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March1993
Form:
OM-160518
Effective
With
Serial No. KD398640
OWNERS
MANUAL
Read and follow these instructions and all
Give this manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install, operate,
or
service this unit.
Call your distributor if you do
not
understand
the directions.
For
help,
call your distributor
or:
MILLER ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI 54912
414-734-9821
Millerfi
~. r.~1~Ic4...1
-
~_ ~
I
1
~.w
Gold SealTM Model
3000
CC/DC
Welding
Generator
For SMAW
Welding
90
Amperes,
25 Volts DC At 60%
Duty Cycle
1.2
kVA/kW DC
Auxiliary
Power With Overload Protection
Kohler CH5+
Air-Cooled,
Four-Cycle,
Gasoline
Engine
Optional
Low
Oil
Pressure
Shutdown Switch
coven
5/92ASt-161
477
PRINTED
IN
~SA
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Table of Contents
Troubleshooting
Related Manuals for Miller 3000
Summary of Contents for Miller 3000
- Page 1 Call your distributor if you do the directions. 5/92ASt-161 coven March1993 Effective With 3000 Welding Generator Welding 25 Volts DC At 60% Duty Cycle Auxiliary Power With Overload Protection Air-Cooled, Four-Cycle, Gasoline Engine...
- Page 3 MILLERS (Equipment This limited warranty supersedes LIMITED WARRANTY Subject conditions below, terms MIg. Co., Appleton. Wisconsin, wsrrsnts to originsl effective date of this limited MILLER equipment sold sfter the tects in material workmanship time it is shipped by LIEU OF OTHER WARRANTIES.
- Page 5 1~oIsfi OWNERS MANUAL CC/DC For SMAW Amperes, kVAJkW DC Kohler CH5+ Optional Read and follow these instructions and all blocks safety carefully. Have only trained install, operate, service this unit. Callyourdistributorifyoudonotunderstand the directions. ST-161 8/92 cover March Effective (jJOJ1 PAW 100 Generator Welding Welding...
- Page 7 ARC WELDING SAFETY PRECAUTIONS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN PACEMAKER WEARERS KEEP AWAY UNTIL AWAY. welding, in most jobs, exposure below is safety information given only Standards listed the next page. Read and follow all Safety INSTALLATION, OPERATION, MAINTENANCE, HAVE ALL...
- Page 9 CYLINDERS explode contain gas under Shielding cylinders pressure. If cylinder damaged, IL~c cylinders normally process, be to treat them sure Protect compressed cylinders mechanical shocks, arcs. upright position by chaining Install and cylinders secure them stationary equipment cylinder support falling tipping.
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Page 11: Table Of Contents
TABLE OF SECTION SAFETY SIGNAL WORDS SECTION SPECIFICATIONS 2-1. Curves Volt-Ampere 2-2. Duty Cycle 2-3. Fuel Consumption Power Curve 2-4. Auxiliary SECTION 3INSTALLATION Location And 3-1. Selecting Checks 3-2. Engine Prestart 3-3. Grounding The Generator To Weld Output 3-4. Connecting SECTION 4OPERATING WELDING GENERATOR SECTION... -
Page 13: Section 2 Specifications
SECTION Read all safety messages Obey safety messages of WARNING and CAUTION. Learn the meaning ELECTRIC SHOCK kill touch live electrical parts. betore~ Disconnect input power installing servicing. NOTE Off switch when Turn SECTION Specification Type Output Constant Rated Weld Output Amperage Range 40 To 100 A... -
Page 15: Volt-Ampere Curves
Curves 2-1. Volt-Ampere > 2-2. Duty Cycle CAUTION EXCEEDING DUTY CYCLE RATINGS exceed indicated duty cycles. < OM-160 518 Page DC AMPERES Figure Volt-Ampere Curves 2-1. will damage unit. OUTPUT RATED ~..., 25 30 50 60 7080 % DUTY CYCLE Figure 2-2. -
Page 17: Fuel Consumption
2-3. Fuel Consumption 1.89 0.42 0.50 1 .66 0.37 0.44 1.42 0.31 0.38 1 .18 0.26 0.31 0.25 0.95 0.21 0.71 0.16 0.19 0.47 0.10 0.12 -IDLE 0.23 0.05 0.06 DC WELD AMPERES Power Curve 2-4. Auxiliary > Figure DC AUX POWER (25 VOLTS) DC POWER KW Figure... -
Page 19: Section 3Installation
SECTION 3INSTALLATION 3-1. Selecting Location And WARNING ENGINE EXHAUST GASES not breathe exhaust Use in open, well-ventilated outside and away from ENGINE EXHAUST SPARKS fire. U.S. only Forestry Department approved spark with all arrestor comply laws. arrestor is spark mandatory and in grass, brush, California,... -
Page 21: Engine Prestart Checks
not let fuel leak from Figure Prestart Checks 3-2. Engine WARNING ENGINE FUEL explosion. before Stop engine fueling. Do not fuel while smoking overfill clean up any tank; during tilting. 3-3. Maximum Welding Generator Tilt fire REMOVE FUEL CAP cause SPRAY may under pressure. - Page 23 The Generator 3-3. Grounding generator auxiliary power neutral is connected to the machine frame. Tools Needed: Figure 3-4. Connecting To Weld Output WARNING ELECTRIC SHOCK Always dry insulating gloves. wear touch live electrical Stop engine before making Read Safety Precautions OM-160 Page Auxiliary...
- Page 25 SECTION OPERATING THE WELDING GENERATOR WARNING ELECTRIC SHOCK touch live electrical Always dry insulating gloves. wear from work and Insulate yourself Stop engine before installing panels Keep covers WELDING can cause weld flammable material. near Watch for fire; keep extinguisher nearby. Do not locate unit combustible surfaces.
- Page 27 OM-160 518 Page Tools Needed: Figure 4-3. Work Clamp Control Figure 4-4. Amperage Controls Figure 4-5. Engine Work Clamp Connect work clamp clean, location paint-free workpiece, close to weld possible. area as brush wire sandpaper clean metal at weld joint area.
- Page 29 Figure Figure EquIpment~) Select Install & Connect Electrode _____ ________________ ________________ _____ Insert Electrode Begin Into_Holder _________________ Figure 4-8. Hour Meter (Optional) 4-6. Engine LOW OIL 4-7. Automatic Low Oil Shutdown ControI~~) Put On Personal Safety ~~JJ Equipment _____ _____ Weldin~ Sequence Of Shielded Metal...
-
Page 31: Auxiliary Power Dc
OPERATING AUXILIARY EQUIPMENT SECTION WARNING ELECTRIC SHOCK touch live electrical before Stop engine making reconnection. Ground generator according national, state, and local codes. equipment grounding Connect earth ground. connect to any electrical distribution normally supplied by utility ELECTRIC SPARKS using auxiliary power disconnect both welding... -
Page 33: Section 6 Maintenance
SECTION MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK not touch live electrical Always dry insulating gloves. wear Insulate yourself from work and Stop engine before installing Keep panels covers ENGINE EXHAUST GASES not breathe exhaust fumes. in open, well-ventilated outside and away from 6-1. -
Page 35: Changing Engine Oil
before Stop engine maintaining. throw engine away take fluids recycling area center. Hours Clean Cleaner Foam Element 6-4~J Changing Engine 6-2. OM-160 518 Page 6-2. Maintenance Schedule Figure Tools Needed: Figure 6-3. Changing Engine 500 Hours engInes Check Valve Clearance manual Every200 hours havealferna... -
Page 37: Adjusting Engine Speed
6-3. Adjusting Engine Speed Cleaner Service 6-4. READ SAFETY BLOCKS at Section Moving Parts Hazard. Have belt guard place before running engine. Figure 6-4. Engine Speed Adjustment READ SAFETY Section Figure 6-5. Air Cleaner Maintenance start before proceeding. Start and load. -
Page 39: Drive Belt Adjustment
Clean Air Intake And Cooling 6-5. 6-6. Drive Belt Adjustment Tools Needed: 9/16,5/8 7/16 Stop engine. Belt Guard Remove five securing belt guard. screws Remove guard inspect belt. Drive Belt Readjust belt tension if necessary. Replace cracked belt. Tensioning Screw Figure OM-160 518 Page... -
Page 41: Overload Protection
Overload Protection 6-7. WARNING CAUTION :DC POWER FOR TOOLS AND LIGHTS ONLY NOT USE AC ONLY RATED TOOLS. CONSULT OWNERS MANUAL! 120V 1OA READ SAFETY BLOCKS Section before 125 volts Replacement fuse rating: maximum. greater, amperes Figure 6-8. Location Of Fl Fuse at start proceeding. -
Page 43: Troubleshooting
6-8. Troubleshooting WARNING ELECTRIC SHOCK not touch live electrical Always dry insulating gloves. wear Insulate yourself from work and Stop engine before installing Keep panels covers ENGINE EXHAUST GASES breathe exhaust fumes. Use in open, well-ventilated outside and away from any HOT PARTS can cause severe Allow... - Page 45 Trouble auxiliary power. Erratic auxiliary power. auxiliary power. Trouble Engine will not start. stalls. Engine rough runs Table 6-2. Power Trouble Auxiliary Remedy Check and replace fuse Authorized Service Station check brushes and Have Factory rings. Have Factory Authorized Service Station check brushes and rings.
- Page 47 P O S I T I V E N E G A T I V E W E L D O U T P U T IIRC2 4 1 t t P / P t t t P L G 2 1 3 3 1 2 1 2 3 4 5 6 7 8 9 1161...
- Page 49 r ( ~ ~ A L T E R N A T O R H O U S I N G 8 6 0 - B S T - 1 5 3 G e n e r a t o r W e l d i n g D i a g r a m N E G A T I V E...
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Page 51: Section 8- Welding
SECTION WELDING METHODS & TROUBLESHOOTING WARNING ELECTRIC SHOCK Always dry insulating gloves. wear Insulate yourself from work and touch live electrical Keep panels covers FUMES GASES your health. of the fumes. Keep your head Ventilate breathing area, Safety Read Material Data Sheets manufacturers instructions for material used. - Page 53 6010 5/32 & 6011 6013 5/32 9115 7,93 3/32 7014 3/IS 7193 5/32 7018 1115 1132 5/32 7024 I/IA 3132 Ni-Cl 3/16 ~1/8 308L 5/32 6010 DEEP 6011 DEEP 6013 E~EN 7014 EP,EN 7018 FLAT 7024 EP,EN HORIZ FILLET NI-CL 308L ELECTRODE POSITIVE ELECTRODE NEGATIVE...
- Page 55 Figure Figure 1O0~3O0 <~ End View Of Work Side View Of Electrode Angle GROOVE WELDS OM-160 518 Page Striking An Arc Scratch Start 8-3. 8-4. Striking Tapping Technique End View Of Work Angle Electrode Holder Figure 8-5. Positioning Electrode Workpiece Drag electrode workpiece...
- Page 57 Weld bead NOTE ~ thickness of base metal. ______________________ Too Small Angle Too Short Slow Figure POOR WELD BEAD GOOD WELD BEAD Figure 8-6. Weld Bead Characteristics shape is affected electrode Correct Angle Drag ELECTRODE ANGLE Normal ARC LENGTH Normal TRAVEL SPEED Conditions That Affect Weld Bead...
- Page 59 Normally, NOTE however, multiple ~~/3 Figure 2To3in (51-76 mm) 1/4in (6.4 OM-160 Page bead is single stringer satisfactory for wide groove weld joints bridging stringer beads work better. 8-8. Ele ctrode Mov ement During Welding ~~I~f 4jI~t~- Figure 8-9. Butt Joints 8-10.
-
Page 61: Welding Troubleshooting
Single-Layer Fillet Weld 8-2. Welding Troubleshooting Possible Causes length Reduce long. Damp electrode. Remove all Workpiece dirty. welding. Tee Joint Figure 8-11. Less Fillet Weld Multi-Layer 8-12. Joint Figure Table 8-1. Porosity Corrective Actions length. electrode. oil, moisture, paint, coatings, slag, rust, grease, Electrode... - Page 63 ~... Causes Possible for electrode. Amperage high Decrease amperage voltage high Reduce length long Possible Causes Insufficient heat Increase amperage. Select input. welding technique. Place Improper Adjust Momentarily Keep Remove all grease, Workpiece dirty. welding. Lack of Penetration Possible Causes Material Improper joint preparation.
- Page 65 Excessive Penetration Possible Causes Excessive heat input. Select lower amperage. Use Increase and/or maintain Possible Causes Excessive heat Select lower amperage. Use smaller electrode. input. Increase Possible Causes Unsteady hand. Possible Causes Excessive heat input. Use restraint Make tack welds Select lower amperage for electrode.
-
Page 67: Section 9 Parts List
SECTION PARTS LIST ST-162 Figure 9-1. Main Assembly OM-160 518 Page... -
Page 69: Figure
Item Dia. Part Mkgs. 147 601 150 721 150 720 020 279 150 123 152 756 +148 975 152 452 146 994 148976 150 412 146 280 151 209 +148 971 601 965 602 213 602 243 148 966 150 217 602 215 PLG2,3 135 134... - Page 71 Item Dia. Part Mkgs. 157908 010368 026843 600325 010521 600681 129527 134746 147552 067101 +154656 147544 152460 152583 150126 137690 +When ordering originally displaying component of 042 769 Optional Automatic Low Oil Shutdown Kit. Part BE SURE TO PROVIDE MODEL AND OM-160 518 Page Description...
- Page 73 Item Dia. Part Mkgs. 150765 154663 152537 604 176 073 690 Neg,Pos 129 525 601 836 010 915 C3,4 131 646 046 432 *012 655 063030 097 924 *Recommended Spare Parts. Part of 042 769 Optional Automatic Low Oil Shutdown Kit. Optional Running Part of 042 781...
- Page 75 Item Dia. Part Mkgs. 148 967 137 198 087 111 01,2 149 243 035 704 ,2,4 R3,4,VR1,2. 149244 152 534 153 064 SURE TO PROVIDE MODEL AND SERIAL NUMBER OM-160 518 Page Description Figure 9-3. Panel, Control w/Components (Fig COVER, (consisting NUT, insert 10-24...