds.com

Blue Star 6000

Contents

Main Blue Star 6000 Page TABLE OF CONTENTS Page SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage . 1-2. Servicing Hazards ELECTRIC SHOCK can kill. 1-3. California Proposition 65 Warnings 1-4. EMF Information SECTION 2 DEFINITIONS h Hours s 2-1. Symbol Definitions SECTION 3 SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications 3-2. Dimensions, Weights, And Operating Angles 3-3. Fuel Consumption (Kohler-Powered Units) . Page TM-499 Page 6 3-6. 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 TM-499 Page 7 3-7. Volt-Ampere Curves MAX MID MIN MID SECTION 4 INSTALLATION 4-1. Installing Welding Generator 4-2. Grounding Generator To Truck Or Trailer Frame 4-3. Grounding Generator When Supplying Building Systems 4-4. Engine Prestart Checks (Kohler-Powered Units) . 4-5. Engine Prestart Checks (Honda-Powered Units) . + . 4-6. Connecting The Battery (Electric-Start Models Only) 4-7. Connecting To Weld Output Terminals 4-8. Selecting Weld Cable Sizes* SECTION 5 OPERATING THE WELDING GENERATOR 5-1. Controls (Kohler-Powered Units) . 5-2. Controls (Honda-Powered Units) (See Section 5-3) 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) . Notes . SECTION 6 OPERATING AUXILIARY EQUIPMENT 6-1. Generator Power Panel 495 218 (USA) . 6-2. Optional Generator Power Panels . TM-499 Page 17 6-3. 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) 6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) SECTION 7 MAINTENANCE 200 h 50 h 7-1. Maintenance Label ENGINE MAINTENANCE 7-2. Routine Maintenance . 8 h 20 h 50 h 100 h 7-3. Overload Protection (Honda-Powered Units) . 7-4. Adjusting Engine Speed (Kohler-Powered Units) 7-5. Adjusting Engine Speed (Honda-Powered Units) SECTION 8 THEORY OF OPERATION Page SECTION 9 EXPLANATION OF ELECTRICAL PARTS 9-1. Safety Precautions Read Before Using This Guide Page + Page Page Page Page SECTION 10 TROUBLESHOOTING 10-1. Troubleshooting Tables A. Welding . B. Generator Power C. Engine Page Page 10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) Page 10-3. Test Points And Values (Use With Section 10-2) 10-4. Waveforms For Section 10-2 10-5. Control Board PC1 Testing Information 10-6. Control Board PC1 Test Point Values 10-7. Replacing Brushes And Cleaning Slip Rings 10-8. Checking Unit Output After Servicing Pre-Operational Checks SECTION 11 DISASSEMBLY AND REASSEMBLY 11-1. Disassembly Of Unit 11-2. Removing Rotor And Reassembling Generator SECTION 12 ELECTRICAL DIAGRAMS . Model Serial Or Style Number Circuit Diagram Wiring Diagram The circuits for Honda-powered units were implemented prior to the effective date of this manual. Page Page Page Page Page Page Page SECTION 13 PARTS LIST FOR LA124002 THRU LB111747 (KOHLER ONLY) Figure 13-1. Main Assembly Page Eff w/LA124002 Thru LB111747 (Kohler Only) Page SECTION 14 PARTS LIST FOR LB111748 THRU LC061260 (KOHLER) AND LB086216 THRU LC061260 (HONDA) Figure 14-1. Main Assembly Page Page Page Page Page SECTION 15 PARTS LIST FOR LC061261 THRU LC552236 (KOHLER & HONDA) . Figure 15-1. Main Assembly Page Page Page Page Page SECTION 16 PARTS LIST FOR LC552237 AND FOLLOWING Figure 16-1. Main Assembly