Miller Electric 3000 User Manual

Millerfi
March1993
Form:
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CC/DC
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SealTM
Generator
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VoltsDCAt
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60%
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Shutdown
and
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Model
Duty
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3000
Protection
Engine
Give
For
or:
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this
manualtothe
call
help,
MILLER
Appleton,
your
ELECTRIC
WI
operator.
distributor
Mfg.
54912
P.O.
Co.,
414-734-9821
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5192
March
1
993
Form:
OM-160
518
1~oIsfi
OWNERS
MANUAL
Effective
(jJOJ1
With
Serial
cI~j\r~J~
No.
KD398640
cover
8/92
ST-161
PAW
CC/DC
Welding
For
SMAW
U
90
Amperes,
U
1.2
kVAJkW
Kohler
CH5+
Optional
U
Read
and
follow
blocks
safety
Have
U
U
477
only
install,
operate,
Callyourdistributorifyoudonotunderstand
the
directions.
these
carefully.
trained
or
and
service
Generator
Welding
VoltsDCAt
25
DC
Auxiliary
Air-Cooled,
Low
Oil
Pressure
instructions
qualified
this
unit.
Power
Four-Cycle,
and
persons
60%
With
Shutdown
all
100
Duty Cycle
Overload
Gasoline
Switch
rt~i
Protection
Engine
U
Give
U
For
U
or:
1079,
this
manualtothe
call
help,
MILLER
Appleton,
distributor
your
ELECTRIC
WI
operator.
Mfg.
54912
P.O.
Co.,
414-734-9821
PRINTED
Box
IN
~SA
PROTECT
AWAY. In
welding,
information
safety
Safety
HAVE
Standards
ALL
QUALIFIED
1.
Do
not
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3.
mats
4.
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YOURSELF
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INSTALLATION,
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ELECTRIC
Touching
severe
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power
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live
wire
welding,
all
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live
touch
hole-free
dry,
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covers.
or
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this
equipment.
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WARNING
most
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live
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live
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power
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equipment
electrical
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AND
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on
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electrical
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whenever
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machine
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wire,
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parts.
gloves
work
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only
next
page.
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safe
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can
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hazardous.
KEEP
precautions
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this
equipment
and
attach
use.
body.
electrical
with
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floor
above
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Repair
state,
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not
undersized,
your
good
contact
equipment.
securelyinplace.
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taken.
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work
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heat and
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instruction
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and
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sparks
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workpiece,
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burns.
metal
to
fire.
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where
flying
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small
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cause
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injury.
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AND
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health.
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proper
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listed
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garments
shoes,
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or
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shields
to
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from
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recommended.
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death.
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removed
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and
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nearby.
bulkhead,
or
or
drums.
welding
long,
and
fire
hazards.
off
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leather
gloves,
cap.
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face
and
flash
while
or
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to
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at
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shields
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9/92
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Protect
mechanical
2.
Install
and
them
to
prevent
CYLINDERS
Shielding
pressure. gas
process,
compressed
shocks,
secure
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stationary
gas
If
damaged,
cylinders
be
sure
gas
and
cylinders
support
arcs.
fallingortipping.
can
explode
cylinders
a
cylinder
are
normally
to
treat
cylinders
in
an
upright
or
equipment
contain
them
from
if
damaged.
under
gas
can
explode.
of
the
part
carefully.
excessive
position
by
cylinder
high
Since
welding
heat,
chaining
to
rack
3.
Keep
circuits. Never
4.
Use
5.
fittings
associated Turn
6.
7.
in
8.
associated
cylinders
allow
only
designed
face
protective
Keep
use
or
Read
and
Standards.
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welding
correct
shielding
for
parts
from
away
cap
connected
follow
equipment,
from
away
electrode
the
specific
in
good
valve
in
place
for
use.
instructions
and
any
to
cylinders,
gas
application;
condition.
outlet
when
over
on
CGA
publication
welding
touch
any
regulators,
opening
valve
except
compressed
other
or
cylinder.
maintain
cylinder
when
gas
P-i
listed
electrical
and
hoses,
and
them
valve.
cylinder
cylinders.
in
Safety
is
1.
securely
2.
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Stop
a
ENGINE
Engines
ENGINE
explosion.
Engine
MOVING
Moving
cut
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in
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before
me
en
SPARKS
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WARNING
EXHAUST
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EXPLODE;
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harmful
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is
PARTS
and
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such
hands
covers,
can
flammable.
can
as
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cause
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skin,
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GASES
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cause
cause
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catch loose
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guards
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and
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gases.
injury.
and
closed
unit.
ACID
kill.
fire
or
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clothing.
and
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explosive
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2.
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open Allow
3.
fuel
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engine.
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To
4.
negative
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6. finished
1.
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5.
ENGINES
equipment
in
used
from
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add
not
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engine
cold
to
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not
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only
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engine
allow
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outside
closed
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hazardous.
or
can
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smoking
before
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before
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room
is
spilled,
remove
people
starting
from
cable
clothing,
and
guards
starting
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when
shield
disconnecting
cause
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charge
(+
batteries
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to
well-ventilated
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engine
fuel.
adding
if
unit
is
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If
possible,
job.
for
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to
clean
up
guards
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STEAM COOLANT
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SECTION
SECTION
2-1. 2-2.
2-3.
2-4.
SECTION
3-1.
3-2. 3-3. 3-4.
SECTION
SECTION
5-1.
5-2.
-
1
SAFETY
2
SPECIFICATIONS
Volt-Ampere
Cycle
Duty
Fuel
Consumption
DC
Auxiliary
3INSTALLATION
Selecting
Engine
A
Prestart
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Connecting
4OPERATING
OPERATING
5
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SIGNAL
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Power
Location
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TABLE
WORDS
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And
Output
THE
WELDING
AUXILIARY
Receptacle
Operation
OF
.
Moving
Auxiliary
Welding
Terminals
GENERATOR
EOUIPMENT
CONTENTS
Generator
Power
System
1
7
10 10
SECTION
6-1.
6-2.
6-3.
6-4.
6-5. 6-6. 6-7.
6-8.
SECTION
SECTION
8-1. 8-2.
SECTION
Figure Figure
Figure
MAINTENANCE
6
Routine
Changing
Adjusting
Air
Clean
Drive
Overload
Maintenance
Cleaner
Air
Belt
Engine
Engine
Service
Intake
Adjustment
Protection
Troubleshooting
7
ELECTRICAL
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8-
Shielded
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9
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9-1. 9-2.
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9-3.
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METHODS
Arc
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Troubleshooting
LIST
Assembly
Front
Control
&
TROUBLESHOOTING
Oil
Speed
And
Cooling
And
Replacement
DIAGRAMS
&
TROUBLESHOOTING
Welding
(SMAW)
w/Components
w/Components
Areas
11
12 13 13
14 14 15
16
18
20 25
28
31
32
OM.160
518
3)93
Read
Obey
Learn
SECTION
all
safety
messages
all
safety
messages
the
meaning
of
WARNING
1
throughout
avoid
to
injury.
and
SAFETY
this
manual.
CAUTION.
SIGNAL
WORDS
rnodl.1
2/93
1
2
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5
6
NOTE
7H
;
ELECTRIC
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Do
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switch
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SECTION
3
_______________
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READ
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when
using
Figure
2
2
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a
CAUTION
1-1.
SAFETY
3-1
high
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before
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Keep
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when
operating.
BLOCKS
proceeding
Information
PARTS
from
SPECIFICATIONS
______________
at
can
moving
and
start
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covers
of
injure.
closed
I
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1
Safety
2
Signal
WARNING
serious
or
CAUTION
or
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Statement
3
Result
4
Safety
Hazard
Hazard
5
6
Safety
Read
safety
bol
shown.
7
NOTE
Special
ation
Alert
Word
means
injury
means
equipment
Of
Instructions
Symbol
Banner
blocks
instructions
related
not
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possible
can
happen.
possible
damage
Hazard
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for
for
to
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death
minor
can
And
To
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each
sym
best
oper
Specification
TypeOfOutput
Rated
Weld
Output
Amperage
Maximum
Welding
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Engine
Engine
Fuel
Engine
Drive
Overall
Weight
Options
Range
Open-Circuit
Process
Power
Speed
Tank
Capacity
Oil
Capacity
Belt
Size
Dimensions
Rating
(No
Load)
Voltage
Constant
90
Amperes,
40
To
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75
Shielded
Welding
1.2
kW,
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1800
rpm
2.3
U.S.
22.4
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See
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Net:
101
See
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Table
Current/Direct
25
A
100
DC
(See
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Arc
(GTAW)
120
Volts
CH5+
Air-Cooled,
Idle
Speed;
(8.7L)
gal
(0.66L)
3-2
lb
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Cover
2-1.
Volts
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kg);
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DC
At
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10
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4150
rpm
113
Ship:
Generator
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Duty
Cycle
Flux
Appropriate
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Weld
And
lb
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kg)
Description
Section
(See
Cored
Arc
Process
Power
Welding
Options
Gasoline
Speed
2-2)
Engine
(FCAW)
And
Gas
Tungsten
Arc
OM-160
518
Page
1
2-1.
Volt-Ampere
Curves
Cl)
0
>
0
100
90
80
60
50
40
30
70
20
10
The
volt-ampere
minimum and
amperage
of
the
welding
other
curves
and
generator.
settings
shown.
maximum
output
fall
curves
capabilities
between
show
voltage
Curves
the
of
the
0
0
25
50
DC
75
AMPERES
Figure
100
2-1.
Volt-Ampere
125
150
Curves
rsDl.1
10/91
SB-152
541
2-2.
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Duty
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w
a
<
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a
DUTY
indicated
300
250
200
150
100
75
50-
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.
RATINGS
RATED
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can
or
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unit
This
allowing
every
--
is
welding
10
minutes.
rated
at
6
60%
minutes
duty
cycle
out
of
OM-160
518
Page
10
2
15
20
%
25
DUTY
Figure
30
40
CYCLE
2-2.
50
Duty
60
Cycle
7080
100
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sbl.2
10/91
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the
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12.5
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DC
Power
Curve
For
120
Volt
Receptacle
OM-160
518
Page
3
SECTION
3INSTALLATION
3-1.
Selecting
a
ENGINE
Do
Use outside
ENGINE
fire.
Use
arrestor
laws.
A
spark
and
California,
state
Properly
Stop
before
Service
A
Location
WARNING
EXHAUST
breathe
not
in
open,
and
EXHAUST
U.S.
only
and
arrestor
in
grass,
Oregon,
and
local
maintain
engine
servicing
spark
And
GASES
exhaust
fumes.
well-ventilated
from
away
Forestry
comply
and
arrestor
building
SPARKS
Department
with
is
mandatory
or
brush,
and
authorities
the
spark
allow
exhaust
arrestor.
spark
away
Moving
can
or
areas,
air
intakes.
local,
in
in
other
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system
from
Keep
leaks
approved
state,
all
National
covered
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flammables.
unit and
all
forest
Washington.
kill.
vent
can
and
Check
to
cool
level
possible
Welding
exhaust
cause
spark
federal
Forests
lands
in
with
down
tilting
fire
Generator
can
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or
engine
2
HOT
PIPE
FALLING
serious
damage.
fuel
and
damage.
2
ENGINE
can
exhaust
Keep
Lift
Unit
Have
two
Move
unit
adequate
It
using
before
skid
oil
EXHAUST
cause
fires.
and
EQUIPMENT
personal
handlesonends
at
persons
with
hand
capacity.
lift
fork
a
vehicle,
transporting.
1
2
Lift
centerof
and
3
Keep
haust
pipe
away
injury
of
adequate
cart
secure
in
18
(457
All
On
Sides
Handles
Lifting
unit
with
handles.
transport
Exhaust
flammables
outlet.
AND
from
and
of
base.
strength
similar
or
mm)
hands
unit.
Outlet
EXHAUST
flammables.
can
cause
equipment
lift
unit.
device
unit
a
on
rwarnl.1
Space
Open
positioned
Obtain
help
from
away
proper
12/91
to
ex
of
in
lift
OM-160
518
Page
Figure
3-1.
Location
~<
And
Movement
Of
The
Welding
5T-161
Generator
4771
ST-151
Inches
A
19
B
14-5/8
C
28-3/4
C
5T.161
Ref.
556/
Millimeters
483
371
730
478
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3-2.
Figure
4
Overall
Dimensions
200
200
Maximum lubrication.
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tilted.
Do
room
out
Do
let
fuel
leak
not
from
cap
during
tilting.
fuel
cap
overfill
not
for
expansion
causing
tilting
at
leaks.
angles
highest
fuel
tank
nd
a
for
proper
when
point
leave
with
tilting
S-0702
3-2.
.~
Engine
ENGINE
explosion.
Prestart
a
Stop
Do
not
not
Do
Checks
WARNING
FUEL
before
engine
fuel
while
overfill
tank;
Figure
can
fueling.
smoking
clean
3-3.
or
up
cause
near
any
Maximum
sparks
spilled
fire
or
fuel.
flames.
Welding
or
Generator
Tilt
REMOVE
SPRAY
under
Rotate before
Angles
FUEL
may
pressure.
fuel
cap
removing
CAP
cause
slowly
cap.
Check
be
cold
Add
injury;
and
all
and
fresh
engine
Figure
6-1).
I
Fuel
Fill
fuel
tanktowithin
of
bottomoffiller
for
space
2
Fill
Oil
Fill
Oil
3
Remove
Reinsert
rests
cap
thread
cap
stick
and
If
oil
is
not
(see
Figure
oil
to
raise
F.
L
to
SLOWLY;
FUEL
wait
until
fluids
daily.
level
on
a
fuel
the
Cap
dipstick dipstick
check
before
first
neck
expansion.
Cap/Dipstick
Tube
and
in
tube
to
up
6-1).
level
tube.
oil
full
Add
collar.
level.
on
on
onto
oil
may
hissing
rwarn3
Engine
surface.
time
in
1
(25
to
wipe
tube
so
Remove
mark,
4
oz
dipstick
FUEL
be
stops
1
9191
must
starting
(see
mm)
provide
off
oil.
fill
oil
Do
not
dip
add
oil
(0.12
L)
from
Figure
3-4.
Checking
Fluid
Levels
rsb4,1
OM-160
11/92ST-16l
518
Page
479
5
3-3.
Grounding
The
Generator
Auxiliary
Power
System
1
Equipment
Terminal
Grounding
The
power
to
3-4.
.~
generator
neutralisconnected
the
machine
Tools
Needed:
-.~
Connecting
.
auxiliary
frame.
a
ELECTRIC
Always
Do
not
Stop
engine
Read
To
Weld
WARNING
SHOCK
wear
dry
touch
live
before
Precautions
Safety
Figure
Output
can
insulating
electrical
gloves.
parts.
making
at
3-5.
Terminals
kill.
weld
any
beginning
Equipment
connections.
output
of
this
manual.
Grounding
Connection
rsb5.1
1/93
ST-i
Ret.
~7
863-A/Ret.
ST-I
rwarnl3,l
81
479
2/92
OM-160
518
Page
I
DC
1
2
~
Receptacle
2
DC
Negative
Positive
()
(+)
Weld
Weld
Output
Output
Receptacle
For
Direct
Current
~
~
tive
(DCEP).
Work
receptacle
cable
to
Electrode
For
Direct
tive
connections.
3
4
Align
receptacle.
rotate
Current
(DCEN),
Weld
Output
Connector
keyways
clockwise
connect
Receptacle
on
Insert
Electrode
and
+
Electrode
reverse
connector connector
until
Posi
work
cable
electrode
receptacle.
Nega
cable
and and
tight
to
in
receptacle.
~-
Ret.
ST-I57863-A/ST-161
Weld
Figure
6
3-6.
Output
Connections
480
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