Professional Documents
Culture Documents
Diagrama Miller Bluestar
Diagrama Miller Bluestar
197 850H
March 2004
Processes
Stick (SMAW) Welding
Description
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers lis lair comprim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Panel 495 218 (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Optional Generator Power Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Generator Power Panel Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) . . . . . . . . . . . . . . . . . .
SECTION 8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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49
Warning: Protect yourself and others from injury read and follow these precautions.
Only qualified persons should install, operate, maintain, and repair this unit.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
Properly install and ground this equipment according to its Owners Manual
and national, state, and local codes.
Always verify the supply ground check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
Frequently inspect input power cord for damage or bare wiring replace
cord immediately if damaged bare wiring can kill.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturers
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an airsupplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
OM-499 Page 1
Protect yourself and others from flying sparks and hot metal.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in
good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
Always wear a face shield, rubber gloves, and protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Stop engine and let it cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any
sparks or open flames.
OM-499 Page 2
Keep hands, hair, loose clothing, and tools away from moving parts.
Block flywheel so that it will not turn while working on generator components.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely removing cap.
READ INSTRUCTIONS.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OM-499 Page 3
READ INSTRUCTIONS.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic
equipment perform this installation.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
OM-499 Page 4
Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.
Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est
endommag un cble dnud peut provoquer une lectrocution.
Isoler la pince de masse quand pas mis la pice pour viter le contact
avec tout objet mtallique.
Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel
avec la pice ou la terre.
Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.
Lire les spcifications de scurit des matriaux (MSDSs) et les instructions du fabricant concernant les mtaux, les consommables, les
revtements, les nettoyants et les dgraisseurs.
Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant
dment form de se tenir proximit. Des fumes et des gaz de soudage
peuvent dplacer lair et abaisser le niveau doxygne provoquant des
blessures ou des accidents mortels. Sassurer que lair de respiration ne
prsente aucun danger.
Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de
larc peuvent ragir en prsence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t
enlev dans la zone de soudure, que lendroit soit bien ventil, et si ncessaire, en portant un respirateur alimentation dair. Les revtements et
tous les mtaux renfermant ces lments peuvent dgager des fumes
toxiques en cas de soudage.
OM-499 Page 5
LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et
sur la peau.
Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 numr dans les normes de scurit).
Porter des protections approuvs pour les oreilles si le niveau sondre est
trop lev.
Utiliser des crans ou des barrires pour protger des tiers de lclair et de
lblouissement; demander aux autres personnes de ne pas regarder larc.
Porter des vtements de protection constitu dans une matire durable, rsistant au feu (laine ou cuir) et une protection des pieds.
Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des
substances inflammables.
Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct.
Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars
correctement conformment AWS F4.1 (voir les normes de scurit).
En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.
Porter des vtements de protection dpourvus dhuile tels que des gants
en cuir, une chemise en matriau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
OM-499 Page 6
Ne pas utiliser le poste de soudage pour charger les batteries ou des vhicules de dmarrage rapide.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brlures.
Toujours vrifier le niveau de liquide de refroidissement dans le vase dexpansion (si prsent), et non dans le radiateur (sauf si prcis autrement
dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme suivant :
Mettre des lunettes de scurit et des gants, placer un torchon sur le bouchon du radiateur.
Dvisser le bouchon lgrement et laisser la vapeur schapper avant
denlever le bouchon.
Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement.
Maintenir ferms et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
lappareil.
En utilisant des fourches de levage pour dplacer lunit, sassurer
que les fourches sont suffisamment longues pour dpasser du ct
oppos de lappareil.
OM-499 Page 7
Affuterr llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manoeuvre est excuter dans un endroit sr lorsque
lon porte lquipement homologu de protection du visage, des mains et
du corps.
Les tincelles risquent de causer un incendie loigner toute substance
inflammable.
Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800) 4636727 ou Toronto : (416) 7474044, site Web : www.csainternational.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West
42nd Street, New York, NY 100368002 (tlphone : (212) 6424900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617)
7703000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de lU.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
rgionaux Tlphone pour la Rgion 5, Chicago : (312) 3532220, site
Web : www.osha.gov).
OM-499 Page 8
Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes :
1. Garder les cbles ensemble en les torsadant ou en les fixant avec du
ruban adhsif.
2. Mettre tous les cbles du ct oppos loprateur.
3. Ne pas senrouler les cbles autour du corps.
4. Garder le poste de soudage et les cbles le plus loin possible de soi.
5. Placer la pince de masse le plus prs possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.
SECTION 3 DEFINITIONS
3-1. Symbol Definitions
Engine Choke
Read Operators
Manual
Engine Oil
Fuel
Battery (Engine)
Engine
Positive
Negative
Alternating Current
(AC)
Output
Seconds
Time
Protective Earth
(Ground)
Hours
Circuit Breaker
Amperes
Volts
Temperature
SECTION 4 SPECIFICATIONS
NOTE
This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.
CC/DC
Weld Output
Range
40 180 A
(60 Hz)
40 160 A
(50 Hz)
Rated
Welding
Output
180 A, 25 V,
30% Duty
Cycle
130 A, 25 V,
60% Duty
Cycle
100 A, 25 V,
100% Duty
Cycle
Maximum
Open Circuit
Voltage
80
(60 Hz)
70
(50 Hz)
Generator Power
Rating
Single-Phase,
6 kVA/kW (Peak)
5.5 kVA/kW
(Continuous)
50/25 A,
110/220 V AC, 50 Hz
120/240 V AC, 60 Hz
Fuel Capacity
Kohler:
1.8 gal (6.9 L) Tank
Honda:
1.7 gal (6.4 L) Tank
Engine
Kohler CS12STG
Air-Cooled,
One-Cylinder,
Four-Cycle,
12 HP (360 CC),
Gasoline Engine
OR
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
OM-499 Page 9
Width
Depth
15
4
Holes
15
15
Weight
15
F
Engine End
802 524-A
802 096
Fuel
60 HZWELD
60 HZAUX
50 HZAUX
50 HZWELD
HIGH IDLE
198 575
OM-499 Page 10
802 122
802 093
OM-499 Page 11
A. 60 Hz Model
250
225
200
LOAD VOLTS
175
150
125
100
75
50
25
0
0
10
15
20
25
30
35
25
30
35
LOAD AMPS
B. 50 Hz Model
250
225
200
LOAD VOLTS
175
150
125
100
75
50
25
0
0
10
15
20
LOAD AMPS
198 570
OM-499 Page 12
A. 60 Hz Model
80
70
LOAD VOLTS
60
50
40
MAX
30
MID
20
MIN
10
0
0
25
50
75
100
125
150
LOAD AMPS
175
200
225
250
225
250
B. 50 Hz Model
80
70
LOAD VOLTS
60
50
40
MAX
30
MID
20
MIN
10
0
0
25
50
75
100
125
150
LOAD AMPS
175
200
198 570
OM-499 Page 13
SECTION 5 INSTALLATION
5-1. Installing Welding Generator
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
Movement
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Location
OR
install1 10/00* 802 524-A / Ref. 151 556 / 158 936-A / S-0854
1
GND/PE
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
OR
OM-499 Page 14
Equipment Grounding
Terminal
Grounding Cable
GND/PE
Ground Device
800 576-B
1/2 in
(13 mm)
Full
Gasoline
1 Fuel Valve
Open valve by turning lever to vertical
position.
Fuel
Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in.
(13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day.
Closed
Closed
Oil
Open
802 511-A
OM-499 Page 15
1/2 in
(13 mm)
Full
gine manual.
1 Fuel Valve
Open valve.
Gasoline
Fuel
Add fresh fuel before starting
engine the first time (see maintenance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Check fuel level on a cold engine
before use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
To
improve
starting:
Open
cold
weather
Full
802 094-A
Connect negative ()
cable last.
Tools Needed:
3/8, 1/2 in
OM-499 Page 16
Tools Needed:
3/4 in
196 914 / 495 178
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 60%
Duty
Cycle
60 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-499 Page 17
50 Hz
60 Hz
1
5
4
802 511-A / 802 0511 / 495 178
To Start (Electric): open fuel valve (see Section 5-4), move throttle lever to Idle, set choke,
and turn engine switch to Start position. Open
choke as engine warms. If engine does not
crank, use recoil starting procedure following
to start engine.
5
6
Engine Switch
Starter Handle
To Start (Recoil): open fuel valve (see Section 5-4), move throttle lever to Idle, set choke,
and pull starter handle. Open choke as engine
warms.
To Stop: turn engine switch to Off.
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
Current Control
Recoil-Start
1
2
Electric-Start
60 Hz
50 Hz
1
OM-499 Page 19
5
6
Current Control
Notes
OM-499 Page 20
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
The welding generator provides power while welding and with the Current control
in any position. However, under these conditions equipment connected to the
welding generator may be subject to larger than normal voltage fluctuations. It is
recommended that only lamps be powered under these conditions.
495 218
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Power is still present at the 240 volt
receptacle when only one circuit
breaker trips.
Unplug power cord before attempting to service accessories or tools.
current increases.
vide 15A/1800W.
receptacles.
4 Circuit Breaker CB1
CB1 protects RC1 from overload. If CB1
opens, RC1 does not work.
Return To Table Of Contents
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Power may still be present at a receptacle when a circuit breaker
trips.
Unplug power cord before attempting to service accessories or tools.
OM-499 Page 22
NOTE
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)
Receptacle
Protected
By
Panel
495 218
(USA)
Panel
495 315
(USA)
Panel
495 219
(USA)
Panel
495 278
(CanadaCSA)
Panel
495 253
(S. Africa)
Panel
495 288
(South
America)
Panel
495 289
(Australia)
Panel
495 290
(Europe)
Panel
495 283
(S.E. Asia)
60 Hz
60 Hz
60 Hz
60 Hz
50 Hz
50 Hz
50 Hz
50 Hz
50 Hz
25A/
5500W
See
Note 2
25A/
5500W
See
Note 2
240 V
Twist Lock
CB1,2
240 V
Duplex
CB1,2
240 V
Duplex
CB3,4
230 V
Single
CB1
15A/
3600W
15A/
3600W
15A/
3600W
230 V
Single
CB2
15A/
3600W
15A/
3600W
15A/
3600W
230 V
Single
CB1,2
15A/
3600W
230 V
Single
CB3,4
15A/
3600W
120 V
Twist Lock
CB1
120 V
Duplex
CB1,3/
CB2,4
120 V
Duplex
CB2
20A/
2400W
120 V
Duplex
CB3
20A/
2400W
120 V
Duplex
CB4
5000W
5000W
Total
Power NOT
to exceed
15A/
3600W
See
Note 2
15A/
3600W
15A/
3600W
30A/
3500W
30A/
3600W
See
Note 1
5500W
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
5500W
5500W
5500W
5000W
5000W
5000W
Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.
2. Do not parallel the two 120V circuits.
3. Do not parallel the two duplex outlets.
For example, for the 495 218 Generator Power Panel,
Calculating total power provided by generator.
(See Section 11 Generator Power Guidelines)
Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 5500W.
The rating plate on electrical apparatus will contain the watts
consumed or the rated input amps. Watts may be calculated by
multiplying the rated voltage by the rated input amps.
watts = volts x amps
3000W
1200W
500W
4700W
3000W
1200W
600W
1000W
5800W
OM-499 Page 23
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
2
3
Tools Needed:
When wired for 120 V loads, each duplex receptacle shares a load with
one half of the 240 V receptacle.
120V
240 V
120 V
5
6
SECTION 8 MAINTENANCE
NOTE
Follow the storage procedure in the engine owners manual if the unit will not be
used for an extended period.
100 h
+40
+104
+30
+86
+59
+10
8h
+32
-10
-15
-20
-10
10W-30
+20
SG-SF/CC-CD
Unleaded
86 + Octane
6.5 l (1.7 US Gal,
11.4 lmp pt)
50 h
0.7 0.8 mm
(0.028 0.031 in)
200 h
OM-499 Page 24
See Engine Manual and Maintenance Label. Service more often if used in severe conditions.
8h
Check fluid
levels. See
Section 5-4
or 5-5
20 h
Check and clean
spark arrestor screen.
See engine manual.
Wipe up spills.
50 h
Service air cleaner
element. See engine
manual.
Clean and
tighten weld
terminals.
100 h
Check
spark
plugs.
Clean Fuel
sediment cup.
200 h
Clean fuel
tank and
strainer.
Replace
unreadable
labels.
300 h
Check valve
clearance.*
500 h
Repair or
replace cracked
cables.
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
OM-499 Page 25
Tools Needed:
Weld/Power Speed
Adjustment
1
Adjustment Screw
Move lever to Run (far right) position. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To decrease speed, turn screw in (clockwise).
Idle Speed Adjustment
3
Adjustment Screw
Top View
Top View
1
802 511-A / Kohler Dwg.
OM-499 Page 26
Adjustment Screw
Pilot Screw
Throttle Stop Screw
Move lever to idle position. Turn pilot screw until engine runs at highest idle speed. Turn stop screw until
engine runs at rated idle speed
(normally about 2-1/4 turns out.)
Stop engine. Close fuel
valve.
2
1
Tools Needed:
1/4, 3/8 in
802 097-A
OM-499 Page 27
SECTION 9 TROUBLESHOOTING
9-1. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check Amperage control setting.
Check weld connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
B. Generator Power
Trouble
No output at generator power ac
receptacles.
Remedy
Reset circuit breakers (see Sections 7-1 and 7-2).
Check receptacle wiring and connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Move throttle lever to 50 Hz position for 50 Hz equipment (see Section 6-1 or 6-2).
Have Factory Authorized Service Agent check capacitor C1, resistor R3 (Kohler only), and circuit
board PC1.
OM-499 Page 28
Trouble
Remedy
C. Engine
Trouble
Engine will not crank (electric-start
models only).
Remedy
Reset ignition circuit breaker (see Section 8-3).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check engine ignition circuit.
Battery discharges between uses (elec- Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
tric-start models only).
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Unstable or sluggish engine speeds.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
OM-499 Page 29
197 857-E
197 857-E
OM-499 Page 31
201 026-A
201 026-A
OM-499 Page 33
3
Be sure equipment
has this symbol
and/or wording.
OR
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
S-0854
Equipment Grounding
Terminal
Grounding Cable
GND/PE
Ground Device
ST-800 576-B
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 11-8).
3
Rating Data
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-499 Page 35
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
OM-499 Page 36
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-499 Page 37
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
HP = 1/4
S-0624
5 Second Rule
OM-499 Page 38
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Customer-supplied
Connect generator with temporary or permanent wiring suitable for the installation.
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. See Section 11-4).
Notes
OM-499 Page 39
Load (Watts)
600
840
10
1200
15
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
Load (Watts)
1200
1680
10
2400
15
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
OM-499 Page 40
2
3
4
2
Work Clamp
Electrode
3
6
1
Workpiece
4
5
6
Slag
Tools Needed:
OM-499 Page 41
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
1
2
3
Electrode
Workpiece
Arc
S-0049
1
2
3
Electrode
Workpiece
Arc
3
S-0050
OM-499 Page 42
90
GROOVE WELDS
10-30
45
45
S-0060
S-0053-A
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
No Overlap
Good Penetration into Base
Metal
S-0052-B
OM-499 Page 43
NOTE
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Correct Angle
10 - 30
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
1
2
2
3
S-0054-A
OM-499 Page 44
1
2
Tack Welds
30
30
Or Less
1
1
2
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
Electrode
Single-Layer Fillet Weld
45
Or Less
Electrode
Fillet Weld
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
12-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-499 Page 45
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
S-0057-B
Possible Causes
Corrective Actions
Damp electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Possible Causes
Corrective Actions
OM-499 Page 46
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Good Penetration
Possible Causes
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove.
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-499 Page 47
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-499 Page 48
26
50
39
40
41
44
43
42
38
37
36
35
34
33
32
45 46 47
31
3
4
5
6
49
30
23
29
10
28
11
22
25
21
20
27
19
18
17
16
15
14
12
802 509-A
OM-499 Page 49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
41
42
43
44
45
46
47
48
49
50
. . . . . 1T . . . . . .
...............
. . . R2/VR1 . . . .
. . . . SR2 . . . . .
. . . . . R3 . . . . . .
. . . . . C1 . . . . . .
...............
...............
...............
...............
172 661
495 193
046 819
495 189
197 795
176 007
494 915
201 223
495 187
188 039
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..
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BLOCK, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, assembly (w/mtg hardware) . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR ASSEMBLY (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock power still present (CSA) . . . . . . . . . . . .
LABEL, current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-499 Page 51
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31
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
OM-499 Page 53
Notes
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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4.
6 Months Batteries
5.
90 Days Parts
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3.
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Replacement Parts
Training (Schools, Videos, Books)
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
PRINTED IN USA
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