Miller 3000 User manual

March1993

Form:

OM-160518

Effective

With

Serial

No.

KD398640

OWNERS

MANUAL



Read

and

these

instructions

and

all



Give

this

manual

the

operator.

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.



Call

your

distributor

you

not

understand

the

directions.



For

help,

call

your

distributor



or:

MILLER

ELECTRIC

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

54912

414-734-9821

Millerﬁ

r.~1~Ic4...1







~







1

~.w

Gold

SealTM

Model

3000



CC/DC

Welding

Generator



For

SMAW

Welding



Amperes,

Volts

60%

Duty

Cycle



1.2

kVA/kW

Auxiliary

Power

With

Overload

Protection



Kohler

CH5+

Air-Cooled,

Four-Cycle,

Gasoline

Engine



Optional

Low

Oil

Pressure

Shutdown

Switch

coven

5/92ASt-161

477

PRINTED

~SA

s

a

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

warranty

supersedes

all

MILLER

warranties

end

exclusive

with

other

guerantees

warranties

eapressed

Implied.

LIMITED

WARRANTY



Subject

the

terms

end

conditions

below,

MILLER

Electric

MIg.

Co.,

Appleton.

Wisconsin,

wsrrsnts

its

originsl

retell

purchsser

that

new

MILLER

equipment

sold

sfter

the

effective

date

this

limited

warranty

tree

tects

material

end

workmanship

the

time

shipped

MILLER.

THIS

WAR

RANT?

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES.

EXPRESS

IMPLIED,

INCLUDING

THE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

replace

any

war

ranted

pans

components

that

tall

due

such

detects

material

workmanship.

MILLER

must

notified

writing

within

thiny

(30)

days

such

defect

failure,

which

lime

MILLER

will

provide

instructions

the

warranty

claim

procadurea

followed.

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

the

event

such

failure

within

the

warranty

time

periods.

All

warranty

lime

periods

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser,

and

are

follows:

Yearn

Pans



Years

Labor

Original

main

power

rectifiers

Yearn



Pans

and

Labor

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

Robots

Years



Pans

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

the

angina

manufacturer.)

Year



Pans

and

Labor

Motor

Driven

Guns

Process

Controllers

Water

Coolant

Systems



Units

Grids



Spot

Welders

Load

Banks



SDX

Transformers



Running

Gear/Trailers

Fietd

Options

(NOTE:

Field

options

are

covered

under

True

BIuenM

for

the

remaining

warranty

period

the

product

they

are

installed

in,

for

minimum

one

yaar



whichever

greater.)

Months



Batteries

Days



Pans

and

Labor

MIS

Guns/TIG

Torches

Plasma

Cutting

Torches

Remote

Controls

Accessory

Kits

Replacement

Pans

MILLERS

True

BiuanM

Limited

Warranty

shall

not

apply

to:

Items

furnished

MILLER,

but

manufactured

others,

such

anginea

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

any.

Consumabla

components;

such

contact

tips,

cutting

nozzles,

conlaclorn

and

relays.

Equipment

that

has

bean

modilied

any

party

other

than

MILLER.

equip

ment

that

has

been

improperly

installed,

improperly

operated

misused

based

upon

industry

standards,

aquipmenl

which

has

not

had

reasonable

and

necessary

maintenance,

equipment

which

han

bean

used

for

operation

outside

the

spacifications

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

THE USE

AND

MAINTENANCE

WELDING

EOUIPMENT

the

avant

warranty

claim

covarad

this

warranty,

the

eacluniva

remedies

shall

ba,

MILLERS

option:

(1)

repair;

(2)

replacement;

or,

where

authorized

writing

MILLER

appropriate

cases.

(3)

the

reasonabia

cost

repair

replace

ment

alan

authorized

MILLER

service

station;

(4)

payment

credit

for

the

pur

chase

price

(lass

reasonable

depracialion

based

upon

actual

usa)

upon

return

the

goods

customers

risk

and

expense.

MILLERS

option

repair

replacement

will

FOB.,

Factory

atAppleton,

Wisconsin,

P.0.6.

MILLER

authorized

ser

vice

facility

determined

MILLER.

Therefore

compensation

raimburse

went

for

transportation

costs

any

kind

will

allowed.

THE

EXTENT

PERMITTED

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL.

INCIDENTAL

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

PROFIT).

WHETHER

BASED

CON

TRACT,

TORT

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

REPRESENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL

THEORY

WHICH.

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW.

CUSTOM

TRADE

COURSE

DEALING.

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE.

WITH

RESPECT

ANY

AND

ALL

EOUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

Some

slates

the

U.S.A.

not

allow

limitations

how

long

implied

warranty

lasts,

the

esciusion

incidental,

indirect,

special

consequential

damages,

the

above

liwitatlon

exclusion

may

not

apply

you.

This

warranty

provides

spa

citic

legal

rights,

and

other

rights

may

available,

but

may

vary

from

stale

stale.

Canada,

legislation

some

provinces

provides

certain

additional

warranties

remedies

other

than

staled

herein,

and

the

astant

that

they

may

not

waived.

Ihe

limitations

and

exclusions

set

out

above

may

not

apply.

This Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

available,

but

may

vary

Irom

province

province.

I

_____________________________

RECEIVING-HANDLING

Before

unpacking

equ(pment,

check

carton

for

any

damage

that

may

have

occurred

during

Shipment.

File

any

claims

for

loss

damage

with

the

delivering

carrier.

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

infDrmation

about

this

equipment,

always

provide

Mode)

Designation

and

Serial

Sty(e

Number.

USe

the

following

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit.

The

information

located

the

rating

label

namep(ate.

Model

__________

Serial

Style

No.

Date

Purchase

miller

5192

March

993

Form:

OM-160

518

Effective

With

Serial

No.

KD398640

OWNERS

MANUAL

Read

and

these

instructions

and

all

Give

this

manual

the

operator.

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.

Callyourdistributorifyoudonotunderstand

the

directions.



rt~i

For

help,

call

your

distributor

or:

MILLER

ELECTRIC

Mfg.

1079,

Appleton,

54912

Co.,

P.O.

Box

414-734-9821

1~oIsﬁ

(jJOJ1

cI~j\r~J~

PAW

100



CC/DC

Welding

Generator



For

SMAW

Welding

Amperes,

Volts

60%

Duty Cycle

1.2

kVAJkW

Auxiliary

Power

With

Overload

Protection



Kohler

CH5+

Air-Cooled,

Four-Cycle,

Gasoline

Engine



Optional

Low

Oil

Pressure

Shutdown

Switch

cover

8/92



ST-161

477

PRINTED

~SA

ARC

WELDING

SAFETY

PRECAUTIONS

Properly

install

and

ground

this

equipment

according

its

Owners

Manual

and

national,

state,

and

local

codes.

When

making

input

connections,

attach

proper

grounding

conductor

first.

Turn

off

all

equipment

when

not

use.

not

use

worn,

damaged,

undersized,

poorly

spliced

cables.

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

good

electrical

(earth)

ground.

11.

not

touch

electrode

contact

with

the

work

ground.

12.

Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.

13.

Wear

safety

harness

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

place.

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

ARC

RAYS

Wear

welding

helmet

fitted

with

proper

shade

filter

(see

ANSI

Z49.

listed

Safety

Standards)

protect

your

face

and

eyes

when

welding

watching.

Wear

approved

safety

glasses.

Side

shields

recommended.

Use

protective

screens

barriers

protect

others

from

flash

and

glare;

warn

others

not

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

hazardous

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

not

breathe

the

fumes.

inside,

ventilate

the

area

and/or

use

exhaust

the

arc

remove

welding

fumes

and

gases.

ventilation

poor,

use

approved

air-supplied

respirator.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners.

Work

confined

space

only

well

ventilated,

while

wearing

air-supplied

respirator.

Shielding

gases

used

for

welding

can

displace

air

causing

injury

death.

sure

the

breathing

air

safe.

not

weld

locations

near

degreasing,

cleaning,

spraying

operations.

The

heat

and

rays

the

arc

can

react

with

vapors

form

highly

toxic

and

irritating

gases.

not

weld

coated

metals,

such

galvanized,

lead,

cadmium

plated

steel,

unless

the

coating

removed

from

the

weld

area,

the

area

well

ventilated,

and

necessary,

while

wearing

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

welded.

WELDING

can

cause

fire

explosion.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

electrode

orwelding

wire

metal

objects

can

cause

sparks,

overheating,

fire.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

(10.7

the

welding

arc.

this

not

possible,

tightly

cover

them

with

approved

covers.

alert

that

welding

sparks

and

hot

materials

from

welding

can

through

small

cracks

and

openings

adjacent

areas

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

welds

cool,

they

can

throw

off

slag.

Watch

for

fire,

and

keep

fire

extinguisher

nearby.

aware

that

welding

ceiling,

floor,

bulkhead,

partition

can

cause

fire

the

hidden

side.

not

weld

closed

containers

such

tanks

drums.

Connect

work

cable

the

work

the

welding

area

practical

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

not

use

welder

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

cut

off

welding

wire

contact

tip

when

not

use.

11.

Wear

oil-free

protective

garments

such

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

cap.

Wear

approved

face

shield

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

protect

skin.

WARNING

ARC

WELDING

can

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

welding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

information

given

below

only

summary

the

complete

safety

information

that

will

found

the

Safety

Standards

listed

the

page.

Read

and

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

electrode

and

work

circuit

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

semiautomatic

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

improperly

grounded

equipment

hazard.

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers.

Disconnect

input

power

stop

engine

before

installing

servicing

this

equipment.

Use

approved

ear

plugs

ear

muffs

noise

level

high.

10.

srI

9/92

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

fans,

rotors,

and

belts

can

cut

fingers

and hands

and

catch loose

clothing.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

place.

Stop

en

before

installing

connecting

unit.

Safety in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

33126

Safety

and

Health

Standards,

OSHA

CFR

1910,

from

Superinten

dent

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.i

from

American

Welding

ciety,

550

N.W.

LeJeune

Rd,

Miami,

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

02269.

ENGINES

can

hazardous.

Use

equipment

outside

open,

well-ventilated

areas.

used

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

Stop

engine

before

checking

adding

fuel.

not

add

fuel

while

smoking

unit

near

any

sparks

open

flames.

Allow

engine

cool

before

fueling.

possible,

check

and add

fuel

cold

engine

before

beginning

job.

not

overfill

tank



allow

room

for

fuel

expand.

not

spill

fuel.

fuel

spilled,

clean

before

starting

engine.

Have

only

qualified

people

remove

guards

covers

for

maintenance

and

troubleshooting

necessary.

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

guards

and

doors

when

servicing

finished

and

before

starting

engine.

Safe

Handling

Compressed

Gases

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

22202.

Code

for

Safety

Welding

and

Cutting,

CSA

Standard

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1R3.

Safe

Practices

ForOccupationAnd

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway.

New

York,

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

IL~c

CYLINDERS

can

explode

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

damaged,

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

the

welding

process,

sure

treat

them

carefully.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

Install

and

secure

cylinders

upright

position

chaining

them

stationary

support

equipment

cylinder

rack

prevent

falling

tipping.

Keep

cylinders

away

from

any

welding

other

electrical

circuits.

Never

allow

welding

electrode

touch

any

cylinder.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

good

condition.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

Keep

protective

cap

place

over

valve

except

when

cylinder

use

connected

for

use.

Read

and

instructions

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

Safety

Standards.

WARNING

ENGINE

EXHAUST

GASES

can

kill.

Engines

produce

harmful

exhaust

gases.

ENGINE

FUEL

can

cause

fire

explosion.

Engine

fuel

highly

flammable.

SPARKS

can

cause

BATTERY

GASES

Always

wear

face

shield

when

working

battery.

EXPLODE;

BATTERY

ACID

can

Stop engine

before

disconnecting

connecting

battery

burn

eyes

and

skin,

cables.

Batteries

contain

acid

and

generate

explosive

gases.

not

allow

tools

cause

sparks

when

working

battery.

not

use

welder

charge

batteries

iump

start

vehicles.

Observe

correct

polarity

and

)

batteries.

(.~

~

~

STEAM

AND

COOLANT

can

skin.

The

coolant

the

under

pressure.

PRESSURIZED

burn

face,

eyes,

radiator

can

very

HOT

and

not

remove

radiator

cap

when

engine

hot.

Allow

engine

cool.

Wear

gloves

and

put

rag

over

cap

area

when

removing

cap.

Allow

pressure

escape

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Sri

9/92

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