April

1978 FORM:

OM-457C

Effective With Serial No. HJ134589

MODEL

Trailblazer

22G

OWN ERS

MANUAL

ITIIIIER

MILLER ELECTRIC MFG. CO.

718 S. BOUNDS ST.

P.O. Box 1079

APPLETON, WI 54912 USA

NWSA CODE NO. 4579

PRINTED IN U.S.A.

$

LIMITED WARRANTY

EFFECTIVE: FEBRUARY 20, 1978

This warranty supersedes all previous MILLER warranties and is ex clusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTYMiller ton, Wisconsin warrants to

Electric

Customer that all

Mfg.

Co.. Applenew and unused

Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.

No warranty is made by Miller with respect to factured engines, trade accessories or other items manuby others. Such engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.

The manufacturers warranty on engines is for a period of one year.

MILLER warranty does not apply to components having normal useful life of less than one welder

(1) year, such as spot tips, relay and contactor points, MILLERMATIC parts that come in contact with the nozzles welding wire including and nozzle insulators where failure does not result from defect in workmanship or materiat.

In the case of Millers breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefor shall be, at Millers option, (1) repair or

(2) replacement or, where authorized in writing by Miller in appropriate cases,

(3) the reasonable cost of repair or replacement at an authorized Miller service station or

(4) payment of or credit for the purchase price (less reasoi~able depreciation based upon actual use) upon return of the goods at Customers risk and expense.

All transactions are

FOB.

Appleton.

Wisconsin.

Upon receipt of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.

As a matter of general policy only, Miller may honor an original users warranty claims on warranted Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equipment to the original user:

1.

Arc welders, power sources, and components.

.

2.

Original main power rectifiers

(Labor 1 year only)

1 year

3 years

3.

All welding guns and feeder/guns 90 days

4.

All other Millermatic Feeders 1 year provided that the user so notifies Miller in writing within thirty

(30) days of the date of such failure.

5.

Replacement or repair parts exclusive of labor 60 days

ANY EXPRESS WARRANTY NOT PROVIDED

HEREIN AND ANY IMPLIED WARRANTY, GUARANTY

OR REPRESENTATION AS TO PERFORMANCE, AND

ANY REMEDY FOR BREACH OF CONTRACT WHICH,

BUT FOR THIS PROVISION, MIGHT ARISE BY

IMPLICATION, OPERATION OF LAW, CUSTOM OF

TRADE OR COURSE OF DEALING, INCLUDING ANY

IMPLIED WARRANTY OF MERCHANTABILITY OR OF

FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT

TO ANY AND ALL EQUIPMENT FURNISHED BY

MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

WRITING, MILLER PRODUCTS ARE INTENDED FOR

ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL

USERS AND FOR OPERATION BY PERSONS TRAINED

AND EXPERIENCED IN THE USE AND MAINTENANCE

OF WELDING EQUIPMENT AND NOT, FOR CONSUMERS

OR CONSUMER USE.

MILLER WARRANTIES DO NOT

EXTEND

EXTEND

TO, AND NO RESELLER IS AUTHORIZED TO

MILLERS WARRANTIES TO, ANY

CONSUMER.

a

ERRATA SHEET

After this manual was printed, refinements in equipment

design

occurred.

This sheet lists ex.cenXioi~s.tadata aooearina later in this manual.

AMENDMENT TO SECTION 3 INSTALLATION

Amend Section 3-3.

EQUIPMENT GROUNDING TERMINAL

Normally engine-driven welding generators

do not

require grounding.

However,

this machine has

auxiliary

power

plant capability; therefore, grounding

of the frame and case is recommended.

Also,

unusual circumstances may re

quire

machine

grounding.

For these reasons a convenient

grounding

terminal is

provided

on all

weld/power

units.

For detailed

grounding

instructions consult your, local or state codes and the latest issue of the National Electrical

Code. If additional information

regarding

your

particular operating

circumstances and/or

grounding requirements

is

needed,

consult a

qualified

electrician or your dealer.

After

determining

the extent to which any

quirements apply

to your

particular

situation,

follow them

explicitly.

grounding

re

Amend

Figure

3-3.

Power Plant Connections

Circuit

Groundingl

Jumper Lead

IShipped Ungrounded)

TC-000 680-B

Figure

3-3. Power Plant Connections

AMENDMENT TO SECTION 5FUNCTION OF GENERATOR CONTROLS

Amend Sections 5-1 and 5-9

Add the

following

CAUTION block at the

beginning

of the section

-

CAUTION: The

auxiliary

power

capability

of this

welding

generator is

primarily

intended for use with

portable

cord-

_______ connected accessory

equipment (lights, drills, grinders,

etc.).

Do not connect this unit to any service

box,

swit

chboard, panelboard,

or other

equipment normally supplied by

other electrical power unless a proper transfer switch and

grounding

procedure

is

employed (see

Section 3-3 for unit

grounding

information). ALWAYS consult the local electric cedures.

utility,

local and state

codes,

and the latest issue of the National Electrical Code for proper installation pro

Since hazardous

voltages

are present, it is recommended that the installation be made

by

a licensed electri clan to avoid

injury

or

damage

caused

by improper

or

faulty

installation.

AMENDMENT TO SECTION 6FUNCTION OF ENGINE CONTROLS

Delete Section 6-7.

ELECTRICAL TACHOMETER (OPTIONAL)

/

AMENDMENT TO SECTION 7- SEQUENCE OF OPERATION

Amend Section 7-2.

POWER PLANT OPERATION

OM-457C Page A

Add CAUTION block at

beginning

of Section

/

CAUTION.: The weld

output

terminals are

electrically energized

when the

engine

is

running.

Disconnect the~

we/ding

cables when not

we/ding

and do not touch the output terminals when the

engine

is

running.

AMENDMENT TO SECTION 9ENGINE MAINTENANCE

-

Amend Section 9-3.

GOVERNOR SERVICE

Weld

speed

of this

engine

is 1850 rpm.

Amend Section 9-4.

CARBURETOR FLOAT SETTING

Carburetor

Change

Effective With Serial No.

HJ185451

I~1t~ Do not

bend, twist,

or

apply

pressure on the float

body.

The float

body,

when viewed from the free

end,

must be centered between and at

right angles

to the machined

surface,

and must move

freely

on the float axle.

This

engine

is

equipped

with a

Teledyne

Walbro carburetor.

To ensure correct fuel level in the float machined surface of throttle

chamber,

check distance (dimension

A, Figure

9-1) from top of float to

body

(no

gasket)

with throttle

body

inverted.

This dimension should be 1-1/16 inches

plus

or minus .020

inch.

To increase or decrease distance from the top of the float

body

to the machined

surface,

use a

long

nose

pliers

and bend the float lever at a

point

close to the float

body.

Delete

Figure

9-2. Carburetor Float

Setting

Amend Section 9-9.

IDLE CONTROL/GOVERNOR LINKAGE ADJUSTMENT

(Figure

9-7)

Amend

Figure

9-7. IDLE CONTROL/GOVERNOR LINKAGE ADJUSTMENT

To obtain proper

engine

idle and/or weld

speed, perform~

the

following procedures:

0M-457C Page B

Figure

9-7.

Idle Control/Governor

Linkage Adjustment

TCO8O 511

1.

Loosen the

Rotate

linkage

nuts

(6

& 8) and remove the hardware (10)

securing

the

linkage

socket

(9)

to the governor.

thelinkage

socket

(9)

until the throttle stop

plate

(2) is about 1/32 inch from the

stop

(1).

A clockwise rotation of the

linkage

socket

(9)

will shorten the governor

linkage (7)

and reduce the gap; a counterclockwise rotation of the be necessary to

linkage

socket

(9)

will

lengthen

the governor

linkage (7)

and widen the gap.

(In some cases it may

adjust

the

linkage

itself to obtain the 1/32 inch gap

required.) Tighten

the

linkage

socket nuts

(6

&

8)

to lock the

position

of the

linkage

sockets (5 & 9).

IMPORTANT Check the

linkage (7J

for freedom of movement

throughout

its entire travel. If the

linkage

is

binding

______________ due to the

linkage

socket nuts (5 & 9)

being

out of proper

alignment,

loosen the

linkage

socket nuts (6 & 8) and rotate the sockets

(5

&

9)

slightly

until unrestricted movement of the

linkage

(7) is restored.

Tighten

the

linkage

socket nuts

(6&8).

CAUTION Ensure that

body

limbs are clear of the fan and the vacuum motor unit before

starting

or

working

on the

~.

engine.

2.

Recheck all

----

-

-

--------~

-:~-~

-------

adjustments

made thus far.

Place the IDLE CONTROL switch in the LOCK OUT

position.

Start the

engine

and allow it to reach normal

operating

temperature (about five minutes).

Ensure that the CHOKE control is

pushed fully

in at this time.

-

3.

Pull the arm butt

(3) toward the front of the

welding

generator to the idle

position.

Maintain pressure on the arm

(3) to

against

the idle screw

(4)

throughout

the

following adjustments:

A.

Rotate the idle screw

(4) to obtain 550 rpm.

Clockwise rotation of the screw

(4) will increase whereas counterclockwise rotation of the screw

(4) will decrease

engine

rpm.

engine

rpm,

B.

Rotate the idle mixture

adjustment

screw

(20)

counterclockwise until the

engine begins

to falter or

roll;

then rotate the screw restricts the fuel

(20) clockwise until the

flow, engine

operates

smoothly.

Rotating

the screw

(20) clockwise

making

the air-fuel mixture leaner.

Rotating

the screw

(20) counterclockwise admits more

fuel, making

the air-fuel mixture richer.

IMPORTANT Ensure that the vacuum motor idle screw

(16)

butts

against

the vacuum motor unit

mounting

plate

BEFORE the throttle stop

plate

(2) butts

against

the idle screw

(4)

prior

to

p/acing

the IDLE CONTROL switch in the

AUTOMA TIC IDLE

position.

To obtain this condition it may be necessary to

adjust

screw

(16).

Check

by manually pivoting

the vacuum motor arm

(17) until screw

(16) butts

against

the

mounting plate.

4.

Place the IDLE CONTROL switch in the AUTOMATIC IDLE

position.

Operation

of the

idling

device is automatic when the IDLE CONTROL switch is in the AUTOMATIC IDLE

position.

When the

engine

is

running, engine

rpm will remain at idle until an arc is

established,

at which time the

engine immediately

comes up to weld rpm. When the arc is

broken,

a time

delay

is controlled

delay

will exist before the

engine begins

to return to idle rpm. The

length

of this time

by

the

setting

of the

time-delay

screw

A in

Figure

9-7. If the

engine

does not go to idle rpm after about ten vacuum line

seconds, adjust

the

time-delay

screw

(A) for the desired time

delay.

This screw is located on the

fitting going

into the intake manifold of the

engine.~

5.

When the

engine

has gone to idle rpm,

adjust

screw

(16) until 1200 rpm is obtained.

I~EIi11~ Do not

readjust

the idle rpm screw

(4) when

adjusting

the vacuum motor idle rpm.

-

IMPORTANT Check the

linkage (19)

for freedom of movement

throughout

its entire travel. If the

linkage

is

binding

______________ due to the

linkage

socket (18)

being

outof proper

alignment

with the fixed

end, adjust

the

tength

of the

linkage.

It willthen be necessary to

readjust

the vacuum motor idle screw

(16) and repeat

Steps

4 and 5.

Is~..tU.I

I ~ ~ Ensure that

body

limbs are clear of the fan and the vacuum motor unit before

working

on the

engine.

6.

Place the IDLE CONTROL switch in the LOCK OUT

position.

Loosen the governor

speed adjusting

screw secur

ing

nut

(11). Adjust the.governor speed adjustment

screw

(12) until a

high

idle rpm of 1850 is obtained.

Tighten

the

securing

nut (11) to maintain the governor

speed setting.

7.

Check the governor

engine regulation by applying

and

removing

the

engine

load. If a governor

sensitivity adjust

ment is deemed necessary, loosen one of the two

locking

nuts (13) and

proceed

with the

following

instructions:

A.

IF REGULATION RANGE IS TOO BROAD

-

Decrease the governor

sitivity adjustment

screw

(14)

inward.

spring

(15) tension

by sliding

the sen

B.

IF REGULATION RANGE IS TOO NARROW

-

Increase the governor

spring

(15) tension

by sliding

the sen

sitivity

adjustment

screw

(14)

outward.

C.

IF ENGINE SURGES

(HUNTS)

UNDER LOAD Increase the governor

spring

(15)

tension

by sliding

the sen

sitivity

adjustment

screw

(14)

outward.

-

-~

8.

Tighten

the two

locking

nuts (13) to maintain the desired governor

sensitivity. Readjust

the governor

sensitivity by repeating Step

7.

) 1~ Whenever the governor

sensitivity (Step

7) is

adjusted,

the

Whenever the governor

speed

governor

speed (Step

6) MUST be

readjusted.

(Step

61 is

adjusted,

the governor

sensitivfty (Step

71 MAY need

readjustment.

Amend Section 9-10. HIGH ALTITUDE CARBURETOR MODIFICATION

(Optional)

(Figure

9-7)

The

Teledyne

Walbro carburetor can be ft.).

Minor

equipped

with an

adjustable

main

jet

for

high-altitude operation (above

4000

adjustment

will be necessary for proper

operation

at a

particular

altitude. Whenever a carburetor

adjust

ment is deemed necessary, see

Figure

9-7 and

proceed

as follows:

Loosen the main

adjustment

screw

locking

nut

(22).

Apply

a near-full

engine

load to the

welding

generator.

Rotate the main

adjustment

screw

(21) clockwise until the

engine begins

to falter and lose RPM. Rotate the main

adjustment

screw

(21) counterclockwise until the

engine

operates

smoothly;

then continue counterclockwise rotation of 1/4 turn.

Rotating

the screw

(21) clockwise restricts the fuel

flow, making

the air-fuel mixture leaner.

Rotating

the screw

(21)

counterclockwise admits more

fuel, making

the air-fuel mixture richer. Remove the

engine

load.

Tighten

the

locking

nut (22).

IMPORTANT

Restricting

the fuel flow to the

point

where the mixture is too lean will-cause valve

burning.

Delete

Figure

9-8.

High-Altitude

Carburetor

Adjustment

AMENDMENT TO SECTION 10

-

TROUBLESHOOTING

Amend

Figure

10-1.

Circuit

Diagram

AC EOWE3 ,,_-_~___

5EU~A4~. GRCcu~UIC

~ S~3ED

72 33

;scfi

r.._77

~

-~

~

127

J,~2

24

23

REAR VIEW

EOW

*.OTE

~ SIAAA ~ AE

AWE A1.DWELE!R jESUS

E~E1r

CAUTION

I

I

c0)

~ -~<

I

CA~.GE-3VER

I

I ~ ~7

NCI.~C:p~V acE ~OLr

I

I

C o~a UETEA

(Q~T C%AL)

/

If

Circuit Diagram No.

B-081 027

Figure

10-1.

Circuit Diagram For Models Effective With Serial No.

HJ211479

OM-457C PageD

-

)tem

No.

6

33

53

77

80

Dia.

Mkgs.

Zi

VS1

Page

4

Page

5

97

100

146

TAC

HM

S2,5

Part No. Listed

In Parts List

Replaced

With

Part No.

010318

053724

017421

036259

025932

015 602

053 966

049685

036 377

024 017

Description

VALVE,

shut

off w/strainer

fuel

GUARD,

fan

CATCH,

door

REACTOR

SUPPRESSOR,

0.75

uf 65 volts ac

(Eff with S/N

HK311202)

Quantity

1

2

2

1

1

032 936

032 936

039 269

OlO

493

053 359

Deleted

032 936

080 487

601158

079 486

010 014

010 891

030 170

011 609

METER (dia.

mkg. changed)

FUSE BOX (Eff with S/N HJ211479)

BLANK,

snap

in 7/8 (Eff with S/N HJ21 1479)

COVER, junction

box (Eff with S/N HJ21 1479)

CLAMP,

steel

cushion 3/4 dia x

13/64 hole (Eff with

S/N HJ21 1479)

BLANK,

snap

in 1 inch dia (Eff with S/N

HJ211479)

BUSHING,snapin3/4IDx1

SWITCH, toggle

SPDT 15 amp 125 volts

2

1

1

1

1

1

1

2

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

OM-457C Page E

p.

TABLE OF CONTENTS

Section No.

Page

No.

SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1 -1.

1

-

2.

1

-

3.

1

-

4.

Introduction

General Precautions

Arc

Welding

Standards Booklet Index

SECTION 2 INTRODUCTION

2-1.

2

-

2.

2

-

3.

2-4.

General

Receiving-Handling

Description

Safety

SECTION 3 INSTALLATION

1

3

4

5

5

5

5

3-1.

Location

3-2.

3

-

3.

3-4.

3- 5.

Weld Output Connections

Equipment

Grounding

Terminal

Remote Amperage Control Connections

120/240 Volts AC Terminals..

SECTION 4 ENGINE PREPARATION

4-1.

4

-

2.

4

-

3.

4

-

4.

4

-

5.

Lubrication

Coolant System

Preparing

New Battery For Service

Air Cleaner

Fuel

SECTION 5 FUNCTION OF GENERATOR CONTROLS

5-1.

5

-

2.

5

-

3.

5

-

4.

5

-

5.

5

-

6.

5-7.

5-8.

5-9.

120 Volts AC Receptacle

Range Switch

Fine Amperage Control

Remote Amperage Control

Volt-Ampere Curves

Duty Cycle

Polarity Switch

Meters

240 Volts AC Duplex Receptacle

7

8

9

9

8

8

10

10

10

10

10

11

11

11

11

SECTION 6 FUNCTION OF ENGINE CONTROLS

6-1.

6

-

2.

6

-

3.

6-4.

6

-

5.

6

-

6.

6

-

7.

6

-

8.

Choke Control

Start Push Button And Switch

Idle Control Switch

Engine Ammeter

Temperature

Gauge

Oil Pressure Gauge

Electrical Tachometer

Total Hour Meter

SECTION 7 SEQUENCE OF OPERATION

7- 1.

7

-

2.

7

-

3.

7

-

4.

Sheilded Metal-Arc (SMAW) Welding

Power Plant Operation

Starting

The Engine

Engine Shut Down

13

13

13

13

12

12

12

12

12

12

12

12

Section No.

SECTION 8 GENERATOR MAINTENANCE

8-1.

General

8

-

2.

83.

Collector

Welding

Ring Brushes

Cables

SECTION 9 ENGINE MAINTENANCE

9-1.

Lubrication

9~ 2.

Coolant

System

9-3.

Governor Service

9. 4.

Carburetor Float

Setting

9- 5.

Vacuum Circuit Air Filter

9.

6.

Idle Control Time

9- 7.

Delay Adjustment

Carburetor Air Temperature Selector

9- 8.

Air Cleaner Service

9- 9.

Idle Control/Governor

9.10.

Linkage

Adjustment

High

Altitude Carburetor Modification

9.11.

9-12.

Key Type Ignition Switch Lubrication

Spark Arrestor

SECTION 10 TROUBLESHOOTING

PARTS LIST

Page

No.

14

14

14

14

14

15

15

15

15

15

16

17

18

18

18

SECTION 1-SAFETY RULES FOR OPERATION OF

ARC

WELDING POWER SOURCE

1-1.

INTRODUCTION

We learn by experience.

Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you.

Safe ing practices developed from experience in the use of weld and cutting are described in this manual.

Research, devel opment, and safe and field experience have evolved reliable installation, operation, and servicing equipment practices.

Acci dents occur when equipment is improperly used or main tained.

The reason for the safe practices may not always be given.

Some are based on common technical volumes to sense, others may require explain.

It is wiser to follow the rules.

Read and understand these safe practices before attempting to install, these operate, or procedures as service the equipment. Comply with applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others.

Failure to observe these safe practices may cause serious in jury or can death.

When be used with safety confidence.

becomes a habit, the equipment

These

General safe practices are divided into two Sections: 1

-

Precautions, common to arc welding and cutting; and

2

-

Arc Welding (and Cutting) (only).

Reference standards: Published Standards on available for additional and more complete safety are also procedures than those given in this manual.

They are listed in the Standards

Index in this manual.

ANSI Z49.1

is the most complete.

1-2.

The

Health

National Electrical Code, Occupational Safety and

Administration, local industrial codes, and local in spection requirements also provide a basis for equipment in stallation, use, and service.

GENERAL PRECAUTIONS

A.

Burn Prevention

Wear protective clothing

leather (or asbestos) gauntlet gloves, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.

Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass).

This is a

MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and flying metal.

Replace cover glass when broken, pitted, or spattered.

See 1-3A.2.

Avoid Oily or greasy clothing.

A spark may ignite them.

Hot metal such as electrode stubs never be ha,dled without gloves.

and workpieces should

Medical first aid and eye treatment.

First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eves and skin burns.

Ear plugs should be worn when working on overhead or in a confined space. A overhead.

hard hat should be worn when others work

Flammable hair preparations should not be used by intending to weld or cut.

persons

B.

Toxic Fume Prevention

Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen depletion that welding (or cutting) may enrichment produce.

or

Prevent them with adequate ventilation as described in ANSI Stan dard Z49.1

listed 1 in Standards index.

NEVER ventilate with oxygen.

Lead

-, cadmium and similar

-.

zinc

-.

mercury

-, and beryllium materials, when welded (Or cut) may

bearing produce harmful concentrations of toxic fumes.

Adequate local exhaust as well ventilation must be as used, or the operator must wear an each person in the area air-supplied respirator.

For beryllium, both must be used.

Metals coated with or containing materials that emit toxic fumes should not be heated unless the work coating is removed from surface, the area is well ventilated, or the operator wears an air-suppied respirator.

Work in a confined space and, if necessary, while only wearing an while it is being ventilated air-supplied respirator.

Gas leaks in a confined space should be avoided.

Leaked gas in large quantities can change oxygen concentration danger ously.

Do not bring gas cylinders into a confined space.

Leaving confined space, shut OFF gas supply at source to prevent stream possible accumulation of gases in the valves have been accidently opened space or if down left open.

Check to be sure that the space is safe before re-entering it.

Vapors from chlorinated heat of the arc gas, and other solvents can be decomposed by the

(or flame) to form PI-IOSGENE, a highly toxic lung and eye irritating products.

The ultra violet (radiant) energy of the arc can also decompose tn chloroethylene and perchloroethylene vapors to form phos gene.

DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.

C.

Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached by the arc, of flame, flying compressed sparks, gases and hot slag cylinders; or heated material; and short circuits.

misuse

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, Out of sight of the goggled operator.

Sparks and slag can fly 35 feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil,

(in electrical grease, and parts) of metallic particles that can cause short circuits.

If combustibles are in work if area, do NOT weld or cut.

Move the practicable, to an area free of combustibles. Avoid paint work spray rooms, cannot be dip tanks, storage areas, ventilators.

If the moved, move combustibles at least 35 feet away Out of reach of sparks and heat; or protect against ignition with suitable and shields.

snug-fitting, fire-resistant covers or

Walls touching combustibles on opposite sides should not be welded on

(or cut).

Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire ex tinguishing equipment during and for some time after weld ing or cutting if: a.

appreciable combustibles tion) are within 35 feet

(including building construc b.

c.

appreciable combustibles are further than 35 feet but can be ignited by sparks openings

(concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks d.

combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.

Hot work permit should be obtained before operation to ensure been supervisors approval that adequate precautions have taken.

After work is done, check that area is free of sparks,

embers, and flames.

glowing

An empty container that held combustibles, or that can pro duce flammable or toxic vapors when heated, must never be welded on or described in cut, unless container has first been cleaned

AWS Standard as

A6.O, listed 3 in Standards index.

OM-457

Page 1

Page 2

This includes: a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustibles solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recom mended in A6.0.

substitute for

Waterfilling just below working level may inerting.

A container with unknown contents should be cleaned (see paragraph above).

to determine if it is

Do NOT depend on sense of smell or sight safe to weld or cut.

Hollow or castings or containers must be vented before cutting.

They can explode.

welding

Explosive atmospheres.

Never weld or cut where the air may contain flammable dust, gas, or liquid vapors

(such as gaso line).

D.

Compressed Gas Equipment

Standard precautions.

Comply with precautions in this manual, and those detailed in CGA Standard P-i, PRECAU

TIONS FOR SAFE

~N CYLINDERS,

HANDLING OF COMPRESSED GASES listed 6 in Standards index.

1.

Pressure Regulators

Regulator relief valve is designed to protect only the regula tor from overpressure; downstream it is not intended to protect any equipment.

Provide such protection with one or more relief devices.

Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed.

Remove faulty regulator from service immediately for repair

(first close cylinder valve).

The following symptoms indicate a faulty regulator:

Leaks

if gas leaks

Excessive externally,

Creep

if delivery pressure continues to rise with downstream valve closed.

Faulty Gauge

if gauge pointer does not move off stop pin when release.

pressurized, nor returns to stop pin after pressure

Repair.

Do NOT attempt repair.

Send faulty regulators for repair to manufacturers designated repair center, where special techniques and tools are used by trained personnel.

2.

Cylinders

Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:

Avoid electrical Circuit contact with rails, electrical wires, or cylinders including third welding circuits.

They can produce short circuit arcs that may lead to a serious accident.

(See

1-3C,)

ICC or

DOT assurance marking must be on each cylinder.

It is an of safety when the cylinder is properly handled.

Identifying gas content.

Use only cylinders with name of gas marked tent.

on them; do not rely on color to identify gas con

Notify supplier if unmarked.

NEVER DEFACE or alter name, number, or other markings on a cylinder.

It is illegal and hazardous.

Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly.

Prohibited use.

Never use than its intended use, a cylinder or its contents for other

NEVER as ~a support or roller.

Locate or secure cylinders so they cannot be knocked over.

Passageways and work areas.

Keep cylinders clear of areas where they may be struck.

Transporting cylinders.

With a crane, use a secure support such as a platform or cradle.

Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or mag no ts.

Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc.

that may cause rupture. Do not allow contents to exceed

130F.

Cool with water spray where such exposure exists.

Protect cylinders particularly valves from bumps, falls, falling objects, and weather.

Replace caps securely when moving cylinders.

Stuck valve.

Do NOT use a hammer or wrench to cylinder valve that can not be opened by hand.

Supplier.

open a

Notify your

Mixing gases.

Never try to mix any gases in a cylinder.

Never refill any cylinder.

Cylinder fittings should never be modified or exchanged.

3.

Hose

Prohibited use.

Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases.

Use ferrules or wire or other clamps designed for the hose (not ordinary substitute) as a binding to connect hoses to fittings.

No copper splice hose.

tubing splices.

Use only standard brass fittings to

Avoid long runs to prevent kinks and abuse.

Suspend hose off ground to wise keep damaged.

it from being run over, stepped on, or other

Coil excess hose to prevent kinks and tangles.

Protect hose from slag, and open flame.

damage by sharp edges, and by sparks,

Examine hose tions.

Immerse regularly for leaks, wear, and loose connec pressured hose in water; bubbles indicate leaks.

Repair leaky or worn hose by cutting area Out and splicing

(1-2D3).

Do NOT use tape.

4.

Proper Connections

Clean orifices cylinder valve outlet of impurities that may clog and damage seals before connecting regulator. Except for hydrogen, crack valve momentarily, pointing outlet away from people and sources of ignition. Wipe with a clean lintless cl 0th.

Match regulator to cylinder.

Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match.

NEVER CON

NECT a regulator designed for a particular gas or gases to a cylindercontaining any other gas.

Tighten connections. When assembling threaded connections, clean and smooth seats where necessary.

Tighten.

If connec tion leaks, disassemble, clean, and retighten using properly fitting wrench.

-

Adapters.

Use a

CGA adapter (available from your between cylinder and regulator, if one is required.

supplier)

Use two wrenches to

HAND threads.

tighten adapter marked RIGHT and LEFT

Regulator outlet (Or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas.

5.

Pressurizing Steps:

Drain regulator of residual gas through suitable vent before opening cylinder screw in

(or

(clockwise).

manifold

Draining valve) by turning prevents excessive adjusting compression heat at high pressure seat by allowing seat to open on pressur ization.

Leave adjusting screw engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in creases lator slowly.

When gauge is pressurized maximum) leave cylinder valve .in

(gauge reaches regu following position:

For oxygen, and inert gases, open fully to seal stem against possible leak.

For fuel gas, open to less than one turn to permit quick emergency shutoff.

Use and pressure charts (available from your supplier) for safe efficient, recommended pressure settings on regulators.

Check for leaks on first pressurization and regularly there after.

Brush with soap solution (capful of Ivory Liquid or equivalent per gallon of water).

Bubbles indicate leak.

Clean off soapy water after test; dried soap is combustible.

E.

User Responsibilities

Remove iately for leaky or defective equipment from service immed repair.

See Use!

Responsibility statement in equip ment manual.

F.

Leaving Equipment Unattended

G.

Close gas supply at source and drain gas.

Rope Staging-Support

Rope staging-support should not ting operation; rope may burn.

be used for welding or cut

1~3.

ARC WELDING

Comply with precautions in 1-1, 1-2, and this section.

Arc

Welding, properly done, is a safe process, but a careless opera tor invites trouble.

The significant voltages.

The equipment carries high currents at arc is very bright and hot.

Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weld ments are hot, and compressed gases may be used.

The wise operator avoids unnecessary risks others from accidents. Precautions and are protects himself and described here and in standards referenced in index.

A.

Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful.

DONT GET BURNED; COMPLY

WITH PRECAUTIONS.

1.

Protective Clothing

Wear long-sleeve clothing addition to

(particularly for gas-shielded arc) in gloves, hat, and shoes (1-2A).

As necessary, use additional sleeves, protective clothing such as leather jacket or flame-proof apron, and fire-resistant leggings.

Avoid outergarments of untreated cotton.

Bare skin collar to vent entry protection.

Wear dark, substantial clothing.

Button protect of chest and sparks.

neck and button pockets to pre

2.

Eye and Head Protection

Protect eyes from exposure to arc.

tric arc without protection.

NEVER look at an elec

Welding helmet or shield containing a

12 or denser must be used when filter welding.

plate

Place shade over no.

face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet radiation can pass or shield should NOT be worn; through to cause burns.

Cracked, broken, or loose filter plates must be replaced

MEDIATELY.

Replace clear cover plate when

IM broken, pitted, or spattered.

Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck.

Looking at an arc momentarily with unprotected eyes

(particularly a high intensity gas-shielded arc) can cause a may leave a permanent dark area retinal burn that in the field of vision.

3.

Protection of Nearby Personnel

Enclosed room or welding area.

For production welding, a separate enclosed bay is best.

In open areas, surround the

Trademark of Proctor & Gamble.

operation with low-reflective, non.cornbustible

screens or panels.

Allow for free air circulation, particularly as floor level.

Viewing the weld.

Provide face shields for all persons who will be looking directly at the weld.

Others goggles.

working in area.

See that all persons are wearing flash

Before doors starting to weld; make sure are closed.

that screen flaps or bay

B.

Toxic Fume Prevention

Comply with precautions in 1-2B.

Generator engine exhaust must be vented to the outside air.

Carbon monoxide can kill.

C.

Fire and Explosion Prevention

Comply with precautions in 1-2C.

Equipments rated capacity.

Do not overload arc welding equipment.

It may overheat cables and cause a fire.

Loose cable connections fire.

may overheat or flash and cause a

D.

Never strike creates a an arc brittle area on a that cylinder or other pressure vessel. It can cause a violent rupture or lead to such a rupture later under rough handling.

Compressed Gas Equipment

Comply with precautions in 1-2D.

E.

Shock Prevention

Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor.

DO

NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur face when welding, without suitable protection.

To protect against shock:

Keep body and clothing dry.

Never work in damp area with out adequate insulation against electrical shock.

Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided.

Sweat, sea water, or moisture between body and the an electrically HOT part

or grounded metal

reduces body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.

1.

Grounding the Equipment

When installing, connect the frames of each unit such as welding power source, control, i&ork table, and water circula tor to the building ground.

Conductors must be adequate to carry

HOT ground currents safely.

Equipment made electrically by stray current may shock, possibly fatally.

Do NOT

GROUND so electrical conduit, or to a pipe carrying ANY flammable gas or a liquid such as oil or fuel.

Three-phase connection.

Check phase requirement of equip ment before installing.

If only 3-phase power is available, connect single-phase equipment to only two wires of the

3-phase line.

Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electri-.

cally HOT

a dangerous condition that can shock, possibly fatally.

Before welding, check ground for continuity.

Be sure conduc tors are touching bare metal of equipment frames at connec tions.

If a ment line cord with a ground lead is provided with the equip for connection to a switchbox, connect the ground lead to the grounded switchbox. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only.

If the line cord comes with a three-prong plug, connect to a grounded mating receptacle.

Never remove the ground prong from a plug, or use a plug with a broken off ground prong.

OM-457 Page 3

Page 4

2.

Electrode Holders

Fully insulated electrode holders should be used.

use holders with protruding screws.

Do NOT

3.

Connectors

Fully insulated lock-type connectors should be used to join welding cable lengths.

4.

Cables

Frequently inspect cables for wear, cracks and damage.

IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly

lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable.

Keep cable dry, free of oil and hot metal and sparks.

grease, and protected from

5.

Terminals And Other Exposed Parts

Terminals and other have exposed parts of electrical units should insulating covers secured before operation.

6.

Electrode Wire

Electrode wire becomes switch of gas metal-arc electrically HOT when the power welding equipment is ON and welding gun other trigger is pressed.

Keep hands and body clear of wire and

HOT parts.

7.

Safety Devices

Safety devices such es interlocks and circuit breakers should not be disconnected or shunted out.

Before

OFF all installation, inspection, or service, of equipment, shut power and remove line fuses (or lock or red-t~ switches) to prevent accidental turning ON of power.

Discon.

nect all cables from welding power source, and pull all 115 volts line-cord plu~.

Do not open power circuit or change polarity while welding.

If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing.

Leaving equipment unattended.

Always shut OFF and dis connect all power to equipment.

Power disconnect switch must be available near the welding power source.

1-4.

STANDARDS BOOKLET INDEX

For more information, refer to the their latest revisions and comply es following applicable: standards or

1.

ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING obtainable from the American Welding

Society, 2501 NW 7th St. Miami; Fla. 33125.

2.

ANSI Standard Z87.i, SAFE PRACTICE FOR OCCUPA

TION AND EDUCATIONAL EYE AND FACE PROTEC

TION, obtainable from American National Standards

Institute, 1430 Broadway.

New York, N.Y. 10018.

3.

American

AND

Welding Society Standard A6.0.

WELDING

CUTTING CONTAINERS WHICH HAVE HELD

COMBUSTIBLES, obtainable same as item 1.

4.

NFPA Standard 51,

FOR WELDING AND

OXYGEN-FUEL

CUTTING,

GAS obtainable

SYSTEMS from the

National Fire Protection Association, 470 AtlantIc

Avenue, Boston, Mass. 02210.

5.

NFPA Standard 51B, CUTTING AND WELDING PRO.

CESSES, obtainable same as item 4.

6.

CGA Pamphlet P-i.

SAFE HANDLING OF COM

PRESSED GASES IN CYLINDERS, obtainablefrom the

Compressed Gas Association, 500 Fifth Avenue, New

York, N. Y. 10036.

7.

OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD.

ING, CUTTING AND BRAZING.

SECTION

2-

INTRODUCTION

Rated

Amperes

Output

Welding

Current

Range

350

@ 40V

100%

Duty Cycle

45 To

475 Amps

Welding Current Ranges

In Amperes

Coarse Ranges Fine Range

Open-Circuit

Voltage

Range

4585

65-140

100-220

130

.

300

220 -475

From Mm.

To Max.

Of

Each Coarse

Range

55 To 90

DC Volts

Power

3kva

120 Volts AC

50/60 Hz.

While Welding

7.5 kva

120/240 Volts AC

50/60 Hz.

As Power Plant

Dimensions

(Inches)

Weight

(Pounds)

?~i~E

Height

-

43-1/2

Width -25

Depth

-

63

1520 1560

~.

Figure 2-1.

Specifications

TB.007

956

Figure 2-2.

Functional Diagram

2-1.

GENERAL

2-2.

This manual has been prepared especially for use in familiar izing personnel with the design, installation, operation, main tenance, and troubleshooting of this equipment.

All informa tion presented herein should be given careful consideration to assure optimum performance of this equipment.

RECEIVING-HANDLING

Prior to installing this equipment, clean all packing material from around the unit and that may have occurred carefully inspect for any damage during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the and purchaser with the carrier.

A copy of the bill of lading freight bill will be furnished by the carrier on request if occasion to file claim arises.

When requesting information concerning this equipment, it is essential that Model

Serial

Description and/or Stock Number and

(or Style) Numbers of the equipment be supplied.

2-3.

DESCRIPTION

This welding generator is driven by a gasoline engine.

The

Unit will produce a dc output for Shielded Metal Arc

(SMAW) output

Welding when used as a welding generator, or an ac of 7.5

kva at

120/240 volts when used as a power generator.

ac

A duplex receptacle on the front panel provides an output of up to

3 kva at

120 volts to power toolt, lights, etc., while welding.

m

This welding generator has reconnectable capability to provide 240 volts ac auxiliary power at the front panel if the optional receptacle kit is ordered.

Should preparation and installation (or information if factory installed) be desired, see

Section 5-9 for complete instructions, and delete all reference to

120 volts ac duplex receptacle and replace with 240 volts dc duplex receptacle.

2-4.

SAFETY

Before the tion at

This will the equipment is put into operation, the safety sec front of this manual should be read completely.

help avoid possible injury due to misuse or improper welding applications.

The and following definitions apply to CAUTION. IMPORTANT.

NOTE blocks found throughout this manual:

CAUTION

oper~g,

and Under this tenance heading, installation, main procedures or practices will be found that if not carefully followed may create a hazard to per sonnel.

OM-457 Page 5

Page 6

IMPORTANT

I

I

U

Under this tenance heading, installation, operating, and main procedures or practices will be found that if not carefully followed nay result in damage to equipmerit.

U

NOTE I

Under this heading, explanatory statements found that need special emphasis to will be obtain the most efficientoperation of the equipmrrnt.

3

-

1.

LOCATION

(Figure

3-1)

SECTION 3

-

INSTALLATION

On most welding generators a lifting device is provided for moving the unit.

However, if a fork lift vehicle is used for lifting the unit, be sure that the lift forks are long enough to extend completely under base.

A proper installation site should be selected for the welding generator remain if the unit is to provide dependable service, relatively maintenance free.

and

F~O~TANT

I

II this welding generator is to be mounted on a trailer

(optional), enture that the engine end is mounted toward the front (hitch end) of the trailer to maintain proper torque weight distribution.

Also ensure that the weight of the trailer is 5 to 10% of the gross vehicle weight.

It is recommended that a properly fitting canvas cover

(optional) be placed over the welding generator when not in operation to protect the unit from the environment.

I I of lift f short e xte nd o ut of the opposite side of the base will expose internal compon ents to damage should the tips of the lift forks pene trate the bottom of the unit.

L

CAUTION

I

If this unit is to be located in a operated indoors, it should be place where the exhaust fumes from the engine can be vented out of the building.

Failure to comply with proper venting may result in stjrious bodily injury or loss of life.

I

;~=ANT;

The engine exhaust system on this has not been welding generator equipped with a spark arrestor unless it was specifically ordered as an optional accessory.

A spark arrestor, maintained in effective working order, is mandatory if this welding generator is to be operated in a

National Forest, or on

California

Grasslands, brush, or forest covered land (see Section

4442 of California Public Resources Code).

For other areas, check your state and local laws.

U

U

A proper installation site into and out of the permits welding freedom of air generator, and also movement least subjects the unit to dust, dirt, moisture, and corrosive vapors.

A minimum of 18 inches of unrestricted space must be maintained between the welding generator front and rear panels and the nearest obstruction.

Also, the underside of the welding generator muss be kept completely free of ob structions.

The installation site should also permit easy removal of the outer enclosure for maintenance functions.

TA-004 285

Figure 3-1.

Dimensional Drawing

3-2.

WELD OUTPUT CONNECTIONS

(Figure

3-2)

To obtain the full rated output from this to select, install, and maintain proper unit, isis necessary welding cables. Failure result in less than to comply in any of these areas may satisfactory welding performance.

U

I

Do not place any filtering device over the intake air passages of the welding generator the volume of intake air and as this would restrict thereby subject the internal components to an overheating condition and subsequent failure.

Warranty is void if any type of filtering device is used.

I

Holes are

3-1 provided in the base for mounting purposes.

Figure gives overall dimensions and the base mounting hole layout.

Ensure that the unit is completely

~iaking any weld output connections.

~own

before

1

A.

Location

The POSITIVE and NEGATIVE weld output terminals are located on the lower portion of the front panel.

Open the lower front access door.

Route the weld cables between the two horizontal pieces of angle iron on the front of the base

(see Figure 3-2) and connect the cables to the weld output terminals. Secure the lower access door.

NOTE i

If the welding generator is equipped with a

POLAR

ITY SWITCH (Optional), the weld output terminals are labeled ELECTRODE and WORK.

1

The connections shown in this figure are for dc Straight polarity.

TB-004 282-A

Figure 3-2.

Weld Output Connections

B.

Welding

Cables

If welding cables were not ordered with this unit, the steps listed should be followed to ensure the best welding performance:

1.

It is recommended that the short as welding cables be kept as possible, be placed close together, and be of adequate current carrying capacity.

The resistance of the welding cables and connections causes a which is added to the voltage of the arc.

voltage

Excessive drop cable resistance may result in the maximum current overloading output as well capability of as reducing this unit.

Proper operation is to a great extent dependent on the use of welding cables and connections that are in good condition and of adequate size.

An insulated electrode holder must be used to ensure the operators safety.

2.

Use Table 3-1 as a the guide for selecting correct cable size for anticipated maximum weld current which will be used.

Table 3-1 shows total cable the electrode and work cable.

length, which includes

Example: If the electrode holder cable is 75 feet long and the work cable is 25 feet long, select the size cable that is recommended for 100 feet at the maximum weld current that is to be used.

3.

Do not use damaged or frayed cables.

4.

Follow the electrode holder manufacturers instructions for installing the electrode holder onto the electrode cable.

5.

Use correct lugs on the weld cable to connect the work clamp and to connect the cables to the weld output terminals.

Install the cables to the output terminals according to Section 3-2A.

6.

Ensure that all connections are clean and tight.

Table 3-1.

Welding Cable Size

WELDING

AMPERES

100

150

200

250

300

350

400

500

TOTAL LENGTI-IOF CABLE ICOPPE RI IN WELD CIA CUlT

50 100 150 200 250 300 350 400

4

2

1

1/0

2/0

3/0

3/0

4/0

4

2

1

1/0

2/0

3/0

3/0

4/0

2

2

1

1/0

2/0

3/0

3/0

4/0

2

1

1/0

2/0

3/0

4/0

4/0

2-2/0

2

1/0

2/0

3/0

4/0

4/0

2-2/0

2~3/0

1

2/0

3/0

4/0

4/0

2~2/O

2-3/0

2-3/0

1/0

3/0

4/0

4/0

2-2/0

2-3/0

3-2/0

24/0

1/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

3-3/0

NOTE.

A,

B.

C.

A-002 702-A

5OFEETOR LESS.

CABLE SIZE IS BASED ON DIRECT CURRENT

100% DUTY CYCLE AND EITHER A 4 lDCl,

VOLTS OR LESS

DROP OR A CURRENT DENSITY OF NOT OVER 300

CIRCULAR MILS PER AMP.

WELD CABLE INSULATION WITH A VOLTAGE

RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT

AGE (CCV) OF THE WELDING GENERATOR MUST BE

USED.

WHILE MOST WELDING GENERATORS HAVE

AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100

VOLTS.

SOME WELDING GENERATORS OF SPECIAL

DESIGN MAY HAVE HIGHER OPEN-CIRCUIT

VOLTAGE.

3- 3.

EQUIPMENT GROUNDING TERMINAL

(Figure

3-2)

Normally, engine-driven Welding generators do not require grounding. However, since this unit has auxiliary power plant capability, grounding of the frame and case may be required,

A grounding terminal has been provided on the front panel for this purpose

(see instructions consult

Figure your local

3-2).

or

For state detailed codes or grounding the latest issue of the National Electrical Code.

3-4. REMOTE AMPERAGE CONTROL CONNECTIONS

(Figure

5-1)

The on

REMOTE AMPERAGE CONTROL the front panel of the receptacle, located welding generator provides a junction point for connecting a

Remote the amperage control

Amperage

Circuitry in the unit.

Control to

To Connect the Remote

AMPERAGE CONTROL

Amperage Control to the REMOTE receptacle, insert the three-prong plug from the remote control into the receptacle and rotate the plug as far as it will turn in clockwise direction.

Once fully rotated, the plug will be locked in the receptacle and will not pull Out under stress.

3-5.

120/240 VOLTS AC TERMINALS

(Figure

3-3) the h igh pote nt ial t hat is p rese nt at t he

120/240 volts ac terminals while the welding generator is operating, it is recommended that connections to the 120/240 volts ac terminals be made only by a licensed electrician to avert any chance of personal injury due to faulty installation.

Never attempt to make connections to the 120/240 volts ac terminals while the engine is operating.

The 120/240 volts ac terminals act as a junction point for connecting accessory equipment to the 7.5

kva, 120/240 volts.

50/60 Hertz power plant.

The power that can be obtained at these terminals may be used to provide standby service to rural, residential, or other buildings requiring

120/240 volts 3 wire connection.

Figure 3-3.

Power Plant Connections

CAUTION

I

Do not engine if NEC is change fuses or Connect any leed wires while running.

Install Circuit grounding jumper lead or local electrical code requires grounded neutral conductor, Insert load lead wires per cord through pro grip box connector.

Strip 1/2 inch insulation and connect to proper load terminals and tighten con nectors securely.

I

I

.

OM-457 Page 7

m

I

I

The FINE AMPERAGE control must be rotated to the

100 (full counterclockwise) position whenever the

120/240 volts power plant is being utilized.

I

I

The the voltage will vary in accordance with the load applied to

120/240 volts terminals. The voltage at various loads may be determined from Figure 3-4.

260

U,

200

0

250

230

~

220

240

210

7.7SKVA

I.SKVA

14.3

~

16.1 KVA

KVA

10 20 30 40 50 60 70 80 90 100 110

~ POWER .MPERES

120

8-005 185

Figure 3-4.

AC Power Curve For 120/240 Volts AC Terminals

SECTION 4

-

ENGINE

PREPARATION

1 Fl

See the Engine Manufacturers manual (F-i 63 for complete engine care.

Engine)

F

I

4-1.

LUBRICATION

This engine was shippAd from the factory with its crankcase filled with the correct amount and type of break-in otherwise ordered.

Check the oil level before oil unless attempting to operate the engine.

It should be up to the FULL mark on the bayonet type indicator. Add a quality brand of oil if the oil level is low. See the oil selection chart, Table 9-1, in Section

9.

~i~RTANTI

I

I

.

If this

.

welding generator is to peratures which are below be

operated in tem

0F, additional anti-freeze will have to be added to the coolant system or the liquid in the system will freeze and thus cause the engine to overheat.

1

I

The the coolant system is equipped with a thermostat should-become defective,

180F be thermostat.

sure the

If replace ment is of equal temperature rating.

Keep Crankcase Oil

At This Level

Never Operate Engine

With Oil Below This Level

U

Do not without run the one.

engine with a defective thermostat or

If this is done, the engine will run cold and will develop excess carbon accumulation and the oil become contaminated with excessive sludge and dirt.

I

The cap radiator for this which is rated at 7 engine psi.

is equipped

If this cap is with ever a pressurized replaced, ensure that the replacement cap has a rating of 7 psi.

TA-900 033-3.1

Figure

4-1.

Oil Level Indicator

L–~RTANT~ I

I

New engines have moving parts.

Thus, very close clearance between it is recommended that their loading of the engine be kept to a minimum during the first 50 hours of operation.

Be sure to check the oil level several times each day during the engine break-in period.

This engine requires about 50 hours of running time before it will be fully broken in.

I

After about 50 and hours of running time, drain the break-in oil change the oil filter.

See the oil selection chart, Table

9-1, in Section 9 for correct oil type and grade to use after the break-in oil is drained.

4-2.

COOLANT SYSTEM

The liquid capacity of the coolant system in this welding generator is 9 quarts

(U.S.

Measure).

This unit is shipped from the freeze to to

0F.

factory with the proper amount of water and anti permit operation of the unit at temperatures down

~on

a hou Id be ax ercised at all times wi~en re moving the radiator pressure cap. The cap will turn to an sure almost full open vision has been made position, at which point a pro to permit veuiting built up pres within the radiator.

Allow the pressure to escape before completely removing the cap from the radiator neck.

When removing the cap, it is recommended that a glove or rag be used to protect the operators hand from possible exposure to extremely hot coolant.

4-3.

A.

PREPARING NEW BATTERY FOR SERVICE

Wet Charged Battery

The wet charged battery tion added and normally is in shipped an with the operational electrolyte status.

solu

However, due to long periods of idleness, the battery may become weak and thus specific gravity require reading

If this level is not charging.

The battery should have a of 1.260

present when

(at 80F) it is to be before operation.

used, charge the battery as instructed in Section 4-3A, step

4.

IMPORTANT

Do not attempt to operate the engine without the battery connected.

Also, do not attempt to remove the battery while the engine is running.

Page 8

NOTE

If the battery does not require any additional charg ing, the only step required to place the battery into operation is to connect the to the negative negative () battery

() terminal on the battery.

cable

.

B.

Dry Charged Battery

This battery is shipped in a dry state.

To prepare the new battery for operation, it will be necessary to obtain electro lyte, proceed as follows:

I

Put on protective eye cover and ing the electrolyte solution.

clothing prior to pour

1.

Remove the battery from the unit and place it on a level work table or other suitable area.

2.

Fill the battery cells to the required level with electrolyte.

3.

Place a battery thermometer in one of the center calls and check the specific gravity of each cell with a battery hydrometer.

4.

The battery temperature must be

80F and the specific gravity reading 1.260

prior to installation.

If both condi tions are not met, structions below: charge the battery following the in

m!st

to cha rging t he batte: the baft ery caps removed.

Failure to remove the caps be could result in the battery charged.

exploding should the battery be over a.

Use an automotive should be type battery charger.

This battery charged at about a

3.5

ampere rate until correct rates electrolyte conditions are met.

Lower charging can be used; however, the time to obtain the correct electrolyte conditions will be longer.

b.

When the battery is charged, disconnect it from the charger and re.check

the electrolyte level.

Add if necessary. Install the battery caps.

c.

Rinse the before empty electrolyte containers with water discarding.

Since battery acid is corrosive to metals, do not pour into a metal sink or drain.

Rinse and mutilate the empty electrolyte container before discarding.

If acid has accidentally spilled on the bat tery or work area during filling or charging, flush off with clear water and neutralize with soda or ammonia solution.

Use the same procedure if add is spilled on clothing.

5.

Re-install the battery in the unit making sure that the negative () terminal of the battery is connected to the negative () battery cable.

4-4.

AIR CLEANER

4-5.

The air type cleaner this with a engine is equipped with, is a dry element replaceable filter element.

The air cleaner re quires no initial service.

FUEL

Figure 4-2 illustrates typical fuel consumption under load conditions.

Fuel specific consumption will vary from one engine to another.

Different brands of condition of the fuel, operating conditions, engine, and many other conditions will af fect the fuel consumption of this engine.

_j

IC ~

0

U

-J

11.35

2.5

10.4

2.29

9.46

2.08

1.87

8.52

7.57

6.62

1.7

1.46

3.0

2.75

2.5

2.25

2.0

1.75

5.67

4.73

1.25

1.04

3.78

0.83

2.84

0.62

1.5

1.25

1.0

0.75

1.98

.95

0.4

0.5

0.21

0.25

50 100 150 200 250 300 350

D.C.

WELD AMPERES AT 100 DUTY CYCLE WELD

400

1.0

2.5

4.0

6.0

9.0

POWER KVA AT 100% DUTY CYCLE

(I! AVAILAILI)

12.0

6-005 606

Figure 4-2.

Fuel Consumption Chart

1IIC~UiR.

Do not attempt to running.

Do not fill the fuel tank with the fill the fuel tank completely engine as cold fuel will expand when exposed to outside temperature in a warm climate or to full it will overflow engine heat, If the thnk is too causing a potential fire hazard.

Never allow fuel to drain on the engine or other com ponents.

The fuel tank is the equipped with a trap area in the bottom of tank, therefore; the tank will not go completely dry.

This trap holds water is located on the and dirt back from the engine.

A drain plug left, bottom of the tank to drain water and dirt from the tank if it should become necessary.

IMPORTANT

I

I

I

Use a good grade of regular gasoline, rated at least at 85 octane, for this engine.

Fuels of lower octane ratings may cause detonations (knocking) which could result in damage to the engine.

The fuel capacity of the fuel tank is 17.5

gallons (U.S.

Measure).

I

OM-457 Pa~ 9

SECTION

5-FUNCTION

OF

GENERATOR CONTROLS

i

The contacts of the FINE AMPERAGE control are of the continuous contact type, possible to fine adjust the thereby making amperage output it while welding

The scale surrounding calibrated from 0 to

100 the FINE AMPERAGE control is percent in increments of ten.

Due to this percentage operator is using calibration, it should be noted that if the this scale to select a fine amperage setting, the use operator and not an is selecting a percentage of the coarse range in actual amperage value.

Fi~jre

5-1.

Generator Controls TB-004 284

5.

1.

120 VOLTS AC RECEPTACLE

Optional 240 Volts AC

(Figure

5-1) (For

Receptacle,

See Section 5-9)

Up to 3 kva of 120 volts ac

50/60 Hertz power is available at this duplex receptacle for operating 120 volts ac or

120 volts universal power tools etc., when the welding generator is being operated at weld rpm.

The ac the load power output voltage will decrease in accordance with applied to power connections.

280 140

260 130

>

240 120

220 110

~ 200 100

0

0

20 30

AC POWER AMPERES AT 120V.

5 10 15

AC POWER AMPERES AT 240V.

40

20

B-005 192-A

Figure 5-2.

AC Power Curve For 120 (And Optional 240)

Volts AC

Receptacle

5-2.

RANGE SWITCH

(Figure

5-1)

The Range switch permits selection of five different amper age ranges.

range

Each of the five switch positions has its amperage indicated on the scale above the Range switch handle.

tMPORTANT

I

U

Do not change the position of the Range switch while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts to become pitted and eventually inoperative.

U

I

53. FINE AMPERAGE CONTROL

Page 10

(Figure

5-1)

The FINE AMPERAGE control select an exact permits the operator to welding amperage.

This control allows adjustment of the welding amperage from minimum to maximum of the coarse amperage range selected by the

Range switch.

I

The FINE AMPERAGE control must be rotated to the

100 (full counterclockwise) position whenever the

120/240 volts power plant is being utilized.

The FINE

AMPERAGE using the control may

120 VOLTS AC front panel.

be in any position when duplex receptacle on the

I

U

5-4.

REMOTE AMPERAGE CONTROL (Figure 5-1)

If a tions

Remote Amperage Control is to be used, make connec from the control to the REMOTE AMPERAGE CON

TROL receptacle as instructed in Section 3-4.

When remote control of the amperage is that the desired,

REMOTE AMPERAGE CONTROL it is essential switch be placed in the REMOTE position.

Likewise, if a

Remote Amperage

Control is not to be utilized, the switch must be in the

STANDARD position.

When in the STANDARD only the FINE AMPERAGE control on the front position panel will control the amperage.

When a

Remote control is

Amperage Control is being used, the remote functioning as a fine amperage adjustment of the

FINE AMPERAGE control tor.

For setting on the WELDING genera example: If the FINE AMPERAGE control on the welding generator is set at the 50% position, the Remote

Amperage Control will provide (from mm.

to max.

positions) fine amperage generator adjustment of one half output for the range selected of by the means welding of the

Range switch.

If full adjustment of the range selected is desired, the FINE AMPERAGE control on the generator must be set at 100% (max.

position).

welding

5-5.

VOLT-AMPERE CURVES

(Figur~5-3)

0 100 200 300

DC AMPIIIS

400 300

Figure 5-3.

Volt-Ampere Curves

600

B-005 130

The volt-ampere curves show the output voltage and current of the welding generator available at any point from the minimum to maximum of each coarse range.

The FINE

AMPERAGE control, controls the output between minimum and maximum curves of each coarse range the that is shown.

Load voltage is predetermined to a large extent by the arc characteristics.

With the use of the volt-ampere curves it is possible to determine what the weld current will be at a particular arc voltage.

Remember, the volt-ampere curves

show the minimum and maximum curves of each coarse range.

When the FINE AMPERAGE control is adjusted, the volt-ampere curve will fall between the minimum and maximum curves of the particular coarse range in use.

5

-

6.

DUTY CYCLE

(Figure

54)

The ten duty cycle of a minute welding generator is the percentage of a period that a welding generator can safely be operated at a given output. This

100 percent duty cycle.

This welding means generator that the is rated at welding generator can

If the welding be safely operated amperes are at rated increased load beyond continuously.

rated output, the to duty cycle will decrease.

Figure 5-4 enables the operator determine the safe output of the welding generator at various duty cycles.

IMPORTANT

I

U

Exceeding the indicated duty cycle will cause damage to the internal components of the welding generator.

U

RATED OUTPUTi

500

~ 450

400

4

0 z

350

300

-~

;;;

-

~bq~

-

-

~%

250

30 40 50 60

% DUTY CYCLE

70

Figure 5-4.

Duty Cycle Chart

80 90 100

B-053 306

57.

POLARITY SWITCH

(Optional)

The POLARITY SWITCH either DC provides a means of selecting

STRAIGHT or

DC REVERSE polarity without changing cable connections.

59.

240 VOLTS AC DUPLEX RECEPTALCE

(Figure

5-1)

(Optional)

This welding generator is equipped with a voltage changeover terminal strip TEl and proper stator to provide reconnection capbility for 240 volts ac.

Although the capability for either

120 or

240 volts ac is present, an optional kit must be purchased if 240 volts is desired at the front panel.

A.

Power Curve For Optional 240 VOLTS AC

Receptacle

(See

Figure

5-2).

Duplex

Up to 3 kva of 240 volts ac

50/60 Hertz power is available at the duplex receptacle for operating power tools, lights, etc., when the welding generator is being operated at weld rpm.

The FINE AMPERAGE control may be in any position when using the 240 VOLTS AC duplex receptacle on the front panel.

I.~

The voltage will vary in accordance with the load applied to the 240 may be

VOLTS AC receptacle.

determined from Figure

The

5-2.

voltage at various loads

B.

Installation Of 240 VOLTS AC Duplex Receptacle

I

I

Ensure that the engine is completely shut down before attempting any connections or examination of com ponents on or near terminal strip TEl.

I

I

TA~

Before proceeding with this installation, familiarize yourself with the circuit diagram in the Trouble shooting Section of this manual.

NOTE

All directions, such as left or right, are with respect to the operator facing the welding generator front panel.

1

I

I

Do not change the position

SWITCH while welding or under of the load, as

POLARITY this causes arcing across the contacts of the switch.

This arcing causes the contacts to become pitted and eventually inoperative.

U

U

If the welding generator is equipped with a

POLAR

ITY SWITCH (Optional), the weld output terminals are labeled ELECTRODE and WORK.

I

To ensure that the weld current output will be in accordance with the labeling of the position on the POLARITY

SWITCH, connect the electrode holder cable to the ELEC

TRODE terminal and the work cable to the WORK terminal.

5- 8. METERS

(Optional)

This welding generator can be equipped with meters.

The meters are an for monitoring the indication of the welding welding operation process.

These and serve as meters are internally connected to the minals.

welding generator output ter

The voltmeter will indicate the voltage at the weld output terminals, not the actual voltage at the welding arc

(due to cable resistance).

The ammeter will indicate the current output of the welding generator.

NOTE i

Retain all hardware removed during installation.

this procedure for

1.

2.

Shut down the side panel.

welding generator and raise the right

Remove center bolt from insulation board

5-5), remove and retain insulation board.

(see Figure

Terminal Strip TEl.

Duplex Receptacle tar Bolt

TA-059 485

Figure 5-5.

Location Of Reconnectable Components

OM-457 Page 11

3.

4.

5.

6.

7.

8.

9.

Remove 120 VOLTS AC located on front panel (see duplex receptacle RC1

Figure 5-5).

Remove leads and allow to hang free.

Connect leads removed from RC1 to the 240 volts ac duplex receptacle RC2 (one on each side of tacle).

recep

Install RC2 in front panel.

Affix supplied 240 VOLTS AC label over

VOLTS AC designation for duplex existing receptacle

120 on nameplate.

Remove and retain

TEl (see Figure 5-6).

jumper links from terminal strip

Move lead No.

3 terminal B to

(only terminal lead

A on jumper link side) from

(same side of TEl).

See

Figure 5-6.

Position

5-6).

jumper links on

TEl for 240 volts (see Figure

10.

11.

Lead No.

3

Install insulation board over

TEl and secure with bolt.

Lower right side panel of welding generator and resume operation.

Lead No. 3

B

C

0

A

B

C

D

TA-059 243

240 VOLTS AC (OPTIONAL) 120 VOLTS Ac (STANDARD)

Figure 5-6.

Jumper Link Arrangement For 120 And 240

Volts AC

SECTION 6-FUNCTION OF ENGINE

CONTROLS

The IDLE CONTROL switch AUTOMATIC IDLE position would usually be used when performing Shielded Metal Arc

Welding (SMAW) as this process does not require a constant rpm.

This only holds true if the 120 VOLTS AC receptacle is not being used.

If accessory power tools are to be operated from the 120 VOLTS AC receptacle, or

120/240 volts ac terminals, place the IDLE CONTROL switch in the LOCK

OUT position.

IMPORTANT

Temperatuu

Gauge

If 120 volts ac power ted from the 120 equipment is going to be opera

VOLTS AC receptacle or

120/240 volts ac the terminals, be sure the equipment is off until engine is operating at full rpm.

The same holds true are when returning the engine to idle.

If power tools operated while the engine is idling, low voltage and frequency (resulting from the lower engine idling rpm) at the power volts receptacle equipment.

may cause damage to the 120

Engine

Ammeter -

Oil Pressure

Gauge

Figure

6-1.

Engine Controls

6-1.

CHOKE CONTROL (Figure 6-1)

A CHOKE control for varying the fuel-air mixture to the engine, is provided on the front control panel of the weld!

power generator.

out, very

When the CHOKE control little air will be admitted to the is pulled engine thru fully the carburetor thereby supplying a richer mixture of fuel.

This position is required if the engine is cold when started.

As the engine warms up it will be necessary to push the CHOKE control inward

When the slowly until it is pushed in as far as it will go.

CHOKE control is fully in, the engine should be ready for operation.

6-2.

START PUSH BUTTON AND SWITCH

(Figure

6-1)

6-3.

A START on push button the front panel for and key operated starting and switch stopping is the provided engine.

Rotating the key operated Ignition switch fully clockwise to

RUN, and pressing the START push button will engage the starter motor and start the engine.

Once the engine has started, release the START push button. To stop the engine, rotate the key operated clockwise to the OFF

Ignition position.

switch fully counter

IDLE CONTROL SWITCH

(Figure

6-1)

This engine is equipped with an automatic idling device as standard equipment.

When the idle control is being em ployed, the engine will remain at idle rpm when the generator is not loaded, thus saving fuel.

An trol

IDLE CONTROL switch, located on the generator con panel, allows control over the operation of the automatic idling device.

The IDLE CONTROL switch is labeled AUTO

MATIC IDLE

-

LOCK OUT.

The AUTOMATIC IDLE tion allows the posi engine to idle until an arc is struck.

The

LOCK OUT position of the switch is used whenever it is necessary or desirable to operate the engine at constant weld rpm

(1800).

120 volts ac

The LOCK power is

OUT position required from must the be

120 used when

VOLTS AC receptacle or when the 7.5

kva power plant is being utilized.

Page 12

6-4.

ENGINE AMMETER

(Figure

6-1)

The ENGINE ammeter being supplied to the registers the charging current which is battery by the charging generator.

It also being registers a discharge equivalent to used by the engine electrical the system amount when the of current generator is not charging.

6-5.

TEMPERATURE GAUGE

(Figure

6-1)

The Temperature gauge indicates the coolant temperature and will indicate when an overheated condition occurs.

6.6.

OIL PRESSURE GAUGE

(Figure

6-1)

The OIL PRESSURE pressure in gauge indicates the lubricating system pounds per square inch.

Normally, the pressure indicated by the gauge should remain constant for a given engine rpm.

Should the pressure fluctuate or drop, stop the engine and do not operate the engine again until trouble has been remedied.

6-7.

ELECTRICAL TACHOMETER (OPTIONAL)

The ELECTRICAL tachometer is a

0-4000 used to indicate engine rpm.

rpm tachometer

6-8. TOTAL HOUR METER (OPTIONAL)

The TOTAL HOUR meter registers the total hours of engine operation.

This information is useful for routine maintenance on the engine.

I

SECTION 7-

SEQUENCE

OF OPERATION

CAUTION

ope~he

Never under generator any with circumstances, any portion of the outer welding enclosure open or removed.

In addition to being a hazard to personnel, weather protection to the internal com ponents of the is void if the unit will be greatly welding generator is reduced.

operated

Warranty with any portion of the outer enclosure open or removed.

1.

Ensure that the engine instructed in Section 4.

has been prepared for operation as

2.

Make connections to the instructed in Section 3-5.

120/240 volts ac terminals as

3.

Rotate the FINE AMPERAGE control to the 100 counterclockwise) setting.

(full

4.

Start the engine as instructed in Section 7-3.

5.

Place the IDLE CONTROL switch in the position and commence operation.

LOCK OUT

EAr1

7-3.

STARTING THE ENGINE

Make sure all electrical

120 VOLTS AC equipment connected to the receptacle and 120/240 volts ac ter minal

The strip is turned off before starting the engine.

engine, when starting, has low rpm which causes low voltage at the output receptacle of the generator.

This could result in damage to electrical equipment.

IMPORTANT

7-1. SHIELDED METAL-ARC (SMAW) WELDING

Prior to clothing welding, it is imperative that proper protective

(welding coat and gloves) and eye

(glasses and/or welding helmet) be put on.

protection

Failure to comply may result in serious or permanent bodily damage.

_________________________

I

I

Check the engine oil level and radiator coolant level.

Make sure no loose parts etc.

are laying in the unit.

Make the before ne~ssary connections to the generator attempting to start the unit.

Fill the fuel tank with fresh gasoline.

1.

Make all welding and electrical connections to the welding generator.

2.

Place the IDLE CONTROL switch in the AUTOMATIC

IDLE position.

This should be done in order to permit the engine to warm up at idle rpm.

3.

Choke the engine as necessary.

4.

Rotate the Ignition switch to the RUN position.

5.

Press the START push button.

1.

Ensure that the

Section 4.

engine has been prepared as instructed in

2.

Make Connections to the weld output terminals as re quired.

3.

Place the Ignition switch in the OFF position.

4.

Rotate the FINE AMPERAGE control to the desired setting.

5.

If a

Remote the REMOTE

Amperage Control is not to be used, place

AMPERAGE CONTROL switch in the

STANDARD to be position.

If a

Remote Amperage Control is used, place the REMOTE AMPERAGE CONTROL switch in the REMOTE position.

6.

Start the engine as instructed in Section 7-3.

7.

Place the IDLE CONTROL switch in the desired position and commence welding.

8.

The FINE AMPERAGE control control if used) may be adjusted

(or while remote welding.

amperage

7-2.

POWER PLANT OPERATION

IMPORTANT

I

Always ensure that the starter pinion h~e stopped and flywheel rotating before re-engaging the starter motor, otherwise the ring or pinion may be damaged.

I

6.

When the

As the engine Starts, release the START push button.

engine warms up, slowly push the CHOKE in.

7.4. ENGINE SHUT DOWN

1.

Remove all weld and power loads from the generator.

2.

Allow the length of engine to idle for a few minutes, allow a time if the engine has been operating longer at full load.

This idling time is to ensure that the intemal engine temperature has a chance to equalize.

~

IMPORTANT

I

Make sure all electrical

120 VOLTS AC equipment connected to the receptacle and 120/240 volts ac ter minal

The strip is turned off before starting the engine.

engine, when starting, has low rpm which causes low voltage at the output receptacle of the generator.

This could result in damage to electrical equipment.

IMPORTANT

Do not operate accessory power equipment from the

120 VOLTS AC receptacle or

120/240 volts terminals during the engine shutdown-idling period.

3.

Place the Ignition switch in the OFF position.

OM-457 Page 13

Page 14

SECTION 8

-

GENERATOR

MAINTENANCE

8-2.

COLLECTOR RING BRUSHES

1

CAUTION__.!

If any work is to be done on the rotor

o~enerator,

remove vent the spark plugs from the engine.

This will pre engine compression from turning the rotor and catching the repairpersons hand between the rotor fan casting and the stationary adapter casting.

Also dis connect the negative I-) battery cable from the battery.

The brushes should be inspected periodically to ensure their proper function.

The conditions.

If the brush life is generator very good has been under operating normal in an extremely dusty or dirty location, a close check of the brushes for freedom of movement and cleanliness should be made a weekly.

Under normal use the slip rings will discolor to dark brown.

If it should become necessary to clean the slip rings, use a

3/0 or finer sandpaper followed by a crocus cloth.

Never use into the emery rings cloth and in as turn part of the emery will embed itself destroy the carbon brushes.

8-1.

GENERAL

Economical power operation and trouble-free service of this weld/ generator are reasonable attention.

based upon regular inspections and

8-3.

WELDING CABLES

Ottasional blowing out of the unit with clean dry com pressed air is recommended.

This should be performed periodically, depending upon the location of the unit and the amount of ckist and dirt in the atmosphere.

Check connections replaced.

periodically for tightness.

The cables should be inspected frequently and all brealc in the insula flon should be repaired with electrical insulating tape or the cables

9-1.

LUBRICATION

SECTION 9

-

ENGINE

MAINTENANCE

9-2.

COOLANT SYSTEM

This engine will require at least 50 hours of running time to become fully broken in.

During this period, the load on the engine should be kept as light as possible.

The oil level should be checked a number of times during an operating day, as some about engines will use oil during the break-in period.

After

50 hours of running time on the break-in oil, drain the oil and factured change the oil filter.

Premium heavy duty oil, manu by any one of the major oil companies, should be used as mended a replacement oil.

Table 9-1 gives a list of recom grades and types of oil to use to keep oil level up during break-in and to use after the break-in oil is drained.

The capacity of the engine with a filter change is 4-1/2 quarts, without a to make sure oil filter change.

4 quarts.

Check the dip stick level is up to the required operating level.

CAUTION

U

N

Caution should be exercised at all times when remov ing the radiator pressure cap.

The cap will turn to an almost full open position, at which point a provision has been made to permit venting within the radiator.

Allow the built up pressure pressure to escape before neck.

completely removing the cap from the radiator

When removing the cap, it is recommended that a glove or rag be used to protect the operators hand from possible exposure to extremely hot coolant.

I

~mixd4erenandso!ls.GeneraIly,motor oils fall into two categories: phosphate base, and sulphonate base.

The phosphate base oils are acidic; the sulphonates are alkaline.

Although both bases produce good oils, mixing the two bases produces a chemical reaction which greatly reduces the lubri cating properties of either oil. The mixing of oils could

~cause

extensive damage to the engine.

1

In normal hours of operation, oil should be changed after about 50 operation with a filter change every

150 hours. The oil should be drained after the normal ticle operating temperature, thus promoting foreign par suspension in the oil and thereby removal when the oil is drained.

Foreign particles engine has been warmed up to tend to settle at the bottom of the crankcase when the oil is allowed removal and thus to cool, thereby contaminating the new oil added.

avoiding

If the engine is to be operated in a temperature below

0F, make sure a good grade of ethylene glycol anti-freeze is added to the coolant often as necessary.

system.

Change

The coolant the system coolant solution capacity is as

9 quarts lU.S.

Measure).

During the break-in period of a new engine, one of the great est of dangers is over-heating.

There are several possible causes over-heating, but the basic items for consideration are engine lubrication and coolant circulation.

At the first make a sign thorough of over-heating, shut check to determine the the engine cause.

down and

Temperature of the engine coolant is regulated by a thermo static valve located in the outlet at the front of the cylinder head.

This unit retards the flow oL coolant until a pre determined

tem~erature

is reached, usually varying between

170F and 180 F.

When the desired temperature is achieved, the valve the system opens and free circulation of the coolant begins.

through

Table 9-1.

Oil Selection Guide

Above 90 degrees Fahrenheit

Not lower than 32 degrees

.

As low as

10 degrees above zero

Fahrenheit

Aslowas lOdegrees slow zero Fahrenheit

Lower than 10 degrees below zero

Fahrenheit

SAE3O or

10W-30

SAE 20 or

20W

1OW-30 or

1OW-20

SAE 20W

1OW-30 or

1OW-20

SAE lOW

1OW-30 or

1OW-20

SAE SW or

5W-20

1 th~ tliermostal uiuud

Ensure that the fail, replace it immediately.

replacement has an equal temperature rating.

Do not run the engine without a thermostat.

If the thermostat remains closed, the engine will over a heat.

run

If the thermostat remains open, or the without a thermostat, the engine will run engine is cold.

As result, excess carbon will accumulate and the oil will become contaiminated with sludge.

I

flTAr~

The engine fan and alternator belts are subject to nor mal wear and should be checked for proper tension periodically.

Check and readjust tension after the first

50 hours of operation, and whenever belts are re placed.

9-3.

GOVERNOR SERVICE

The governor speed setting and sensitivity setting are factory set to obtain Correct weld rpm and engine response to chang ing load conditions.

The governor speed control setting is factory locked with a lead seal.

Do not remove this seal un less absolutely necessary.

NOTE

The governor, as used in does not have a

No conjunction

Load Surge with this engine, adjustment as

,d~cribed in the Engine Manual.

The and engine is factory set to operate at

1200 rpm idle speed

1800 rpm when it comes up to weld speed.

For infornia tion concerning governor adjustment, refer to the Engine

Manual, Page 41, paragraph entitled Pierce Governor.

9-4.

CARBURETOR FLOAT SETTING

A.

Zenith Carburetor

NOTE

Do not bend, twist, or apply pressure on the float bodies.

The float bodies when viewed from the free end of the bodies must be centered between and at right angles to the machined surface and must move freely on the float axle.

To ensure tance correct fuel level in the float

(dimension A, Figure 9-1) chamber, check dis from top of floats to machined surface of throttle body (no gasket) with throttle body inverted.

This dimension should be 1-5/32 inches plus or minus 1/32 inch.

To increase or decrease distance from the top of the float bodies to the machined surface, use a long nose pliers and bend the float lever at a point close to the float body.

9-5.

VACUUM CIRCUIT AIR FILTER

(Figure

9-3)

In order to provide clean air for the vacuum circuit, a brass fitting type air cleaner is provided on the underside of the idle control valve.

See Figure 9-3 for location on the engine.

This brass fitting will have to be removed and cleaned in gasoline or a suitable solvent periodicelly to ensure proper engine operation.

Brass

On

Fitting Located

Underside Of Idle

Control Valve.

TA-900 955-bA

Figure 9-3.

Vacuum Circuit Air Filter Location

9-6.

IDLE CONTROL TIME DELAY ADJUSTMENT

(Figure

9-4)

Operation of the idling device is automatic when the IDLE

CONTROL switch is in the AUTOMATIC IDLE position.

When the until an engine arc is is started, engine established, at rpm which will remain time the at idle engine immediately comes up to weld rpm.

When the arc is broken, a time delay will exist before the engine begins to return to idle rpm.

The length of this time delay is controlled by the setting of Screw A in Figure 9-4.

This screw is located on the vacuum line engine.

fitting going into the intake manifold of the

Figure 9-4 shows the adjustment of this screw.

In Engine Compartment d

TA-900 955-7

Figure 9-1.

Carburetor

Float

Setting

B.

Marvel-Schebler Carburetor

To ensure correct distance fuel level in the float

(dimension B, Figure 9-2) from chamber, check top of floats to gasket face with throttle body inverted.

This dimension should be 1/4.

To increase or decrease distance from the top of the float bodies to the gasket face, use a long nose pliers and bend the float lever at a point close to the float body.

The edge of the float should be kept parallel with the gasket.

Screw A

Adjust Clockwise 1/8

Turn At A Time To Increase

Idle Time

L..

Delay.

~

__j

TA-gOD 955-3A

Figure 9-4.

Idle Control Time Delay Adjustment

9-7.

CARBURETOR AIR TEMPERATURE SELECTOR

(Figure

9-5)

Air Cleaner

Figure 9-2. Carburetor Float Setting

TA-008 835

Air Inlet

Manifoid

Stove

Selector

(Shown In Coid

Weather Position)

TA-900 955-4

Figure 9-5. Carburetor Air Temperature Selector

OM-457 Page 15

The air intake to the air tube which cleaner is equipped with a selector allows the air to be drawn either from the sur rounding engine compartment air or heated air, drawn from around the exhaust manifold of the engine.

Heated air will prevent carburetor icing in cold weather.

Figure 9-5 shows the selector tube in the cold weather operating position.

remain about 1 /2S

When away the tube is in this position, it must from the air cleaner inlet.

For warm weather slide it all the way operation, loosen the selector tube and down against the manifold and re-tighten.

9-8.

AIR CLEANER SERVICE

(Figure

9-6)

A.

Daily

Service

1.

Open the engine compartment door nearest the air clean er.

2.

Make certain that the dirt and foreign screen on material.

the weather cap is free of

B.

Weekly Service

Service tions or paper element once every when loss of power week is noted.

under normal

Servicing condi element is accomplished in the following manner:

1.

Remove filter element lock assembly and seal.

2.

Inspect the gasket on the end of the element for damage.

Wipe Out inside of air cleaner housing before installing element.

Do not use the element if the gasket is demaged or missing.

3.

It is recommended that the element should be after ten replaced washings or at the end of the season, whichever comes first.

NOTE

U

When it becomes necessary to service the air the field, follow the procedure outlined in cleaner in

Figure 9-6.

It is on recommended that a hand for spare element always be kept replacement.

New elements are available from your distributor.

I

I

U

For a

temporary expedient

in the

field,

the element

.can

be cleaned by

tapping

the side or the end care

fully against

the palm of the hand.

CAUTION: Do not tap ele ment against a hard surface.

The element may be damaged by doing so.

Compressed air,

not to ex ceed 100 lbs. of pressure can clean the element. In sert nozzle inside the ele ment and blow out dust.

Clean dust from the out side of the element

by holding

the nozzle at least

6 inches from the ele ment.

If

compressed

air is not

available,

or if soot,

oily

vapor, or any ent dirt is pres which cannot be re moved by

compressed

air, then the element is to be washed.

Agitate

element in warm water

containing

a

non-sudsing detergent.

CAUTION: Do not use water hotter than the hand can stand; solvents or oil; fuel oil, or gasoline.

Reverse flush with clean water to

thoroughly

rinse all loosened

foreign

ma terial from the filter.

5.

Shake out excess water from the element and allow to air

dry.

CAUTION: Do not attempt to remove excess water by using compressed air.

6.

An even fine pattern of

light through

the element, when a

light

is held inside the element, indicates that the element is clean.

Any large

spot of

light

in dicates that the element is dam aged

and, therefore,

is unfit for further use.

Replace

the element.

Figure 9.6.

Air Cleaner Service

Page 16

To minimize down

time,

created

by waiting

for the element to

dry,

it is

suggested

that the

newly

cleaned filter be

replaced by

a similar

standby

unit.

TA-900 716-7

A See Figure 9-4

10

1

(2

'

~

TC-003 226

Figure 9-7. Idle Control/Governor Linkage Adjustment

9-9.

IDLE

MENT

CONTROL/GOVERNOR LINKAGE ADJUST

(Figure

9-7) in the event that proper engine idle and/or weld rpm is not being attained, perform the following procedures to calibrate the engine for proper idle and weld rpm:

1.

Adjust the length of the governor linkage (item

1,

Figure 9-7) so that the throttle stop plate (2) is about

1/32 from the stop

(3).

To adjust the linkage (1), loosen the hardware linkage securing nuts (5) and remove the

(6) securing the linkage socket(s) (4) to the governor and carburetor.

(4) accordingly rotation of the to obtain

Rotate the the 1/32 linkage socket(s) gap.

Clockwise linkage socket(s) )4( will shorten the governor linkage (1) and thus reduce the gap.

Con versely, counterclockwise rotation of the linkage socket)s) (4) will lengthen the governor linkage )1) and thus increase the gap.

2.

Rotate the sockets linkage socket(s) )4) slightly until the

(4) are parallel but in opposite directions with respect to each other.

Secure the

(5) to lock the position of the linkage linkage socket nuts socket(s) (4).

~thelinkage~edomofmovement

throughout its entire travel.

If the linkage )1) is bind ing due to the linkage socket(s) (4) being cocked relative to each other, repeat Step 2.

I

4.

5.

A.

B.

Position the arm etor linkage throttle stop

(8) laterally so that the carbur socket plate

(4)

(2) does not throughout touch its the entire travel.

Position the arm

(8) radially so that the arm

(8) travels an equal distance to imaginary center line drawn the center of the throttle shaft either side

(9).

of an perpendicular to

Tighten the alignment screw

(7) and recheck the ad justments made in Steps 1 and 2.

sta

rti~7

t he e ngine and while wo r ki ng on t he engine, ensure that body limbs are clear of the fan and of the vacuum motor unit.

I

Recheck all connections made thus far.

IDLE CONTROL switch in the LOCK OUT

Place the position.

Start the welding generator engine and allow the engine to reach normal operating temperature (about five minutes).

Ensure that the CHOKE control is push ed fully in at this time.

Pull the arm

(8) toward the front of the welding gener ator to the idle position.

Maintain pressure on the arm

(8) to butt the idle screw

(10) against the stop (3) throughout the following adjustments:

3.

Loosen the alignment screw

(7) and position the arm

(8) radially and laterally until the following conditions are simultaneously met:

A.

Rotate the idle screw

(10)

Clockwise rotation of the to obtain screw

400 rpm.

(10) will in crease engine rpm whereas counterclockwise

OM-457 Page 17

Page

18

B.

rotation of the

Screw rpm.

(10) will decrease engine

Rotate the idle mixture adjustment

Screw

(11) clockwise until the engine begins to falter or roll, then rotate the screw

(11) counterclock wise until the engine operates Smoothly.

Rotating the screw

(11) clockwise restricts the air flow, making the air-fuel mixture richer.

Rotating the screw

(11) counterclockwise ad mits leaner.

more air, making the air-fuel mixture

6.

7.

Connect vacuum the vacuum motor motor linkage (12) from the unit to the carburetor.

Manually pivot the vacuum motor arm

(14) until screw

(16) butts against the vacuum motor unit mounting plate.

If this is not possible due to the idle screw screw

Screw

(10) butting against the stop

(3) before the

(16) butting against the mounting plate, adjust

(16) so that screw

(16) butts against the vacuum motor butts uni~ mounting plate before idle screw

(10) against stop

(3).

IMPORTANT

Ensure that the screw

(16) butts position.

against the mounting plate before the idle screw

(10) butts against the stop

(3) prior to placing the IDLE CONTROL switch in the

AUTOMATIC IDLE

8.

9.

Place the IDLE CONTROL s~it~h in the AUTO

MATIC IDLE position.

is automatic when the

Operation

IDLE of the idling device

CONTROL switch is in the AUTOMATIC IDLE position.

Once the engine is started, engine rpm will remain at idle until an arc is established, at which time the engine immediately comes up to weld rpm. When the arc is broken, a time delay will exist before the engine begins to return, to idle rpm.

The length of this time delay is controlled by the

If setting of the time-delay screw

A the engine does not go to in idle rpm after

Figure 9-4.

about ten seconds, adjust the desired time delay.

time-delay

This screw screw is

(A) located for on the the vacuum the line fitting going into the intake manifold of engine.

Figure 9-4 shows the adjustment of this screw.

When the engine has gone to Idle rpm, adjust screw

(16) until 1050 rpm is obtained.

NOTE

U

-

Do not readjust the idle rpm screw

(10) when ing the vacuum motor idle rpm.

adjust~

I

I.

Check the linkage (12) for freedom of movement throughout its entire travel; If the linkage (12) is bind ing due to the linkage socket (14) )eing cocked rela tive the to the linkage (12) fixed end adjust the linkage and repeat Steps 7. 8, & 9.

length of

10.

11.

Place the IDLE CONTROL switch in the LOCK OUT position.

Loosen the governor speed adjusting screw securing nut

(19). Adjust the governor speed adjust ment tained.

screw

(20) until a high idle rpm of 1800 is ob

Tighten the securing nut

(19) to maintain the governor speed setting.

Check the governor engine regulation by applying and removing the engine load.

If a governor sensitivity adjustment is deemed necessary, loosen one of the two locking nuts

(21) and proceed with the following instructions:

A.

B.

C.

IF REGULATION RANGE IS TOO BROAD

Decrease the governor spring (22) tension by sliding the sensitivity adjustment screw

(23) inward.

IF REGULATION RANGE IS TOO NARROW

Increase the governor spring (22) tension by sliding the sensitivity adjustment screw

(23) outward.

IF ENGINE SURGES

LOAD

(HUNTS)

Increase the governor

UNDER spring (22) ten sion by sliding the sensitivity

(23) outward.

adjustment screw

12.

Tighten the two locking nuts

(21) to maintain the desired governor sensitivity.

Readjust the governor sensitivity by repeating Step 11.

NOTE

Whenever the governor ed, the governor speed sensitivity (Step 11) is adjust

(Step 10) must be readjusted.

Whenever the governor speed governor sensitivity (Step 11)

(Step 10) is adjusted, the may need

readjustment.

9-10. HIGH ALTITUDE CARBURETOR MODIFICATION

(Optional) (Figure

9-8)

The Zenith carburetor main jet for may be equipped with an adjustable high altitude operation (above 4000 ft).

Minor adjustment will be necessary for proper operation at a particular altitude.

Whenever a carburetor adjustment is deemed necessary, refer to figure 9-8 and proceed as follows:

Loosen the main near main full engine adjustment screw locking nut

(1). Apply a load to the welding generator.

Rotate the adjustment screw

(2) clockwise until the engine begins to falter and lose rpm.

Rotate the main adjustment screw

(2) counterclockwise until the engine operates smoothly, then continue counterclockwise rotation for 1/4 turn.

Ro tating the screw

(2) clockwise restricts the fuel flow, making the air-fuel mixture leaner.

Rotating the screw

(2) counter clockwise admits more richer.

Remove the fuel, engine load.

making the air-fuel mixture

Tighten the locking nut

(1).

~icting

the fuel tUre is too lean will cause valve point where the mix burning.

9-11.

KEY TYPE IGNITION SWITCH LUBRICATION

Applicable)

(If

Periodically, depending on the location of the unit and the amount of moisture in the air, or when binding is noticed, remove spraying the a key and lubricate the Ignition switch by generous amount of lubricant into the key slot.

Wipe excess of f of the nameplate.

It is recommended that lubriplate chain and cablefluid which is non-gumming and is also an anti-oxidant and penetrating oil or a similar product be u~ed.

9-12.

SPARK ARRESTOR

(Optional)

Internal combustion bustible engines operating in a highly environment are a common fire hazard.

com

Glowing carbon particles sufficient heat to blown out with the ignite materials.

While exhaust can retain no practical spark arresting device will stop all sparks, this device will minimize fire hazards by removing and trapping most solid particles provided that it is properly maintained.

The carbon trap should be serviced weekly or every

50 operating hours, whichever occurs first.

The entire spark arrestor should be inspected every

1000 operating hours or three times per season:

tMPORTANT

I

I

The has engine exhaust system on this not been welding generator equipped with a spark arrestor unless it was specifically ordered as an optional accessory.

A spark arrestor, maintained in effective working order, is mandatory if this welding generator is to be operated in a

National Forest, or on

California grasslands, brush, or forest covered land (see Section

4442 of California Public Resources Code).

For other areas, check your state and local laws.

I

A.

Inspection

1.

Visually examine the outside of the device for holes, cracks, or metal corrosion.

2.

With the engine stopped, look inside the spark arrestor outlet tube with a flashlight or other light source.

Visually examine the vanes and the outlet tube for metal or weld failure.

The vanes must be firmly attached to the inlet tube and the outlet tube must be completely intact (this is an important factor in maintaining spark arresting efficiency).

3.

Check the arrestor is mounting clamp to ensure that the spark securely mounted.

Replace the spark arrestor if inspection reveals any signs of failure.

B.

Servicing

The Carbon Trap

I

I

Service the device in an area where there is from flying sparks or hot carbon particles.

no danger

I

1.

Stop the engine and allow the exhaust system to cool.

2.

Remove the cleanout arrestor plug with a wrench.

If from a the bottom of the crust has spark formed over the hole, break it loose with a screwdriver or similar tool.

3.

Start the engine and run it at idle rpm to blow collected particles out the cleanout hole.

If particles are slow to discharge, momentarily cover the end of the exhaust stack.

4.

Stop the engine. Replace and secure the cleanout plug.

Vacuum

Motor

Unit

Figure 9-8.

High-Altitude

Carburetor Adjustment

TC-003 226

SECTION 10-

TROUBLESHOOTING

CAUTION

t~ternalcir

Hazardous voltages are present on cuitry of the welding generator while the engine is running.

Shut down the engine before attempting any inspection or work on the inside of the unit.

Troubleshooting of internal circuitry should be formed by qualified personnel only.

per

The following chart is designed to diagnose and provide remedies for some of the troubles that may develop in this welding generator.

It is assumed that proper installation has been made, according to

Section 3 of this manual, and that the welding generator has been developed.

functioning properly until this trouble

Use this chart in conjunction with the circuit diagram while performing troubleshooting procedures.

If the trouble is not remedied after performing these procedures, the nearest

Factory Authorized Service Station should be contacted.

In all cases of equipment malfunction, the manufacturers recommendations should be strictly followed.

OM-457 Page ig

TROUBLE

No weld output or output from

120/240

120/240 volts volts ac terminals.

120 VOLTS AC receptacle RC1 Output ~S normal,

~

No output from terminals.

Weld

120/240.voltsac

Output is normal as well as output from 120

VOLTS AC receptacle RC1.

No output from 120 VOLTS AC receptacle well as

Rd.

Weld output as

120/240 volts power plant output is normal.

No weld or ac power output,

Erratic weld current.

-.

Engine speed remains at idle rpm when arc is struck and IDLE

CONTROL switch S2 is in

AUTOMATIC IDLE position.

Engine will not return to idle rpm when arc is broken and IDLE

CONTROL Switch S2 is in

AUTOMATIC IDLE position.

-

~

PROBABLE CAUSE

R EM 0 T E AM P E A AG E

CONTROL switch S5 is in

REMOTE position with no remote a mpe rage connected to welding control generator.

Remote n o t amperage secure i n control

A plug is

EMOTE

AMPERAGE receptacle RC2.

CONTROL

Fuse Fl and/or F2 is open.

Loose connections at volts ac terminals.

120/240

Defective power winding.

Loose connection at

AC receptacle Rd.

120 VOLTS

Defective 120 volts ac winding.

Defective brushes.

-Defective rotor.

Damp or-defective electrodes.

Loose or dirty connections.

Check .leads

and Contacts of the

RANGE Switch-S3.

Magnetic field not closing reed switch CR1.

Coil of idle control solenoid valve-

GS1 burned out.

Filter on solenoid plugged.

Idle control valve GS1 closed.

Idle control valve GS1 plugged.

Leak in vacuum line.

Shorted IDLE CONTROL switch

S2.

-

AEMEDY

Place the REMOTE AMPERAGE CONTROL switch S5 in the STANDARD control to the position or connect a remote amperage

REMOTE AMPERAGE CONTROL receptacle

RC2.

Insert remote amperage

RC2 and rotate-as far as control plug fully into receptacle possible in a clockwise direction.

Check and replace fuses Fl or

F2 as required.

Secure connections.

Have power winding replaced at authorized service station.

Secure all connections to 120 VOLTS AC receptacle PCi.

Have 120 volts station.

ac winding replaced at authorized service

Replace brushes.

Have rotor replaced at authorized service station.

-

Use new, dry electrodes.

Check Connections both inside and outside of generator.

welding

Discoloring of brass contacts could indicate heating caused by loose connection.

Replace contact or switch plate of 53.

Replace CR1.

Apply 12 vdc to solenoid coil GS1 and check for proper operation.

Clean filter.

See Section 9-8 for cleaning procedure.

Open valve GS1 by turning in a counterclockwise direction.

Remove and clean GS1.

Check line.

Check switch S2 with ohmmeter.

-

-

1f it becomes necessary to replace any fuse in the welding generator, ensure that a fuse of the proper size is used.

Page 20

NOTE GROUND STRAP MUST RE

INSTALLED RETWEEN ENGINE

ERAME AND WELDER FRAME

1-

EQUIPMENT

GROUND

AC POWER

NEUTRAL GROUNDING

IF DESIRED

PIC.R

I3~ft45

~

~

ThERR4

30t~

j3,

~t50~

5333

JR~~

127

~

LOW 23 2D

REAR DIEW

r~<CI

I

I

C0)

P4RU.

lh-<

I p

I

CAUTION

REFER TO OWNERS

ATTEMPTING UOLTDGE

I

OPTIONDL

INCLUDING

EIT

2ADVOLT

RECEPTACLE

I

LP GAS AlT

TOTAL TIME

AND

METER

Figure 1O~1.

Circuit

Diagram

Circuit Diagram No. CB-901 775-itt

OM-457 Page 21

PARTS

LIST

April

1978 FORM:

OM-457C

Effective With Serial No. HJ134589

OM-457 Page 1

Figure A

Main Assembly

54

55

56

57

58

11

~ a1_

~ w

CD

-I 0 a 0 0 9

0 (11 0

03 C~ CD

Page 3

52

53

54

55

5~

57

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

25

26

27

28

18

19

20

21

22

23

24

45

46

47

48

12

13

14

10

11

8

9

15

16

17

5

6

7

.

Item

No.

Dia.

Mkgs.

Factory

Part No.

49

50

51

Figure

A

1

2

3

4

Batt

Description

Main Assembly

017 430

010434

006698

018 858

602 938

010870

010 318

006 014

007 829

010 289

STRAP, mounting

fuel tank

STRIP,rubber 1/2x 2x 2

TANK,fuel

(consisting

of)

.

CAP, tank

fuel

FITTING, pipe

-

galvanized

plug

FITTING,pipe-brassnipplehexl/8NPT

VALVE, shut-off

w/strainer

FITTING, brass

flared inverted elbow male 1/4 x

1/8 NPT

LINE, fuel (usedwith Marvel

-

Schebler carburetor)

FITTING, brass

flared inverted connector male 1/4 TBG x

1/8 NPT

017 479

031 868

018 765 AIR

018 859

CLEANER, intake

carburetor dry type

(consisting

of)

.

CAP, air cleaner

intake

008698

010 433

*017 309

.

.

.BAFFLE,dust-cap

NUT,

wing

steel 7/16-20

ELEMENT, air cleaner

018 861

SEAL, weather

lift eye

BRACKET, mounting

air cleaner

000 272

.

BODY, air cleaner

.

CLAMP, air cleaner

010 861

018 365

023 626

022 899

010515

CLAMP, hose 1-1/16-2 clamp dia

HOSE, intake

air

CABLE, battery

insulated

DOOR, access

battery

BOLT,J 5/16-18

005612

008766

035 968

027 529

DOOR,side

COVER,top

WASHER, neoprene

5-7/8 x

3-5/8 x

1/16

PIN, cotter

1/4 x

3-1/2

010 875 CLAMP, muffler 2 inch dia

*028262

MUFFLER,exhaust

015 700

010 955

BRACKET ASSEMBLY, mounting

muffler

.

WASHER, flat

steel 13/32 ID x

2 OD x

1/8

(consisting

of)

073 355

027564

053724

017 363

028 404

605 982

008 777

006015

006 037

005 112

018 757

017 594

020 365

025 453

025 884

025 182

605 429

026 837

605 430

025181

005108

.

SPR ING, compression

.SPACER,anti-noise

GUARD,fan

HOSE, i~adiator

upper

RADIATOR

(consisting

of)

.

CAP, radiator 7 lb pressure

ENCLOSURE, radiator

FITTING,pipe-brassdraincockl/4NPT

HOSE, radiator

lower

ENGINE, gas

electric start (consisting of)

.

BLADE, fan (included with engine

see engine parts list)

.

CONTROL, weld/idle vacuum

(See

Fig.

D Page 10)

.

CLAMP, stove

manifold

.

STOVE, manifold

.

SENDER, temperature

.

SENDER, pressure

oil

.

BRACKET, mounting

alternator

.

.

.

ALTERNATOR, 35 amp 12 volts

INSULATOR, terminal

nylon

PULLEY, single belt

negative

(engine

ground alternator)

.TUBING,steel5/BODxl2gawallxl/2

.PIPE,blackl-1/2x 15

010 089

.

FITTING, pipe

brass coupling 1/8 NPT

Figure B GENERATOR ASSEMBLY (See Page 6)

017421 CATCH,door

017 477 ROD, holddown

battery

*015

709 BATTERY, 12 volts 53 amp

023 641 CABLE, battery

uninsulated

017 431 HOLDER, battery

Quantity

1

1

2

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

5

1

4

2

1

1

1

1

6

1

1

1

2

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

Item

No.

Dia.

Mkgs.

Figure

A

Factory

Part No.

Main Assembly (Contd.)

Description

62

63

64

65

66

67

68

58

59

60

61

69

70

71

72

73

74

75

76

77

R2,3

TEl

VR1

SR1,2

Zi

78

78

79

80

81

82

83

VS1

Z2

030 060

023892

007 894

010266

017420

004 444

000 553

010 144

603 107

038 621

053 967

RESISTOR, WW adj 375 watt 20 ohm

CABLE,ground

MOUNT, engine

SPRING,extension

LATCH,door

UPRIGHT, base

center

MOUNT, dual stud

generator

CLAMP, nylon 7/16 dia

HOSE, neoprene

slit 5/32 ID x

11/32 OD (order by foot)

BLOCK, terminal 30 amp

4 pole

INSULATION, rectifier

038 620

052 372

035860

038493

035 704

031 926

008 780

LINK, jumper

.

terminal block

BRACKET, mtg.

terminal strip

RECTIFIER ASSEMBLY

(consisting

of)

.VARISTOR,3joule390volts

.RECTIFIER, integrated 6amp 600 volts

HEAT SINK, rectifier

UPRIGHT, base

front

004 291 BASE

036259

025138

REACTOR

(consisting

of)

.COIL,lefthand

025 139

025 140

004 556

.

COIL, center

.

COIL, right hand

DOOR, access

front lower or

031 318 PANEL, hinged

lower right (used when unit has TAC)

Figure C PANEL, front

upper with components (See Page 8)

025 932 SUPPRESSOR, 0.75 uf 10 ohm w/leads

028 218

031 220

603 125

004 426

FRAME,

mounting

reactor & stabilizer

STABILIZER

STRIP, cotton

1/8 x

4 (4 ft reqd

order by ft)

KIT, label (includes all labels)

Parts for Optional Equipment

A2

RC2

S4

Shunt

TAC

025 103

604 103

025 234

031 317

027 847

038 311

011 281

010 082

010805

011 948

019 603

024694

038 769

103633

103634

604 318

039 046

039 044

039 045

053 032

601 976

601 880

601 879

027 851

030 084

032936

METER, amp dc 5OMV 0-600 scale

RECEPTACLE, straight

.

duplex grounded 2P3W 15 amp

250 volts

CAP, straight

.

grounded 2P3W (used with RC2)

.

.

SWITCH & TERMINAL, polarity & power output

(consisting

of)

BRACKET,

mounting

.

switch & terminal board

INSULATOR, switch

.

polarity

.

SWITCH, polarity (consisting of)

..

.

.

TUBING, steel 5/8 OD x

5/32 wall x

1/2

Ig

.

..

HANDLE, switch

.

GUIDE, contact-switch

..

KNOB, ball

..

BEARING

.

.

CONTACT BOARD ASSEMBLY, movable

..BUSBAR

..

MOUNTING BOARD

.

.

NUT, steel

-

self.tocking

hex 1/4-20

.TERMINAL

BOARD, power output

black

..

BUS BAR

(consisting

of)

.

.

TERMINAL BOARD, black

..

CLIP, spring

.

bus bar

.

.

..

SCREW, cap

steel hex hd 1/2-13 x

1-1/2

NUT, steel

hex jam 1/2-13

..

NUT, steel

hex full 1/2-13

COVER, switch & terminal board

SHUNT, meter 5OMV 600 amp

TACHOMETER,electric 12 volts 4000 rpm

Quantity

1

1

1

1

1

1

1

1

2

1

1

2

1

1

2

2

1

1

1

1

1

1

1

1

1

1

OM-457 Page 4

1

1

2

1

1

1

1

1

1

1

2

1

1

2

1

1

1 ft.

1

2

2

1

2

1

1

1

1

1

1

4 ft.

1

Item

No.

Dia.

Mkgs.

Figure

A

Factory

Part No.

Main Assembly (Contd.)

Description

~

Quantity

TT

V

017 390

020 374

032 936

025 638

027 561

010 429

010 875

031 466

BRACKET, mtg.

tachometer

BRACKET, mtg.

tachometer to engine

METER, hour 4-40 volts

METER, volts dc 0-100 scale

MUFFLER, exhaust

low noise

JET, carburetor

-

high

altitude

CLAMP, muffler 2 inch dia

PIPE, black 1-1/2 x

4-3/4

*Re~mmended Spare

Parts.

BE SURE TO PROVIDE STOCK. MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

2

97

98

99

100

Page 5

Figure B Generator Assembly

TO-006 562

Item

No.

Dia.

Mkgs.

Factory

Part No.

Description Quantity

Figure B Generator Assembly (See

Fig.

A Page 3 Item 52)

108

109

110

111

112

113

114

115

116

117

97

98

99

100

101

102

103

104

105

106

107

91

92

93

94

95

96

SR3

F1,2

SR3

032311

**003

632

024617

053390

035917

035776

025525

010021

018614

018665

600270

*020034

025321

025516

025305

037956

025271

025517

025305

037 957

025 306

026 203

039 269

*012625

039169

010493

059017

039207

ENDBELL

DIODE ASSEMBLY, reverse polarity

.INSULATOR

(consisting

DIODE, 275 amp

250 volts reverse polarity

INSULATOR

CHANNE.L, neoprene

1/4 inch x

11-1/2 long

BOX, fuse

holder

FUSE, cartridge 45 amp

250 volts

HOLDER, fuse cartridge 60 amp

250 volts

BUSHING, snap

5/8 ID 7/8 mounting hole

STATOR of)

BAFFLE,

air

GUARD, generator

ROTOR, generator

(consisting

RING, retaining-external of)

BEARING, ball

FAN, rotor

KEY, steel 3/8 x

3/8 x

2

ROD, threaded end

CLAMP, steel cushion 9/16 dia x

11/32 hole

BRUSH SET

(consisting

of)

CAP, brush holder

.BRUSHHOLDER

BRUSH, contact

BRACKET, mounting

brush holder

DIODE ASSEMBLY, straight polarity

.INSULATOR

(consisting

of)

DIODE, 275 amp 250 volts straight polarity

*Recommended Spare Parts.

**Rotor is available on an exchange basis. Contact Factory Service Department for details.

BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

1

1

1

1

1

1

1

1

1

6

2

1

1

2

1

5

1

1

1

2

3

1

1

2

3

1

1

1

OM-457 Page 6

Figure Cl

146

Page 7

164

Figure C Panel, Front

-

Upper With Components

TC-006 071-A

Item

No.

Dia.

Factory

Mkgs.

Part No.

Figure C

Description

Panel, Front

-

Upper With Components (See Fig.

A

Page

4 Item 79)

Quantity

146

147

148

149

150

140

141

142

143

144

145

151

152

153

154

155

156

157

158

159

160

131

132

133

134

135

136

137

138

139

S3

Ri

S2,5

RC3

RC1

Si

P81

CR1

161

162

163

164

Oil

A

Temp

019 754

010 836

HANDLE, switch

range

PIN, spring

compression

NAMEPLATE (order by stock, model, and serial numbers)

039 046

601 879

.

TERMINAL, power output

black

NUT, steel

hex full 1/2-13

039044 .BUSBAR

(consisting

of)

601 880

039 045

039 043

.

.

NUT, steel

.

hex jam 1/2-13

TERMINAL BOARD, black

601 976

010 528

059 343

.

.

CLIP, spring

bus bar

SCREW, cap

steel hex hd 1/2-13 x

1-1/2

TUBING, steel 1/2 OD x

11 ga wall x

1-1/4

BRACKET, mounting

.

meter

059262 BRACKET, mounting

meter

011 413 SWITCH, range

(See Fig.

Cl Page 9)

*605

960 RHEOSTAT, WW 300 watt

34 ohm

053 359

032 897

604 176

SWITCH, toggle SPST 20 amp

125 volts

RECEPTACLE, twistlock

grounded 2P3W

RECEPTACLE,straight-duplex grounded 2P3W 15 amp

125 volts

S~NITCH, ignition

key type w/o start 005 372

011 767

034876

039 047

601 976

039043

039049

SWITCH, push button

starter

RELAY,reed

TERMINAL, power output

red

(consisting

.

SCREW, cap

steel hex hd 1/2-13 x

1-1/2 of)

.CLlP,sprir~g-busbar

.TERMINALBOARD,red

.

NUT, steel

hex jam 1/2-13

.BUS BAR

601 880

039044

601 879

031 858

019 755

602 178

019 790

039 241

039 237

039 239

.

NUT, steel

hex full 1/2-13

PANEL, front

upper

HANDLE, rheostat

SCREW, set-steel 1/4.20

x

3/8 (used with handle)

CONTROL, push

pull

GAUGE, pressure

oil

METER, amp dc 60-0-60

GAUGE, temperature

*Recommended Spare

Parts

BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

OM-457 Page 8

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

Item

No.

Figure Cl

Factory

Part No.

Description

011 413 Switch, Range (See

Fig.

C

Page

8 Item 144)

011 322

010 671

017 428

011 412

011 490

011 025

011 010

011 009

010 200

010 202

010 201

011 007

011 018

011 489

011 018

010 200

010 202

010 201

011 095

011 019

011 012

011 013

BRACKET, mounting

-

swit~h

SPRING

(consisting of)

LOCATOR, quadrant

CONTACT BOARD ASSEMBLY

(consisting

of)

CONTACT ASSEMBLY, movable

(consisting

of)

SPRING, pressure

CONTACT, switch

copper

.

CONTACT, switch

bronze

SPACER, contact .024

thick

.

SPACER, contact

1/8 thick

SPACER, contact

1/16 thick

.

SPRING, pressure

CONTACT, stationary

CONTACT ASSEMBLY, stationary

CONTACT, stationary

SPACER, contact .024 thick

SPACER, contact

1/8 thick

.

SPACER, contact

1/16 thick

CONTACT BOARD, stationary

CONTACT BOARD, movable

SHIM, guide

.

contact board

(consisting

of)

GUIDE, contact board

stationary

Quantity

9

6

2

1

2

2

3

3

1

1

3

1

2

2

1

TB-Oil 273 TB-Oil 412

Figure Cl Switch, Range

BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

Page 9

Item

No.

Dia.

Mkgs.

Factory

Part No.

Figure D

Description

018 757 Control, Weld/Idle Vacuum (See Fig.

A Page 3 Item 42)

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

SR4

GS1

017 417

604 393

604 392

603 931

603 470

010 869

020 963

018 097

020 962

010 561

031 252

020 964

003 304

023 030

603 802

017 544

015 713

018 160

024 799

018 098

010 334

LINKAGE ASSEMBLY, vacuum

actuator

NUT, speed 3/16 inch

RIVET, steel

round head 3/16 x

3/4

RECEPTACLE, screw

1/4 dia

VALVE, shut-oft

needle

BUSHING, brass

pipe reducer 1/4 MPT 1/8 FPT

TUBING, copper

3/16 OD x

.030 waIl x

13-1/2

CHAMBER, vacuum

HOSE, neoprene

7/64 ID x

4

TEE, brass 1/8 x

1/8

RECTIFIER, selenium

TUBING, copper

1/4 OD x

.030 waIl x

1

VALVE, 12 volts dc 2 way

1/4 IPS port 1/8 orifice

BREATHER, brass

pipe vent

RIVET, steel

round head 1/4 x

2

BRACKET, mounting

chamber vacuum

GROMMET, rubber -5/16 ID x

1/2 hole 3/16 groove

LINKAGE ASSEMBLY, vacuum to carburetor

(consisting

of)

BALL JOINT, 1/4-28 thread

BOLT, hook 1/4-28 x

1/2 x

3-3/4

CLIP, clevis

rod end

206

.207

205

Quantity

1

1

2

1

208

209

202.

201.

211

TA-018 757-C

Figure D Control, Weld/Idle Vacuum

BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

OM-457 Page 10