Miller Electric BLUE STAR 6000 TM-499C Spécifications

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorTM-499C August 2004Eff. w/Serial Number LA124002 (Kohler)Eff. w/Serial Number L

TM-499 Page 63-6. Generator Power Curves198 570The generator power curves showthe ac power available in amperesat the receptacles.A. 60 Hz ModelB. 50

TM-499 Page 73-7. Volt-Ampere Curves198 570The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding ge

TM-499 Page 8SECTION 4 − INSTALLATION4-1. Installing Welding Generatorinstall1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-085418 in(460 mm)18 in

TM-499 Page 94-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical codes.23800 576-B1 Equipment Gr

TM-499 Page 104-5. Engine Prestart Checks (Honda-Powered Units)802 094-AFullFullGasoline1/2 in(13 mm)1Check all fluids daily. Engine mustbe cold and o

TM-499 Page 114-7. Connecting To Weld Output Terminals196 914 / 495 1781 Positive (+) Weld OutputTerminal2 Negative (−) Weld OutputTerminalFor Direct

TM-499 Page 12SECTION 5 − OPERATING THE WELDING GENERATOR5-1. Controls (Kohler-Powered Units)802 511-A / 802 0511 / 495 1786760 Hz. Weld and generator

TM-499 Page 135-2. Controls (Honda-Powered Units) (See Section 5-3)802 094-A / 802 095 / 495 187Recoil-StartElectric-Start60 Hz50 Hz13621457

TM-499 Page 145-3. Description Of Controls (Honda-Powered Units) (See Section 5-2). Weld and generator power output stops ifgenerator overheats or eng

TM-499 Page 15SECTION 6 − OPERATING AUXILIARY EQUIPMENTThe welding generator provides power while welding and with the Current controlin any position.

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-

TM-499 Page 166-2. Optional Generator Power PanelsRef. ST-802 124 / H-495 290 / H-495 283 / 495 277Generator Power Panel 495 315(USA)Generator Power P

TM-499 Page 176-3. Generator Power Panel RatingsUnless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles.NOTETotal

TM-499 Page 186-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)plug3-11/99 − 802 5271 Plug Wired For 120/240 V,3-Wire L

TM-499 Page 197-2. Routine MaintenanceRecycleenginefluids.Y Stop engine before maintaining.. See Engine Manual and Maintenance Label. Ser-vice more of

TM-499 Page 207-3. Overload Protection (Honda-Powered Units)1 Ignition Circuit Breaker(Electric-Start Models Only)The circuit breaker protects the en-

TM-499 Page 217-5. Adjusting Engine Speed (Honda-Powered Units)802 097-AAfter tuning engine, check enginespeeds. See table for proper noload speeds. I

TM-499 Page 221 EngineSupplies force to turn revolvingfields.2 Revolving Field (Rotor)Turns at 3700 rpm maximum (60Hz) for weld and power. The speedan

TM-499 Page 239 Main Rectifier SR2Changes ac weld current to dc.10 Suppressor VR1/R2Protects SR2 from overload.11 Stabilizer L1Smooths weld output cur

TM-499 Page 24SECTION 9 − EXPLANATION OF ELECTRICAL PARTSelect_parts 7/049-1. Safety Precautions − Read Before Using This GuideY WARNING: ELECTRIC SHO

TM-499 Page 25PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONCLAMP A spring-loaded connection device. A goodexample would be the “work clamp” used toconnect t

TABLE OF CONTENTSSECTION 11 − DISASSEMBLY AND REASSEMBLY 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-499 Page 26PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONIGBT A device that is used as an “electronicswitch”. When a signal is applied to the gate(G), cur

TM-499 Page 27PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONMOTOR A device that converts electrical energy intomechanical energy. Typically used to feedwire

TM-499 Page 28PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONSCR A Silicon Controlled Rectifier (SCR) is anelectrical device with three connections,anode, cat

TM-499 Page 29PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONPRESSURESWITCHA change in the pressure of a gas or liquidwill actuate this switch.OPENSONINCREASE

TM-499 Page 30PART NAME CIRCUIT SYMBOLPICTUREFUNCTIONTRANSFORMER A device that changes AC voltage from onemagnitude to another. Typically used toreduc

TM-499 Page 31SECTION 10 − TROUBLESHOOTING10-1. Troubleshooting TablesA. Welding. See Section 10-2 for test points andvalues and Section 13 and follow

TM-499 Page 32Trouble RemedyHigh weld output. Check Current Control R1 setting.Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).Ch

TM-499 Page 33Trouble RemedyDisconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor ifnecessary.Disconnect stator

TM-499 Page 34Trouble RemedyEngine stopped during normaloperation.Check fuel level (see Section 4-4 or 4-5).Open fuel valve (see Section 4-4 or 4-5).

TM-499 Page 35NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

TM-499 Page 3610-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)V6, A, BSee Section 10-4 forwaveforms A,B,C,DSee also

TM-499 Page 37197 857-E

TM-499 Page 3810-3. Test Points And Values (Use With Section 10-2)Voltage Readingsa) Tolerance − ±10% unless specifiedb) Condition − 70°F (21°C); col

TM-499 Page 3910-4. Waveforms For Section 10-2Test Equipment Needed:5 ms 50 VA. DC/CC Open-Circuit Voltage, No Load, 60 Hz5 ms 20 VB. 25 Volts DC,

TM-499 Page 4010-5. Control Board PC1 Testing Information802 524 / 198 221-ABe sure plugs are secure beforetesting. See Section 10-6 forspecific value

TM-499 Page 4110-6. Control Board PC1 Test Point ValuesPC1 Voltage Readingsa) Tolerance − ±10% unlessspecifiedb) Condition − no load; throttlelever

TM-499 Page 4210-7. Replacing Brushes And Cleaning Slip RingsST-802 524 / ST-801 842Y Stop engine.1 Generator End Panel2 Brush Assembly3 Brush Holder4

TM-499 Page 4310-8. Checking Unit Output After ServicingST-802 524Start engine.Move throttle control lever to 60 Hzposition.1 Weld Output TerminalsChe

TM-499 Page 44SECTION 11 − DISASSEMBLY AND REASSEMBLY11-1. Disassembly Of Unit802 524Use Section 10-2 to determine iftrouble is in stator, rotor, engi

TM-499 Page 4511-2. Removing Rotor And Reassembling Generator802 524 / 802 509Y Do not damage rotor or sta-tor windings during this pro-cedure.To remo

TM-499 Page 1SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING1-1. Symbol UsageOM-499H, safety_rtm 8/03Means Warning! Watch Out! There are possible hazards

TM-499 Page 46SECTION 12 − ELECTRICAL DIAGRAMS. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differen

TM-499 Page 47197 857-EFigure 12-2. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)Or LA347885 And Following

TM-499 Page 48197 857-EFigure 12-3. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)Or LA347885 And Following

TM-499 Page 49197 858-CFigure 12-4. Wiring Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler)Or LA347885 And Following (

TM-499 Page 50201 026-AApply small amount of conductive electric com-pound (Part No. 603 978) to terminals wherefactory-applied compound had been pre

TM-499 Page 51201 026-AApply small amount of conductive electric com-pound (Part No. 603 978) to terminals wherefactory-applied compound had been pre

TM-499 Page 52SC-198 222Figure 12-7. Circuit Diagram For Control Board PC1 Eff. w/ Serial No. LA124002 And Following (Kohler)Or LA033425 And Following

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorTM-499C August 2004Eff w/LA124002 Thru LB111747(Kohler Only)For OM-499 (197 850

TM-499 Page 54SECTION 13 − PARTS LIST FOR LA124002 THRU LB111747(KOHLER ONLY)802 509. Hardware is common andnot available unless listed.73233343128293

Eff w/LA124002 Thru LB111747 (Kohler Only)TM-499 Page 55DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 +495 247 TOP, control bo

TM-499 Page 2STEAM AND HOT COOLANT can burn.D If possible, check coolant level when engine iscold to avoid scalding.D Always check coolant level at ov

Eff w/LA124002 Thru LB111747 (Kohler Only)TM-499 Page 56. Hardware is common and not available unless listed.196 921Generator Power Panel 495 315Gener

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorTM-499C August 2004Eff w/LB111748 Thru LC061260 (Kohler)Eff w/LB086216 Thru LC0

TM-499 Page 58SECTION 14 − PARTS LIST FOR LB111748 THRU LC061260 (KOHLER)AND LB086216 THRU LC061260 (HONDA)802 509-A. Hardware is common andnot availa

Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)TM-499 Page 59DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main AssemblyQuanti

Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)TM-499 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main Assembly (Cont

Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)TM-499 Page 61. Hardware is common and not available unless listed.196 921123567

Eff w/LB111748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda)TM-499 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-2. Generator Power Pan

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorTM-499C August 2004Eff w/LC061261 Thru LC552236(Kohler & Honda)For OM-499 (

TM-499 Page 64SECTION 15 − PARTS LIST FOR LC061261 THRU LC552236(KOHLER & HONDA)802 509-A. Hardware is common andnot available unless listed.73233

Eff w/LC061261 Thru LC552236 (Kohler & Honda)TM-499 Page 65DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main AssemblyQuantity1 +495 247 TOP, con

TM-499 Page 3SECTION 2 − DEFINITIONS2-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel Battery (Engine) EnginePosi

Eff w/LC061261 Thru LC552236 (Kohler & Honda)TM-499 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly (Continued)Quantity40 495

Eff w/LC061261 Thru LC552236 (Kohler & Honda)TM-499 Page 67. Hardware is common and not available unless listed.Generator Power Panel 495 315 (USA

Eff w/LC061261 Thru LC552236 (Kohler & Honda)TM-499 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-2. Generator Power Panels (Figure 15-1, Ite

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorTM-499C August 2004Eff w/LC552237 And Following(Kohler & Honda)For OM-499 (

TM-499 Page 70SECTION 16 − PARTS LIST FOR LC552237 AND FOLLOWING802 509-A. Hardware is common andnot available unless listed.7323334312829302346404144

Eff w/LC552237 And Following (Kohler & Honda)TM-499 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 16-1. Main AssemblyQuantity1 +495 247 TOP, con

Eff w/LC552237 And Following (Kohler & Honda)TM-499 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 16-1. Main Assembly (Continued)Quantity38 HM 1

Eff w/LC552237 And Following (Kohler & Honda)TM-499 Page 73. Hardware is common and not available unless listed.Generator Power Panel 495 315 (USA

Eff w/LC552237 And Following (Kohler & Honda)TM-499 Page 74DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 16-2. Generator Power Panels (Figure 16-1, Ite

Notes

TM-499 Page 43-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 20-3/4 in (527 mm)DWidth 22-3/4 in (577 mm)Depth 31-1/4 in (793 mm)BY Do n

PRINTED IN USA  2004 Miller Electric Mfg. Co.Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USAInte

TM-499 Page 53-4. Fuel Consumption (Honda-Powered Units)802 122Continuous Welding3-5. Duty Cycle802 093Duty cycle is the percentage of 10minutes that