Miller 3000 Owner'S Manual Download Page 44 | Manualshive

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Summary of Contents for 3000

Page 1: ...stributor 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 O...

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Page 3: ...ER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EOUIPMENT In the avant 01 a warranty claim covarad by this warranty the eacluniva remedies shall ba at MILLERS option 1 repair or 2 replacement or where authorized in writing by MILLER in appropriate cases 3 the reasonabia cost of repair or replace...

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Page 5: ...Callyourdistributorifyoudonotunderstand the directions rt i U U For help call your distributor or MILLER ELECTRIC Mfg 1079 Appleton WI 54912 Co P O Box 414 734 9821 1 oIsfi jJOJ1 cI j r J PAW 100 CC DC Welding Generator For SMAW Welding U 90 Amperes 25 Volts DC At 60 Duty Cycle U 1 2 kVAJkW DC Auxiliary Power With Overload Protection Kohler CH5 Air Cooled Four Cycle Gasoline Engine Optional Low Oi...

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Page 7: ...t workpiece and hot equipment can cause fires and burns Accidental contact of electrode orwelding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved co...

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Page 9: ...9W 1R3 Safe Practices ForOccupationAnd Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51 B from National Fire Protection Association Batterymarch Park Quincy MA 02269 IL c CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged...

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Page 11: ...wer DC Receptacle 5 2 Auxiliary Equipment Operation 1 11 12 13 13 14 14 15 16 2 2 3 3 4 5 6 6 7 10 10 SECTION 6 MAINTENANCE TROUBLESHOOTING 6 1 Routine Maintenance 6 2 Changing Engine Oil 6 3 Adjusting Engine Speed 6 4 Air Cleaner Service 6 5 Clean Air Intake And Cooling Areas 6 6 Drive Belt Adjustment And Replacement 6 7 Overload Protection 6 8 Troubleshooting SECTION 7 ELECTRICAL DIAGRAMS SECTIO...

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Page 13: ...o Avoid Hazard 5 Hazard Symbol If Available 6 Safety Banner Read safety blocks for each sym bol shown 7 NOTE Special instructions for best oper ation not related to safety Turn Off switch when using high frequency Specification Type Of Output Rated Weld Output Amperage Range Maximum Open Circuit Voltage Welding Process Description Auxiliary Power Rating Engine Engine Speed No Load Fuel Tank Capaci...

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Page 15: ...s of other settings fall between the curves shown rsDl 1 10 91 SB 152 541 0 25 50 75 100 125 150 DC AMPERES EXCEEDING DUTY CYCLE RATINGS will damage unit Do not exceed indicated duty cycles warn7 1 2 92 This unit is rated at 60 duty cycle allowing welding 6 minutes out of every 10 minutes RATED OUTPUT 50 10 15 20 25 30 40 50 60 7080 100 Duty cycle is how long the unit can operate within a ten minu...

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Page 17: ... 0 12 IDLE 0 23 0 05 0 06 0 0 15 30 45 60 75 90 DC WELD AMPERES 25 VOLTS 0 2 0 4 0 6 0 8 1 0 1 2 DC POWER KW rsb2 I 10 91 SB 153 250 Figure 2 3 Fuel Consumption Curve 2 4 DC Auxiliary Power Curve The dc power curve shows the aux iliary power in amperes available at 140 the 120 volt dc receptacle 80 0 Q60 40 20 0 0 2 5 5 0 7 5 10 12 5 15 DC AMPERES SB 152 758 Figure 2 4 DC Power Curve For 120 Volt ...

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Page 19: ... flammables HOT ENGINE EXHAUST AND EXHAUST PIPE can cause fires Keep exhaust and pipe away from flammables FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift Unit at handles on ends of base Have two persons of adequate strength lift unit Move unit with hand cart or similar device of adequate capacity It using a fork lift vehicle secure unit on a proper skid before transp...

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Page 21: ...FUEL may be under pressure Rotate fuel cap slowly and wait until hissing stops before removing cap rwarn3 1 9191 Check all fluids daily Engine must be cold and on a level surface Add fresh fuel before starting engine the first time see Figure 6 1 I Fuel Cap Fill fuel tank to within 1 in 25 mm of bottom of filler neck to provide space for expansion 2 Oil Fill Cap Dipstick 3 Oil Fill Tube Remove dip...

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Page 23: ...ne before making any weld output connections Read Safety Precautions at beginning of this manual rwarnl3 l 2 92 1 2 I DC Negative Weld Output Receptacle 2 DC Positive Weld Output Receptacle For Direct Current Electrode Posi tive DCEP connect work cable to Work receptacle and electrode cable to Electrode receptacle For Direct Current Electrode Nega tive DCEN reverse cable connections 3 Weld Output ...

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Page 25: ... ventilated areas or vent exhaust outside and away from any building air intakes ENGINE FUEL can cause fire or explo sion Stop engine before fueling Do not fuel while smoking or near sparks or flames Do not overfill tank clean up any spilled fuel t MOVING PARTS can cause injury Keep away from moving parts such as fans belts and rotors Keep all doors panels covers and guards closed and securely in ...

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Page 27: ...es 2 3 Ret ST 157 883 A Figure 4 4 Amperage Control 1 Fuel Shutoff Valve Open valve before starting engine Close valve when unit is not in use or during transport 2 Throttle Control Lever Use lever to start and stop engine and select engine speed To start engine move lever to Run 3 Choke Control Lever Use lever to regulate carburetor air fuel mixture Move choke lever to right choke on if starting ...

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Page 29: ...ne does not start until sufficient oil is added to engine Fill engine with oil to F mark on dip stick see Figure 3 4 Ref ST 157 863 Figure 4 7 Automatic Low Oil Shutdown Optional Install Connect EquIpment Electrode Personal Safety I I Set ControI Start Eng Uia __ Select Put On ________________ ________________ Equipment JJ ________________ _____ _____ _____ _____ _____ g pmen Insert Begin Weldin E...

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Page 31: ...ble for incandescent lights and portable power tools with 115 or 120 volt AC DC or DC ratings This power must not be used to power any AC only rated equipment rwarn8 1 10 92 Figure 5 1 Auxiliary Power DC Receptacle And Circuit Protection 5 2 Auxiliary Equipment Operation lnstat Co n ct TurnOnA liarY Begin Ope on Figure 5 2 Sequence Of Auxiliary Equipment Operation X MOVING PARTS can cause serious ...

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Page 33: ...hing when working on a hot engine Maintenance to be performed only by qualified per sons rwarn9 I 10 91 6 1 Routine Maintenance The maintenance label is located on the fuel tank above the throttle control lever see Figure 6 3 Recommended Oil API Service Classification SF SG CC CD Below 32F 0C SAE 5W 20 SAE 5W 30 Above 32F 0C SAE 1OW 30 SAE 1OW 40 Check oil daily 4 oz Add to Full on dipstick Oil Ca...

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Page 35: ...e Stop engine Change engine oil at interval listed in Figure 6 1 Change oil while en gine is still warm 1 Support Block Use blocks large enough to provide room for oil pan 2 Oil Fill Cap Dipstick Remove oil fill cap dipstick before draining oil 3 Oil Drain Plug Remove plug Allow enough time for oil to drain completely Reinstall plug 4 Maintenance Label Fill crankcase with new oil to F mark on dips...

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Page 37: ... Figure 6 4 Engine Speed Adjustment Stop engine 1 Air Cleaner Cover 2 Retaining Screw Loosen retaining screw and re move air cleaner cover 3 Wing Nut Remove as shown 4 Foam Element Precleaner Wash element in warm water with detergent Rinse all detergent from element and allow to air dry Saturate element with clean en gine oil Squeeze out excess oil Reinstall element on paper element 5 Paper Elemen...

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Page 39: ...d and loosen securing screws Remove belt Adjust belt tension by turning tensioning Remove guard and inspect belt Install new belt and hand tighten securing screw in or out until proper belt tension is screws Reinstall tensioning screw obtained 2 Drive Belt Check belt tension by pressing belt midway Readjust belt tension if necessary Replace between pulleys Apply about 8 5 lb 3 9 kg Reinstall belt ...

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Page 41: ...reater 10 amperes maximum 10 A Fuse Fl protects the unit from overload or short circuit on the 120V dc receptacle If Fl is open the engine continues to run but there is no output at the receptacle Weld output is still available 120V 1OA DC 0 Turn fuse holder counterclockwise to remove fuse Put new fuse In fuse holder Push fuse holder into panel and turn clockwise to secure Fl If fuse continues to ...

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Page 43: ... securely in place Troubleshooting to be performed only by qualified persons rwarnhl 1 11 91 Table 6 1 Welding Trouble Trouble No weld or auxiliary power output Remedy Low weld output Broken drive belt Have Factory Authorized Service Station check generator brushes and slip rings Section 6 6 Have Factory Authorized Service Station check generator 6 3 Check and adjust engine speed Tune up engine fo...

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Page 45: ...ine manual Section 6 7 a 6 6 6 3 Low auxiliary power Check and adjust engine speed Perform engine maintenance as necessary to achieve full horsepower see engine manual Check drive belt tension Have Factory Authorized Service Station check generator Trouble Engine will not start Open fuel shutoff valve Remedy Check oil level Check optional oil level shutdown switch Check fuel level in tank Move thr...

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Page 47: ...1351391241 I I I 313 I 15 16 17 13312 ENGINE EXCITATION PLG2 RC2 PLG3 RC3 _ jA _ _ 46 E i IIj 1 4 4 2 RUNNING PLG3 RC3 HOUR METER OPTIONAL arJJ3 IGNITIONKILL TAB I I LOW OIL SHUTOOWN OIL ENG LEVEL GNO L PLG2 RC2 POSITIVE DC WELD OUTPUT NEGATIVE 7 58 152 539 A 25 POS PLG3 RC3 B I 15 I25VDCAUX POWER Figure 7 1 Circuit Diagram For Welding Generator ...

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Page 49: ...r I BLK L r L I ALTERNATORI HOUSING SP4 GR Wsilo NEGATIVEOUTPUT ST 153 860 B Figure 7 2 Wiring Diagram For Welding Generator ...

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Page 51: ...e touching welded metal Wear protective gloves and clothing MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions WELDING CURRENT can damage elec tronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close t...

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Page 53: ... 0 0 2 0 It I w 2 uJ 0 6010 EP ALL DEEP 6011 EP v ALL DEEP MIN PREP ROUGH HIGH SPATTER 6013 E EN v ALL LOW GENERAL 7014 EP EN y ALL MED SMOOTH EASY FAST 7018 ER v ALL LOW LOW HYDROGEN STRONG 7024 EP EN FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL ER ER v ALL LOW CAST IRON 308L ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Figure 8 2 Electrode An...

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Page 55: ... lifted to high If electrode sticks to work piece use a quick twist to free it S 0049 Ii 2 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free the electrode S 0050 3 1O0 3O0 End View Of Work Angle Side View Of Electrode Angle GROOVE WELDS 0 3...

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Page 57: ... Moderate Crater During Welding Weld a new bead or layer for each 5 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration Into Base Metal S 0052 B Angle Too Small H NOTE Weld bead shape is affected by electrode angle arc length travel speed and ______________________ thickness of base metal Correct Angle Angle Too Large Drag ELECTRODE ANGLE Li L_ Spatter Too Short Normal T...

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Page 59: ...through 3 4 in 5 19 mm thick Cut bevel with oxyacetylene or plasma cut ting equipment Remove scale from material after cutting A grind ercan also be used to prepare bev els Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 l6in 5mm 9 0662 L I f 4jI t NOTE Normally a single stringer bead is satisfactory for most narrow groove w...

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Page 61: ...ode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Figure 8 8 Remove slag before making another weld pass S 0060 S 0058 A S OO61 2 1 Electrode 300 Or Less 2 Single Layer Fillet Weld Move electrode in...

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Page 63: ... proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Table 8 4 Lack Of Penetration Lack Of Penetration shallow fusion b...

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Page 65: ...weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique Table 8 8 Distortion Distortioncontraction of weld metal dur ing welding that forces base metal to move Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint b...

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Page 67: ...SECTION 9 PARTS LIST Figure 9 1 Main Assembly ST 162 841 OM 160 518 Page 28 ...

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Page 69: ...GENERATOR consisting of 1 23 RC2 135 133 CONNECTOR rectgP S rcpt Amp 1 641765 0 1 114066 CONNECTOR rect skt 20 l4ga Amp 350536 1 9 150 496 PULLEY V sgl grv 3 75Odia x 3 500P x 670 bore 1 150497 SPACER fan 1 150 498 FAN generator 6 469dia 1 150 502 BEARING ball 1 150 503 BEARING roller 1 150 506 BRUSH HOLDER ASSEMBLY generator 1 24 155063 BASE 1 25 148 965 SCREEN handle base 1 26 Fig 9 3 PANEL cont...

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Page 71: ... w micron filter BUSHING tankfuel MOUNT dual stud 625dia 250 20 stud 625 high AUTO ARC hand held shield When ordering a component originally displaying a precautionary label the label should also be ordered Part of 042 769 Optional Automatic Low Oil Shutdown Kit BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Item Dia No Mkgs Part No 45 157908 46 010368 47 026843 48 6003...

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Page 73: ...UT speed push on type 500 stud 1 5 RC1 604 176 RECEPTACLE str dx grd 2P3W iSA 125V 1 073 690 PLUG str grd armd 2P3W iSA 125V P S 5266DF 6 Neg Pos 129 525 RECEPTACLE twlk insul fern Dinse type 50 70 series 2 7 601 836 NUT brs hex 250 20 jam hvy 3 8 010 915 WASHER flat brs 250 ID x 625 OD x O3lthk 2 9 C3 4 131 646 CAPACITOR ASSEMBLY 1 10 046 432 HOLDER fuse mintr 1 11 Fl 012 655 FUSE mintr cer 1OA 2...

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Page 75: ...ription Quantity 1 148 967 COVER consisting of 1 137 198 NUT insert 10 24 3 2 087 111 CLAMP capacitor 1 375dia clip 2 3 01 2 149 243 CAPACITOR elctlt 950uf 100VAC 2 4 SRi 2 4 035 704 RECTIFIER integ 40A 800V 3 5 R3 4 VR1 2 151 530 SUPPRESSOR 2 6 R2 149244 RESISTOR WWadj25W3ohm 1 7 152 534 PANEL mtg components 1 8 R3 153 064 RESISTOR WW adj lOW 1 ohm 1 1 7 2 6 5 4 3 ST 151 475 OM 160 518 Page 32 ...

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