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FORM: OM-458M
Millerfi
April
1991
Effective With Serial No. KA8951 89
MODEL: TRAILBLAZERfi 44G
OWNERS MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with special emphasis on the safety material throughout the manual, before installing, operating, or maintaining this equipment.
This unit and these instructions are for use only by persons trained and experienced in the safe operation of welding equipment.
Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor If you do not understand these instructions.
fully
SB-086 640-C
MILLER ELECTRIC Mfg.
Co.
AMlllerGroupLtd., Company
P0 Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
PRINTED IN U.S.A.
I
J
LIMITED WARRANTY
lb
EFFECTIVE: AUGUST 6, 1990
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY hereof, MILLER Electric rants to its
Subject to the terms and conditions
Mfg.
Co., Appleton.
Wisconsin war
Distributor/Dealer that all new 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 engines, trade accessories or other items manufactured by others.
Such engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any. All engines are warrantied by their manufacturer for two years from date of which have a one original year.
purchase, except
2000 hour warranty.
Deutz engines to
Except as specified below, MILLERs warranty does not apply components having normal useful life of less than one (1) year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding wire including nozzles and nozzle insulators where failure does not result from defect in workmanship or material.
MILLER shall be required to honor warranty claims on war ranted 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, robots, and components
2.
Load banks
3.
Original main power rectifiers
(labor 1 year only)
4.
All welding guns, feeder/guns and torches
5.
All other MILLERMATIC Feeders
6.
7.
.
.
Replacement or repair parts, exclusive of labor
Batteries
.
1 year
1 year
3 years
90 days
1 year
60 days
6 months provided of the that MILLER is notified date of such failure.
in writing within thirty (30) days
As.a
matter of general policy only, MILLER may honor claims submitted by the original user within the foregoing periods.
In the case of MILLERs breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at MILLERs option (1) repair or (2) replace ment or, cases, where authorized in writing by MILLER in appropriate
(3) the reasonable cost of repair or replacement at an authorized MILLER service station or for the
(4) payment of or credit purchase price (less reasonable depreciation based upon actual and use) upon expense. MILLERs return option of of the goods repair or at Customers replacement risk will be
FOB., Factory at Appleton, Wisconsin, or
FOB.
at a
MILLER authorized service facility, therefore, no compensation for transportation costs of any kind will be allowed.
notice of apparent defect or failure.
MILLER
Upon shall receipt of instruct the claimant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED
SENTATION AS TO
WARRANTY, GUARANTY OR REPRE
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 MERCHAN
TABILITY OR OF F!TNESS FOR PARTICULAR
WITH
PURPOSE,
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.
MILLERS WARRANTIES DO NOT
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO, ANY CONSUMER.
I
I
L
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred.
This sheet lists exceptions to data appearing later in this manual.
AMENDMENT TO SECTION 5 AUXILIARY POWER
Amend Chart 5-2. AC Power Curve For 120/240 Volts AC Terminals (No Weld Load Condition)
Chart 5-2.
AC Power Curve For 120/240 Volts AC Terminals (No Weld Load Condition)
250
245
Cl)
240 o
>
0
~
230
225
220
0 10 20 30
AC AMPERES
40 50 60
SB-085 329-A
AMENDMENT TO SECTION 11 ELECTRICAL DIAGRAMS
Amend Diagram 11-1.
Circuit Diagram For Welding Generator (see Pages 2 and 3 on this Errata Sheet)
AMENDMENT TO SECTION 12 PARTS LIST
Amend Parts List as
Follows:
**
Part
No.
Replaced
With
60-110
..
039 169
....
149 541
Description
..
HOLDER, fuse crtg 60A 250V 2 fuse
~First digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
L.
REMOTE
C~T AOL
I ~T ION AL I
-I
DID
OM-458M Page 2
IT
0
?7
0
J
0
49
0
42
L
L p9
SOLEMID
VALVE
DSP
_
J
12 VD.T
~ATTERV
TA0.~TEP
(~TI~AL.)
Diagram 11-1.
Circuit Diagram For Welding Generator
-I
-J
LOW DPRENT I r
L
AC
POWER
UTPAL
NATI~AAL
~~JC
A~C
AS
LDCAL
PE~JIPED BY
ELEcTPrC C~S
5, 5t S~ 50 51 lESt SjP
3th1
FROAT VIEW
AC
2DC PEVEPSE
3DC STPAI~4T
5
ELECTW~
Circuit Diagram No. SD-i 36 407-B
OM-458M Page 3
CERTIFICATE
NAME OF
EQUIPMENT:_____________________________
MODEL NO.
SERIAL NO._________________________
DATE:
_________________
This
equipment
has been type-tested under standardized field test conditions as recommended by the
Joint Industry Committee on High Frequency Stabilized Arc Welding Machines found to radiate less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit established by the Federal Com munications Commission for equipment of this type.
Installations using this equipment on the basis of these tests, may reasonably be expected to meet the radiation limitations established by the Federal Communications Commission, only when installed, oper ated and maintained as specified in the instruction book provided.
USERS CERTIFICATION
The welding equipment identified above has been installed in accordance with the specific instructions applicable to this model as outlined in the instruction book furnished. It is being used only for the purpose for which it was intended and is being maintained and operated in accordance with the manufacturers instruc tions.
Date Installed
_____________________________
Signed
OM.458M
4/91
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damUse the following spaces to record the Model Designa age that may have occurred claims for loss or during shipment.
File any tion and Serial or
Style Number of your unit.
The infor damage with the delivering carrier.
mation is located on the data card or the nameplate.
Assistance for filing or settling claims may be obtained from the distributor and/or the equipment manufacturModel
_________________________________________ ers Transportation Department.
Serial or
Style No.
____________________________
When requesting information about this equipment, al ways provide the Model Description and Serial or
Style Date of Purchase
Number.
______________________________
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
ArcWelding
Standards Booklet Index
1
1
4
5
SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
2-2.
General Information And Safety
Safety Alert Symbol And Signal Words
SECTION 3 SPECIFICATIONS
3-1.
3-2.
3-3.
Volt-Ampere Curves
Duty Cycle
Description
SECTION 4 INSTALLATION OR RELOCATION
6
6
8
9
9
4-1.
4-2.
43.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
Location
Spark Arrestor/Muffler Installation
Connecting The Battery
Fuel
Lubrication
Coolant System
Equipment
Grounding
Terminal
Weld Output Connections
Remote Amperage Control Receptacle
Remote Contactor Receptacle
Shielding Gas Connections
SECTION 5 AUXILIARY POWER
5-1.
5-2.
5-3.
5-4.
5-5.
General
Auxiliary Power Generator
Auxiliary Power Receptacles
Field Installation Instructions For 240 Volts Duplex Receptacle
.
7.5
KVA/KW Power Plant
15
15
15
16
17
12
14
14
15
9
10
11
11
12
12
12
Section No.
SECTION 6 EVALUATING AUXILIARY POWER REQUIREMENTS
6-1.
6-2.
Auxiliary Power Generators
Load Evaluation
6-3.
6-4.
Generator Capability
Standby Power Connections
Diagram 6-1.
Standby Power Equipment And Connections
6-5.
Auxiliary Power Extension Cord Selection
SECTION 7OPERATOR CONTROLS
7-1.
Process Switch
7-2.
7-3.
7-4.
7-5.
7-6.
Ampere Ranges Switch
Amperage & Voltage Adjustment Control
Remote Amperage Control Switch
Remote Contactor Control Switch
AC/DC Selector Switch
High-Frequency Switch
Postflow Timer
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
Meters
Choke Control
Start Push Button And Ignition Switch
Low Oil Pressure And
Shutdown
High Coolant Temperature
System Switch
Auto Idle Switch
7-14.
7-15.
Battery Charging Light
Engine Temperature And Oil Pressure Light
7-16.
Engine Hours Meter
7-17.
Low Current Control (Optional)
7-18.
Tachometer (Optional)
7-19.
Oil Pressure Gauge (Optional)
7-20.
Temperature Gauge (Optional)
7-21.
Air Cleaner Service Indicator (Optional)
7-22.
Fuel Gauge (Optional)
SECTION 8 SEQUENCE OF OPERATION
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
Gas Tungsten Arc Welding (GTAW)
Gas
Low
Tungsten Arc Welding (GTAW) With
Current Control Option
Shielded Metal Arc Welding (SMAW)
7.5
KVA/KW Power Plant Operation
Starting The Engine
Stopping The Engine
SECTION 9 MAINTENANCE
9-1.
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
9-8.
9-9.
9-10.
Routine Maintenance
Air Cleaner Service And Optional Indicator
Battery Replacement Procedure
Maintenance-Free Battery Charging
Tungsten Electrode
Servicing The Spark Arrestor
Spark Gaps
Carburetor Air Temperature Selector
Automatic Idle Control/Governor Linkage Adjustment
Brushes And Slip Rings
27
28
28
28
28
28
29
29
29
29
29
24
25
25
26
26
26
26
27
27
27
27
29
30
31
31
31
32
32
33
35
35
36
38
38
39
39
41
Page No.
18
19
21
21
22
23
Section No.
SECTION 10 TROUBLESHOOTING
10-1.
General
10-2.
Booster Battery Jump Starting
10-3.
Overload Protection
10-4.
Circuit Board Handling Precautions
10-5.
Troubleshooting
SECTION 11
-
ELECTRICAL DIAGRAMS
Page
42
42
42
43
44
No.
Diagram 11-1.
Circuit Diagram For Welding Generator
Diagram 11-2.
Circuit Diagram For Automatic Idle Control Board PCi
Diagram 11-3.
Circuit Diagram For HF Start Control Board PC2
.
.
.
.
48
50
50
SECTION 12 CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
12-1.
General
12-2.
Definitions
12-3.
12-4.
12-5.
High-Frequency Radiation
Location
General Installation Procedures
12-6.
12-7.
Guidelines For Installation Of High-Frequency Assisted
Arc Welding Power Sources
Installation Guidelines Checklist
SECTION 13 PARTS LIST
51
51
52
52
52
54
54
Figure 13-1.
Main Assembly
Figure 13-2.
Panel, Front Lower w/Components
Figure 13-3. HF Panel
Figure 13-4.
Panel, Control-HF
Figure 13-5.
Circuit Card, Weld/Idle Control PCi
Figure 13-6.
Circuit Card, Output-Current Detector PC2
Figure 13-7.
Panel, Front-Upper w/Components
Figure 13-8.
Generator
LIST OF CHARTS AND TABLES
Table 3-1.
Chart 3-1.
Chart 3-2.
Chart 3-3.
Chart 4-1.
Table 4-1.
Chart 5-1.
Chart 5-2.
Table 6-i.
Table 6-2.
Table 6-3.
Table 6-4.
Table 9-i.
Table 9-2.
Table 9-3.
Table 10-1.
Table 10-2.
Table 10-3.
Specifications
Volt-Ampere Curves
Volt-Ampere Curves With Low Current Control Option
Duty Cycle
Fuel Consumption Curve
Weld Cable Size
AC Power Curve For 120 (And Optional
Duplex Receptacle (No Weld Load
240)
Condition)
Volts
AC Power Curve For 120/240 Volts AC Terminals
(No Weld Load Condition)
Power Requirements
Single-Phase Induction Motor Starting KVA/HP
Requirements
Cord Lengths For 120 Volt Loads
Cord Lengths For 240 Volt Loads
Maintenance Schedule
Air Cleaner Service
Tungsten Size
Weld/Power Troubleshooting
Auxiliary Power Troubleshooting
Engine Troubleshooting
56
61
62
63
64
65
66
68
16
17
20
21
23
24
33
34
37
44
46
47
9
11
14
7
8
8
SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
INTRODUCTION
We learn by experience.
Learning safety through per sonal experience, like a child touching a hot stove is harmful, wasteful, and unwise.
Let the experience of oth ers teach you.
Safe practices developed from experience in the use of welding and cutting are described in this manual.
Re search, development, and field experience have evolved reliable equipment and safe installation, opera tion, and servicing practices.
Accidents occur when equipment is improperly used or maintained. The rea son for the safe practices may not always be given.
Some are based on common sense, others may technical volurrips to explain.
It is wiser to require follow the rules.
Read and understand these safe practices before at tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par ticular equipment used and their instruction manuals, for personal safety and for the safety of others.
Failure to observe these safe practices may cause seri ous injury or death. When safety becomes a habit, the equipment can be used with confidence.
These safe practices are divided into two
Sections:
1-General Precautions, common to arc welding and cut ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety are also available for additional and more cedures than complete pro those given in this manual.
They are listed in the Standards Index in this manual.
ANSI Z49.1
is the most complete.
The National Electrical Code,
Health
Occupational Safety and
Administration, local industrial codes, and local inspection requirements also provide a basis for equip ment installation, use, and service.
1-2.
GENERAL PRECAUTIONS
Different arc welding processes, electrode and fluxes can produce different fumes, alloys, gases, and radiation levels.
In addition to the information in this manual, be sure to consult flux and electrode manu facturers Material Safety Data Sheets (MSDSs) for specific technical data and precautionary measures concerning their material.
A.
Burn Prevention
Wear protective clothing-gauntlet gloves designed for use shirt in welding, hat, and high safety-toe shoes. Button collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side shields underneath, appropriate filter lenses or plates
(protected by clear cover glass).
This is a
MUST for welding or cutting, (and from radiant energy and chipping) to protect the eyes 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 and should never be handled without gloves.
workpieces
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 eyes and skin burns.
Ear plugs should be worn when working on overhead or in a confined space.
A hard hat should be worn when others work overhead.
Flammable hair preparations should not be used by per sons intending to weld or cut.
B.
Toxic Fume Prevention
Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce.
Prevent them with adequate ventilation as described in ANSI Standard
Z49.1
listed in Standards Index. NEVER ventilate with oxygen.
Lead
-, cadmium
-, zinc-, mercury
-,and beryllium-bear ing and similar materials, when welded (or cut) may pro duce harmful concentrations of toxic fumes.
Adequate local exhaustventilation must be used, or each person in the area as well as the plied operator must wear an air-sup respirator.
For beryllium, both must be used.
Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated and, if necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respira tor.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con centration dangerously.
Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open.
Check to be sure that the space is safe before re-entering it.
Vapors from chlorinated solvents can be decomposed by the heat of the arc
(or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating prod ucts.
The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene va pors to form phosgene.
DO NOT WELD or cut where sol vent vapors can be drawn into the welding or cutting at mosphere or where the radiant energy can penetrate to
OM-458 Page 1
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, flame, flying sparks, hot slag or heated mate rial; misuse of compressed gases and cylinders; and short circuits.
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, grease, and (in electrical parts) cause short circuits.
of metallic particles that can
If combustibles ere in area, do NOT weld or cut.
Move the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, venti lators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on work should be
(or cut).
Walls, ceilings, and floor near protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable fire extin guishing equipment during and for some time after weld ing or cutting if: a.
appreciable combustibles (including building construction) are within 35 feet b.
appreciable combustibles are further than 35 feet but can be ignited by sparks c.
openings (concealed orvisible) in floors orwalls within 35 feet may expose combustibles to sparks d.
combustibles adjacent to walls, ceilings, roofs, or metal partitions can be conducted heat.
ignited by radiant or
Hot work permit should be obtained before operation to ensure supervisors approval that adequate precautions have been taken.
After work is done, check that area is free of sparks, glowing embers, and flames~
An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.O, listed
7 in Standards Index.
This includes: a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combusti bles solubility) followed by purging and inerting with ni trogen or carbon dioxide, and using protective equip-
OM-458 Page 2 ment as recommended in A6.O.
Waterfilling just below working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph).
Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before welding or cutting. They can explode.
Explosive atmospheres.
Never weld or cut where the air may contain flammable dust, gas, or liquid vapors
(such as gasoline).
D.
Compressed Gas Equipment
Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-i, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN
DERS, listed 11 in Standards Index.
1.
Pressure Regulators
Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream with one or more equipment.
Provide such protection 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 re pair (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 pressurized, nor returns to stop pin after pressure release.
Repair.
Do NOT attempt to 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 cylinders including third rails, electrical wires, or welding circuits.
They can produce short circuit arcs that may lead to a serious acci dent.
(See 1 -3C.)
ICC or
DOT assurance of marking must be on each cylinder.
It is an safety when the cylinder is properly han dled.
Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content.
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 a cylinder or its contents for other than its intended use, NEVER as a roller.
support or
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 sup port such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture.
Do not al low contents to where exceed 130F.
Cool with water spray 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 open a cylinder valve that can not be opened by hand.
Notify your supplier.
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 nary clamps designed for the hose (not ordi wire or other substitute) as a binding to connect hoses to fittings.
No copper tubing splices.
Use only standard brass fit tings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to~ keep it from being run over, stepped on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con nections. Immerse pressured hose in water; bubbles in dicate leaks.
Repair leaky or worn hose by cutting area out and splic ing (1-2D3).
Do NOT tape.
4.
Proper Connections
Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing outlet away from with people a clean lintless cloth.
and sources of ignition.
Wipe
Match that the regulator to cylinder.
Before connecting, check regulator label and cylinder marking area, and that the regulator inlet and cylinder outlet match. N EVER
CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.
Tighten connections.
When assembling threaded con nections, clean and smooth seats where necessary.
Tighten.
If connection leaks, disassemble, clean, and retighten using properly fitting wrench.
Adapters.
Use a
CGA adapter (available from your sup plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT and
LEFT HAND threads.
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 be fore opening cylinder (or manifold valve) by turning ad justing screw in (clockwise). Draining prevents exces sive compression heat at high pressure seat by allowing seat to open on pressurization.
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 slowly.
When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in fol lowing 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 pressure safe and charts efficient,
(available from your recommended pressure supplier) settings for on regulators.
Check for leaks on first pressurization and regularly there-after.
Brush with soap solution (capfull of Ivory Liq uid* or equivalent per gallon of water).
Bubbles indicate leak.
Clean off soapy water after test; dried soap bustible.
is com
E.
User Responsibilities
Remove leaky or defective equipment from service im mediately for repair.
See User Responsibility statement in equipment manual.
F.
Leaving Equipment Unattended
Close gas supply at source and drain gas.
G.
Rope
Staging-Support
Rope staging-support should not be used for welding or cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-458 Page 3
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 operator invites trouble.
The equipment carries high currents at significant voltages.
The arc is very bright and hot.
Sparks fly, fumes rise, ultraviolet and in frared energy radiates, weidments are hot, and com pressed gases may be used.
The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described here and in stan dards 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 gasshielded arcs are more severe and painful.
DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
1.
Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A).
As nec essary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire-resistant leggings.
Avoid outer garments of untreated cotton.
Bare skin protection.
Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock ets to prevent entry of sparks.
2.
Eye and Head Protection
Protect eyes from exposure to arc.
NEVER look at an electric arc without protection.
Welding helmet or shield containing a filter plate shade no.
12 or denser must be used when welding.
Place over face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY.
Replace clear cover plate when 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 retinal burn that may leave a permanent dark area in the field of vision.
3.
Protection of Nearby Personnel
Enclosed welding area.
For production welding, a sepa rate room or enclosed bay is best. In open areas, sur round the operation with low-reflective, non-combusti ble screens or panels.
Allow for free air circulation, par ticularly at floor level.
OM-458 Page 4
Viewing the weld. Provide face shields for all persons who will be looking directly at the weld.
Others working in area.
See that all persons are wearing flash goggles.
Before starting to weld, make sure that screen flaps or bay doors are closed.
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 may overheat or flash and cause a fire.
Never strike an arc on a cylinder or other pressure ves sel.
It creates a brittle area that can cause a violent rup ture or lead to such a rupture under rough handling.
D.
Compressed Gas Equipment
Comply with precautions in 1 -2D.
E.
Shock Prevention
Exposed hot conductors or other bare metal in the weld ing circuit, or in ungrounded, ment can fatally shock a person whose conductor.
DO NOT electrically-HOT body equip becomes a
STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable protection.
To protect against shock:
Wear dry insulating gloves and body protection.
Keep body and clothing dry.
Never work in damp area without 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 be tween body and an electrically HOT part or grounded metal reduces the electrical resistance, and could en able dangerous and possibly lethal currents to flow through the body.
A voltage will exist between the electrode and any con ducting object in the work circuit.
Examples of conduct ing objects include, but are not limited to, buildings, elec trical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off.
1.
Grounding the Equipment
Arc welding equipment must be grounded according to the National Electrical Code, and the work must be grounded according to ANSI Z49.1
Safety In Welding
And Cutting.
When installing, connect the frames of each unit such as welding power source, control, worktable, and water cir culator to the building ground.
Conductors must be ade quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly fa tally.
Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel.
Three-phase connection.
Check phase requirements of equipment 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 equip ment ground lead to the third (live) wire, or the equip ment will become electrically HOT-a dangerous condi tion that can shock, possibly fatally.
Before welding, check ground for continuity.
Be sure conductors are touching bare metal of equipment frames at connections.
If a line cord with a ground lead is provided with the equipment 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 re ceptacle, the
ground
lead must be connected to the ground prong only.
If the line cord comes with a threeprong
Never plug, connect to remove the a grounded mating receptacle.
ground prong from a plug, or use a plug with a broken off ground prong.
2.
Electrode Holders
Fully insulated electrode holders should be used.
Do
NOT use holders with protruding screws.
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 grease, and protected from hot metal and sparks.
5.
Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units should have insulating covers secured before operation.
6.
Electrode a.
Equipment with output on/off control (contactor)
Welding power sources for use with the gas metal arc welding (GMAW), gas tungsten arc welding (GTAW) and similar processes nor mally are equipped with devices that permit onoff control of the welding power output.
When so equipped the electrode wire becomes electri cally HOT when the power source switch is ON and the welding gun switch is closed.
Never touch the electrode wire or any conducting ob ject in contact with the electrode circuit unless the welding power source is off.
b.
Equipment without output on/off control (no contactor)
Welding power sources used with shielded metal arc welding (SMAW) and similar proc esses may not be equipped with welding output on-off control devices.
With such power equip ment the electrode is electrically HOT when the power switch is turned ON.
Never touch the electrode unless the welding power source is off.
7.
Safety Devices
Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or redtag switches) to prevent accidental
Disconnect all cables from welding turning ON of power.
power source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld ing.
If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing.
Leaving equipment unattended.
Always shut OFF and disconnect all power to equipment.
Power disconnect switch must be available near the welding power source.
F.
Protection For Wearers of Electronic Life Sup port Devices (Pacemakers)
Magnetic fields from high currents can affect pacemaker operation.
Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations.
1-4.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or their latest revisions and comply as applicable:
1.
ANSI Standard
AND
Z49.1, SAFETY IN WELDING
CUTTING obtainable from the American
Welding Society, 550 N.W.
LeJeune Rd, Miami,
FL 331 26.
2.
NIOSH, SAFETY AND HEALTH IN ARC WELD
ING AND GAS WELDING AND CUTTING ob tainable from the Superintendent of Documents,
U.S.
Government Printing Office, Washington,
D.C.
20402.
3.
4.
5.
OSHA, SAFETY AND HEALTH
29CFR
STANDARDS,
1910, obtainable from the Superinten dent of Documents, U.S.
Government Printing
Office, Washington, D.C. 20402.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri can way,
National Standards Institute, 1430 Broad
New York, NY 10018.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-458 Page 5
6.
7.
8.
9.
10.
11.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROC
ESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding
Society, 550 N.W.
LeJeune Rd, Miami, FL 33126.
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association,
Quincy, MA 02269.
Batterymarch Park,
NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protec tion Association, Batterymarch Park, Quincy, MA
02269.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association,
Quincy, MA 02269.
Batterymarch Park,
CGA Pamphlet P-i ,SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
12.
13.
14.
15.
from the Compressed Gas Association, 1235 Jef ferson Davis Highway, Suite 501, Arlington, VA
22202.
CSA Standard W1i7.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
NWSA booklet, WELDING SAFETY BIBLIOG
RAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadel phia, PA 19103.
American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable from the American
LeJeune
Welding Society, 550 N.W.
Rd, Miami, FL 33126.
ANSI Standard Z88.2, PRACTICE FOR RESPI
RATORY PROTECTION, obtainable from the
American National Standards
Broadway, New York, NY 10018.
Institute, 1430
SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
GENERAL INFORMATION AND SAFETY
A.
General
Information presented in this manual and on various la bels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.
The nameplate of this unit uses international symbols for labeling the front panel controls.
The symbols also ap pear at the appropriate section in the text.
B.
Safety
The installation, operation, maintenance, and trouble shooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others.
Therefore, this equipment is to be in stalled,
Sons operated, and maintained only by qualified per in accordance with this manual and all applicable codes such as, but not limited to, those listed at the end of Section 1 Safety Rules For Operation Of Arc Weld ing Power Source.
2-2.
SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are used throughout this manual to call attention to and iden tify different levels of hazard and special instructions.
a This safety alert symbol is used with the signal words WARNING and CAUTION to call atten tion to the safety statements.
a WARNING statements identify procedures or practices which must be followed to avoid seri ous personal injury or loss of life.
a CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.
IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip ment.
OM-458 Page 6
SECTION 3 SPECIFICATIONS
Table 3-1.
Specifications
Rated
Output
At 100%
Duty Cycle
AC
Amperagel
DC Amperage
Ranges Ranges
Fine Adjustment In Each Range
35 to 400 30 to 300
Max.
Open-
Circuit
Voltage
(OCV)
Single-Phase
AC
Auxiliary
Power
Weight
Net Ship
300 Amps At
34 Volts AC
Min.-50
45-75
75-140
130-240
210-Max
Min.-40
35-60
55-100
90-180
150-MaX.
80 AC
72 DC
3
26 kVA/kW 60 Hz
Amps At 1 20V
Or 13 Amps
While
At 240V
Welding
1620 lbs.
(735 kg)
1660 lbs.
(752 kg)
300 Amps At
32 Volts DC
7.5
KVA/KW6O Hz
31 Amps At 120/240V
As A Power Plant
Conforms with NEMAEW1 (ANSI C87.1), ELECTRICARC WELDING POWER SOURCES, Class (1/100)
(
41-1/4 in.*
(1048 mm)
25 in.
(635 mm)
Add 14 in.
(356 mm) for spark arrrestor/mutfier.
C
D
E
F
G
A
B inches
70
64
54
52
40
32
17
Millimeters
1778
1626
1372
1321
1016
813
432
H
J
M
N
K
L inches
15
8
3
23
25
11/16
Millimeters
381
203
76
584
635
17
N
K
Figure 3-1.
Overall DImensions And Base Mounting Hole Locations
SB-086 640-C
OM-458 Page 7
3-1.
VOLT-AMPERE CURVES (Charts 3-1 And 3-2)
/
~
.
RATED WELD OUTPUT
The volt-ampere curves show the voltage and amper age output capabilities of the welding generator.
Curves of other settings fall between the curves shown.
A.
AC Mode
80
70
60
Cl)
50
0
>
40
30
20
10
0
0 100 200 300 400
AC AMPERES
Chart 3-1.
Volt-Ampere Curves
B.
DC Mode
80
70
60
~50
~40
0
~
30
20
10
0
0 500 600
SB-085 283-B
100 200 300 400
DC AMPERES
500 600
SB-085 284.8
A.
AC Mode
I 00
90
80 ci,
I-
-J
0
>
C
-J w
70
60
50
40
U
30
20
0
0
Chart 3-2.
Volt-Ampere Curves With Low Current Control Option
0 20 30
AC WELD AMPS
40 50
SA-Ill 860.A
B.
DC Mode
I 00
90
80
C),
I
0
>
C
-J uJ
70
60
50
40
U
0
30
20
0
0
0 0 20 30
DC WELD AMPS
40 50
SA-111 881-A
OM-458 Page 8
3-2.
DUTY CYCLE (Chart 3-3)
The duty cycle is the percentage of a ten minute period that a welding generator can be operated at a given out put without overheating and damaging the unit. This welding generator is rated at 100% duty cycle when op erated at 300 amperes. The unit can be operated contin uously at rated load without causing damage to the unit.
Refer to the Duty Cycle Chart (Chart 3-3) to determine the output of the welding generator at various duty cy des.
a CAUTION: EXCEEDING DUTY CYCLE RAT
INGS will damage unit.
Do not exceed indicated duty cycle(s).
Chart 3-3.
Duty Cycle
RATED OUTPUT,
600
600
-
~.
(I)
~300
U a.
200 a
-J
U
~160
100
0
10 16 202630 40
Z DUTY CYCLE
6080708090100
SB-085 375-A
3-3.
DESCRIPTION
Rated weld output is 300 amperes at 34 volts ac, or
300 amperes at 32 volts dc.
This unit is a constant current ac/dc arc welding genera tor driven
Continental by a four-cylinder, gasoline water-cooled engine (F-163).
It is
Teledyne designed for
Shielded Metal Arc Welding (SMAW) and Gas Tungsten
Arc (GTAW) Welding.
This unit is specially prepared for operation in harsh and corrosive environments.
The duplex receptacle provides a total of 3 kVNkW, 26 amperes of 120 volts ac
The unit can be auxiliary power while equipped with a
240 volt ac welding.
duplex receptacle that provides 13 amperes of auxiliary power while welding.
The 7.5
kVA/kW ac power amperes at plant
120/240 volts ac can provide up to
31 auxiliary power when not welding.
The following optional equipment can be provided on the welding generator and is covered within this Owners
Manual:
*
*
Remote Amperage Control
Low Current Control
* Tachometer
*
*
Oil Pressure Gauge
Air Cleaner Service Indicator
* Temperature Gauge
* Fuel Gauge
IMPORTANT: Fora complete listing ofAccessories and
Optional Equipment, see back cover of this welding gen erator Owners Manual.
SECTION 4 INSTALLATION OR RELOCATION
IMPORTANT: Read entire Section 12 on equipment that produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in stallation procedures.
IMPORTANT: Unless otherwise specified, all direc tions, such as left or right, are with respect to the opera tor facing the welding generator front panel.
4-1.
LOCATION (Figures 3-1 And 4-1)
A proper installation site should be selected for the weld ing generator if the unit is to provide dependable service and remain relatively maintenance free.
engine EXHAUST GASES can a WARNING: kill.
Operate in open, well-ventilated areas, or if operated indoors, vent engine exhaust out side the building.
Keep engine exhaust ing air intakes.
outlet away from build a CAUTION: RESTRICTED AIRFLOW causes overheatIng and possible damage to Internal parts.
Maintain at least 18 inches (457mm) of unre stricted space on all sides of underside free of obstructions.
unit, and keep
Do not place any filtering intake air passages of this device welding over the generator.
Warranty is void if any type of used.
filtering device is
OM-458 Page 9
The service life and operating efficiency of this unit are reduced when the unit is subjected to extreme levels of dust, dirt, moisture, corrosive vapors, and extreme heat.
A.
Lifting Equipment a WARNING: INCORRECT LIFTING will dam age internal can cause parts; FALLING EQUIPMENT serious personal injury and equipment damage.
Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other heavy options, accessories, or devices.
Use equipment of adequate capacity to lift the unit.
If using lift forks to handle this unit, be sure the lift forks are long enough to extend out of the opposite side of the base.
Using liftforks too short will expose internal com ponents to damage should the tips penetrate the bottom of the unit.
of the lift forks
B.
Mounting Unit Onto Trailer a CAUTION: UNCONTROLLED TILTING OF
TRAILER can result in personal injury or equipment damage.
Install welding generator onto trailer with en gine end toward hitch end of trailer.
Distribute is weight so that trailer tongue weight approximately 10% of the gross trailer weight.
Follow trailer manufacturers instructions when mounting welding generator onto trailer.
OPERATION ON UNLEVEL SURFACE cause severe can improper lubrication and result in engine damage.
Operate unit in an approximately level position.
See Figure 4-1 for maximum allowable tilt for proper operation.
Check crankcase oil level with unit on a level surface.
Exceeding these limits can cause severe engine damage.
Base mounting holes provide the capability to install and secure the unit on a running gear, trailer, transport ve hicle, or in a permanent location.
Figure 3-1 gives over all dimensions and base mounting hole layout.
The mounting location should allow sufficient room to re move the top cover and side panels for maintenance and repair functions.
Use a properly fitting cover
(optional) over the welding generator when not in operation to protect the unit from the environment. Be sure unit is cool before installing any cover.
OM-458 Page 10
Front
Panel
Side View Of Unit
End View Of Unit
S -0024
Figure 4-1.
Allowable Tilt Angles For Welding
Generator Engine
C.
Spark Arrestor Considerations a WARNING: ENGINE EXHAUST SPARKS can cause fire.
Exhaust spark arrestor must be installed in accordance with local, state, and federal regulations.
A spark arrestor/muffler is provided for installation onto the engine exhaust pipe on this welding generator as standard equipment (see Section
4-2).
A spark arrestor, maintained in effective this working order, is mandatory if welding generator is to be operated in a
National
Forest or on covered land
California Grasslands, brush, or forest
(see Section 4442 of California Public
Resources Code).
For other areas, check your state and local laws.
4.2.
SPARK
TION
ARRESTOR/MUFFLER INSTALLA a WARNING: HOT ENGINE PARTS can cause severe burns.
If applicable, stop engine, and allow exhaust system to cool before tension.
installing exhaust ex
1.
2.
3.
4.
Open right side panel, and secure in open tion.
posi
Install spark arrestor/muffler through top cover opening onto exhaust pipe.
(Be sure to face spark arrestor/muffler away from air cleaner; see
Figure
3-1).
Secure spark arrestor/muffler in place with supplied clamp.
Close and secure right side panel.
4-3.
CONNECTING THE BATTERY (Figure 4-2) a WARNING: BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material.
Wear a face shield and proper protective clothing when working with batteries.
ABNORMAL VOLTAGE can cause damage to engine electrical components.
Do not operate connected.
engine without battery
Do not disconnect battenj while engine is running.
IMPORTANT: Be sure
IGNITION switch is in the OFF position before connecting battery.
This unit is equipped with a maintenance-free battery.
To place unit into service, proceed as follows:
1.
Be sure
IGNITION switch is in the OFF position.
2.
Remove bolt from battery access door, and open door (see Figure 4-2).
3.
Connect tive negative () battery cable to the nega battery terminal.
4.
Close and secure access door with bolt.
No other preparation should be required.
If battery does not supply enough power to tery according to Section 9-4.
crank engine, charge bat
Do not refuel if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill expansion.
fuel tank to top; allow room for
IMPORTANT: Fill fuel tank with fresh fuel before starting engine the first time.
Do not fill tank to top, allow room for expansion.
Rust and corrosion preventative was added to inside of fuel tank and engine at the factory and could cause rough engine running if not properly diluted with a full tank of fresh fuel.
This welding generator is shipped with a small amount of fuel in the fuel tank and with the fuel shut-off valve, lo cated under the fuel tank, in the open position.
See the unit maintenance label and
(F-i 63 engine Owners Manual engine) for fuel recommendations. The capacity of the fuel tank is 16 gallons (60 liters).
Chart 4-i illustrates typical fuel consumption under spe cific load conditions.
Fuel consumption varies from one engine to another.
Different brands of fuel, operating conditions, condition of the engine, etc., affect the fuel consumption of this engine.
a CAUTION: POOR
FUEL can
QUALITY, LOW OCTANE damage engine.
Use clean, fresh, unleaded gasoline meeting engine manufacturers specifications (see engine maintenance label for minimum oc tane rating).
Do not mix oil with gasoline,
Do not use gasohol or gasoline alcohol fuel blends.
Gasoline with a lower octane rating than speci fied may cause detonation could damage the engine.
(knocking) which
Regular gasoline may be used; however unleaded gasoline is preferred because it reduces pollution and combustion chamber
Owners Manual for deposits.
See engine complete fuel information.
Chart 4-1.
Fuel Consumption Curve
Right Rear
Corner Of Base
Figure 4-2.
Battery Location
Battery
SB-138 751
4-4.
FUEL (Chart 4-1) a WARNING: REMOVE FUEL CAP
FUEL SPRAY may cause be under pressure.
SLOWLY;
Injury; FUEL may
Rotate fuel cap stops before slowly and wait until removing cap.
hissing
ENGINE FUEL can cause fire or explosion.
Stop engine before checking or adding fuel.
Do not spill fuel; if spilled, wipe up.
I
I
2.50
2.29
2.05
1.37
1.70
1.45
1.29
1.04
0.53
0.52
0.40
0.21
2.75
2.50
2.29
2.00
1.75
1.50
1.29
1.00
0.75
0.50
0.29
cii
DC WELD
0~02O0
AMPERES AT
ID 2.5
4D 50
PON~K~AT ~ox
260300350450
~0X DIJTY CYCLE
9.0
ovry
~.0
~
SB.005 606
OM-458 Page 11
4-5.
LUBRICATION
The engine is shipped with its crankcase filled with SAE
20 break-in oil.
If the oil level is not up to the full mark on the dipstick, add oil in the according to the recommendations engine Owners Manual (F-163 engine) before starting the engine.
4-6.
COOLANT SYSTEM
IMPORTANT: See maintenance label, located on unit, and engine Owners Manual (F163 gasoline engine) for complete engine care information.
The radiator is equipped with a pressurized cap which is rated at 7 psi (48 kPa).
If cap is replaced, be sure replacement cap has a rating of 7 psi (48 kPa).
To remove radiator cap, place rag over cap, and turn cap to an sure almost full open position to allow venting of pres from within the radiator. Allow all pressure to es cape before completely removing the cap.
When operating in temperatures below 0 F (-18 C), the engine may not warm upto operating temperature.
If the engine is run cold, sludge and excess carbon will accu mulate in the engine.
To prevent the engine from running cold in temperatures below 0 F (-18 C), restrict airflow through the radiator.
Airflow may be restricted by using a radiator shutter kit (optional), or covering 1/2 to 2/3 of the radiator with cardboard, plywood, or other material. Do not cover entire radiator because this will cause over heating.
A.
Coolant
The liquid capacity of the coolant system in this welding generator is 9 quarts (8.5 liters).
This unit is shipped from the factory with the proper amount of water and ethylene glycol base antifreeze to permit operation at tern pera tures down to 0 F (-18 C).
IMPORTANT: If unit will be operated in temperatures below 0 F (18 C), ethylene glycol base antifreeze must be added to the coolant system to prevent freezing.
B.
Thermostat a CAUTION: INCORRECT ENGINE TEMPERA
TURE will damage engine.
Do not operate thermostat.
engine without a correct
Replace thermostat immediately if it becomes inoperable.
If thermostat remains closed, the overheat.
If thermostat remains engine will open or the engine is run without a thermostat, the engine will run cold. As a result, sludge and excess car bon will accumulate in the engine.
4-7.
EQUIPMENT GROUNDING TERMINAL (Fig ure
4-3)
EQUIPMENT
GROUND
Normally, engine-driven welding generators do not re quire grounding.
However, this machine has auxiliary power plant capability; therefore, and case is recommended.
grounding of the frame
Also, unusual circum stances may require
Sons a convenient machine grounding grounding.
terminal is
For these provided rea on all weld/power units.
For detailed grounding instructions consult your na tional, regional, and local codes. If additional information regarding your operating circumstances and/or ground ing requirements is needed, consult a qualified electri cian or your dealer. After determining the extent to which any grounding requirements situation, follow them explicitly.
apply to your particular
The coolant system is equipped with a
180 F (80 C) thermostat.
If the thermostat is replaced, be sure that the replacement has an equal temperature rating.
C.
Radiator a WARNING: PRESSURIZED HOT COOLANT
AND STEAM can burn face, eyes, and skin;
REMOVING RADIATOR PRESSURE CAP can cause serious injury.
Allow engine to cool down completely before removing radiator cap.
Wear proper area when gloves, and use a rag over cap removing radiator cap.
Allow all pressure to escape before com pletely removing cap from radiator.
OM-458 Page 12
4-8.
WELD OUTPUT CONNECTIONS (Figure 4-3)
:
0
RATED WELD OUTPUT
To obtain the full rated output from this unit, it is neces sary to select,
Failure to prepare, comply in and install proper any of these areas weld may cables.
result in unsatisfactory welding performance.
Hlgh~Frequency
Assembly
(see Section 9-7)
Electrode Weld
Output Terminal
120V 26AAC
Duplex Receptacle
(see Section 5-3)
Remote
Control
Amperage
Receptacle
Remote Contactor
Control Receptacle
ShieldIng
Gas Valve
Work Weld
Output Terminal
Gas In
Gas Out
SB-086 642-B
Figure 4-3.
Front Panel Connections
A.
Weld Cable Selection
Use the following guidelines to select weld cables:
1.
2.
3.
Use the shortest possible cables, and place
Ca bles close together.
Excessive cable lengths may reduce output or cause unit overload due to added resistance. Excessive cable length also in creases high frequency radiation (see Section
12).
Use weld cable with an insulation voltage rating equal to or greater than the maximum open-cir cuit voltage (ocv) of the welding generator (see
Table 4-1 for unit maximum ocv rating).
Select weld cable size according to maximum weld output and total in weld circuit. For length of connecting cables example, if a 25 foot (7.5 m) electrode holder (torch) cable is used with a
25 foot (7.5 m) work cable, select the cable size rec ommended in Table 4-1 for 50 feet (15 m).
The maximum recommended cable length when us ing high frequency is 50 ft.
(15 m).
4.
Do not use damaged or frayed cables.
B.
Weld Cable Preparation
1.
2.
3.
Install correct size lugs of adequate amperage capacity onto ends of both cables for work clamp, electrode holder if connecting applicable, and weld output terminals.
If applicable, install electrode holder onto weld cable following manufacturers instructions.
An insulated electrode holder must be used to en sure operator safety.
Install work clamp onto cable.
OM-458 Page 13
Table 4-1. Weld Cable Size
Welding
Amperes
100
150
200
250
300
350
400
500
600
Total Cable
100 ft.
Or Less
(30 m)
(Copper) Length In Weld Circuit Not Exceeding*
150 ft.
(45 m)
1
200 ft.
J
(60 m)
250 ft.
(70 m)
1
300 ft.
(90 m)
350 ft.
(105 m)
10 To 60%
Duty Cycle
60 Thru 100%
Duty Cycle
10 Thru 100% Duty Cycle
4
3
3
2
1
1/0
1/0
2/0
3/0
1
1/0
2/0
2/0
3/0
4/0
4
3
2
1/0
2/0
3/0
4
2
1
3/0
4/0
2-2/0
3
1
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
2
1/0
2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2-4/0
1
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
400 ft.
(120 m)
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
*WeId cable size mils per ampere.
(AWG) is based on either a 4 volts or less drop or a current density of more than 300 circular
S-0007/8-88
C.
Weld Cable Connections
ELECTRODE
I.
S
WORK a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from battery before making any weld output connections.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
1.
Open the lower front access door, and route cables between the two horizontal pieces of angle iron on the front of the base.
2.
For Gas Tungsten Arc Welding (GTAW); a.
Connect torch cable or connector to ELEC-
TRODE weld output terminal. Be sure that the torch connector does not touch the access door when closed.
b.
Connect one end of work cable to WORK weld output terminal.
IMPORTANT: Weld polarity is determined by the posi tion of the AC/DC Selector switch (see Section 7-6).
3.
For Shielded Metal Arc Welding (SMAW); a.
Connect end of electrode holder cable to ELEC-
TRODE weld output terminal.
b.
Connect one end of work cable to WORK weld output terminal and piece.
remaining end to work-
OM-458 Page 14
IMPORTANT: Weld polarity is determined by the posi tion of the AC/DC Selector switch (see Section 7-6).
4.
Close and secure access door.
4-9.
REMOTE AMPERAGE CONTROL RECEPTA
CLE(Figure4-3)
REMOTE
AMPERAGE CONTROL
~j A
The 4-socket Remote Amperage Control receptacle, lo cated on the welding generator front panel, is used to connect a
Remote Amperage Control rheostat to the internal circuitry of the welding generator.
To connect the Remote Amperage Control to the Remote receptacle, align keyway, insert the four-prong plug from the Remote Amperage Control into the recep tacle, and rotate the plug clockwise.
4-10.
REMOTE CONTACTOR RECEPTACLE (Fig ure
4-3)
REMOTE CONTACTOR
~
V~
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not touch weld contactor is output terminals when energized.
Do not touch electrode and work clamp at the same time.
The 2-socket REMOTE CONTACTOR receptacle, lo cated on the welding generator front panel, is used to connect the supplied Remote Contactor Control switch to the internal circuitry of the welding generator.
To connect the Remote Contactor Control switch to the
Remote receptacle, insert the 2-prong plug from the Re mote Contactor Control switch into the receptacle, and rotate the plug clockwise.
4-11.
SHIELDING GAS CONNECTIONS (Figure 4.3)
-e
GAS OUT GAS IN
The GAS IN and GAS OUT fittings have 5/8-18 righthand threads
1.
Open lower front access door, and route hoses between the two horizontal pieces of angle iron on front of base.
2.
Connect hose from shielding gas supply regula tor/flowmeter to GAS IN fitting.
3.
Connect shielding gas hose from torch to GAS
OUT fitting.
4.
Close and secure access door.
SECTION 5 AUXILIARY POWER
POWER OUTPUT a WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from battery before internal inspection or reconnection.
making
Ground generator according to al/applicable national, state, and local electrical codes.
Do not connect to any electrical distribution system normally supplied by utility power un less a proper transfer switch and procedure are employed.
grounding
Keep away from moving parts such as fans, belts, and rotors.
Keep all covers and panels in place while operating.
Warranty is void if unit is operated with any portion of the outer enclosure removed.
ELECTRIC SPARKS can cause fire.
Disconnect weld cables when using auxiliary power.
The weld output terminals are electrically energized when the engine is running
Process switch is in the GTAW unless the position and the
Remote Contactor Control switch is open.
Watch for fire.
Keep a fire how to use it.
extinguisher nearby, and know
LOW VOLTAGE AND FREQUENCY can dam age electrical equipment.
Turn off or unplug al/electrical equipment con nected to auxiliary power before starting or stopping the engine.
When starting or stopping, the engine has low speed which causes low voltage and frequency.
5-1.
GENERAL
Calculate load requirements before connecting equip ment to the auxiliary power receptacles or junction box
(see Section 6).
5-2.
AUXILIARY POWER GENERATOR
The 7.5
kVAJkW ac power amperes at plant
120/240 volts ac can auxiliary provide up to 31 power when not welding.
IMPORTANT: This unit is designed to supply ac auxilia ry power only when operating at weld/power rpm.
5-3.
AUXILIARY POWER RECEPTACLES (Chart
5.1
And Figure 7-1)
A.
120 Volts 26 Amperes AC Duplex Receptacle
12OV26A~\j
AC
Rated auxiliary power output is 3 kVNkW of 120 volts ac
60Hz at the 1 20V 26AAC duplex receptacle RC1 Up to
15 amperes can be drawn from either half of the I 20V
26AAC duplex receptacle; however, total load on the du plex receptacle cannot exceed 26 amperes.
The voltage at various loads can be determined from
Chart 5-1.
The combined continuous load of all recep tacles cannot exceed the kVA/kW rating of the genera tor.
B.
Optional 240 Volts 13 Amperes AC Duplex Re ceptacle
Rated auxiliary power output is 3 kVNkW of 240 volts ac
60 Hz at the 240V 1 3A AC duplex receptacle RC2.Up
to
13 amperes can be drawn from either half of the 240V
1 3A AC duplex receptacle.
OM-458 Page 15
Chart 5-1.
AC Power Curve For 120
140 280
130 260
~ 120 ~ 240
110 220
100 200
0
240) Volts
0
0
0
(And Optional
Duplex Receptacle
(No Weld Load Condition)
10
AC AMPERES IN 240V MODE
10 20 30 40
AC AMPERES IN 120V MODE
50
SB-005 192-B
C.
Connections
The 120 and optional 240 volts ac duplex receptacles are for use with cord-connecting accessory equipment.
Plug in or turn on equipment when engine is running at weld/power speed.
D.
Overload Protection
OVERLOAD BREAKER
FOR AC RECEPTACLE
00
WARNING: ELECTRIC SHOCK can kill.
.
Do not touch live electrical parts.
Stop engine, and battery cable from disconnect negative () battery before inspecting, maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
HOT engine PARTS can cause severe burns.
Wear protective gloves and clothing when working on a hot engine.
Maintenance to be performed only by qualified persons.
IMPORTANT: All directions, such as left or with respect to the operator facing the right, are welding generator front panel.
Retain all hardware removed during this pro cedure for rein stallation.
1.
2.
3.
4.
5.
Open right side doors, and secure in open posi tion.
Remove right side panel.
Remove center bolt from insulation board (see
Figure 5-1); remove and retain insulation board.
Remove the 120V 26A AC from the front duplex receptacle panel, and disconnect leads 1, 3, and 42 from the receptacle.
Reconnect leads 1 and 3 to the 240 volts ac du plex receptacle (one on each side of receptacle).
Reconnect lead 42 to the ground (green) terminal on the receptacle.
Overload breakers CBI and CB2 are provided to protect the welding generator from overload and fault condi tions. if either half of the 1 20V duplex receptacle is over loaded, both overload breakers trip and the entire recep tacle becomes inoperative.
If either half of the optional
240V duplex loaded receptacle is overloaded, only the over receptacle half becomes inoperative; the re maining receptacle portion is fully operational.
If it be comes necessary to reset
Section 10-3.
the overload breakers.
see
5.4.
FIELD INSTALLATION INSTRUCTIONS FOR
240 VOLTS DUPLEX RECEPTACLE (Figures
5-1 And 5-2)
A voltage changeover terminal strip, located behind the right side panel, provides reconnection capability for 240 volts ac.
Although the capability for 240 volts ac is pres ent, an optional kit must be purchased if 240 volts is de sired at the front panel.
For the 240 volts auxiliary power output of the unit, see
Section 5-3B.
OM-458 Page 16
Insulation Board
R&. S-0502
Figure 5-1.
Location Of Reconnectable
Components
6.
7.
8.
9.
10.
11.
12.
13.
Install the 240 volts ac receptacle in the front panel.
Affix the 240V 1 3A AC label over existing 1 20V
26A AC designation on the nameplate.
Move lead 3 (see Figure 5-2) from terminal B on the changeover terminal strip to terminal A.
Position the jumper links on the changeover ter minal strip for 240 volts (see Figure 5-2).
Reinstall insulation board.
Reinstall right side panel.
Reconnect negative () battery cable.
Close and secure right side doors.
120 Volts AC (Standard) 240 Volts AC (Optional)
Ref.
S-0503
Figure 5-2.
Jumper Link Arrangement On Terminal
Strip TEl For 120 And 240 Volts AC
A
B
C
D
5-5.
7.5
KVA/KW POWER PLANT (Chart 5-2 And
Figure 5-3)
A.
General
The terminals, located behind the left side door, provide
7.5
kVA/kW of 120/240 volts ac, 31 amperes, 60 Hz sing le-phase ac power for operating 50/60 or
60 Hz power tools or providing standby service to rural, residential, or other buildings requiring 120/240 volts ac,
3 wire con nection.
The voltage at the 120/240 volts ac terminals will vary according to the applied load. The voltage at various loads can be determined from Chart 5-2.
Chart 5-2. AC Power Curve For 120/240 Volts AC
Terminals (No Weld Load Condition)
260
250
240
(I)
0
>
230
220
210
200 o to 20 30 40 50 60 70 80 90 100 110
AC AMPERES
SB-005 185-A
Junction
Lead 42
Shipped Unconnected r
\
94 llV24oVl
91
__
O~~,(~\OI~
l~1l
120V
I
-I
I-
Left Side Of
FIgure 5-3.
Power Plant Connections
Junction Box
SC-121 578
S-0559
OM-458 Page 17
B.
Connection Procedure a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Keep junction box cover in place while engine is running.
Stop engine, and disconnect negative () battery cable from battery before making connections or changing fuses.
Ground in accordance with NEC, state, and local codes; install circuit grounding lead (in side junction box) to box mounting hardware, and be sure that a proper ground is connected to the Equipment vided on the
Grounding Terminal pro equipment frame (see Figure
7-1).
INCORRECT FUSES can cause damage~ equipment
Use only fuses of correct size, type, and rating
(see Parts List).
IMPROPER VOLTAGE OR FREQUENCY can damage equipment.
Read all equipment instruction manuals before making connections.
Use only equipment suitable for operation on
50/60 or
60 Hz power.
Turn off or disconnect electrical equipment from 120/240 volts fuse block before starting or stopping the engine.
Place the AUTO IDLEswitch in the OFF posi tion.
Rotate AMPERAGE & VOLTAGE ADJUST
MENT control to 100.
7.
8.
9.
3.
4.
1.
2.
5.
6.
Open left side door, and secure in open position.
Remove cover from junction box.
Install circuit grounding lead if required.
Remove snap-in blank from junction box.
Install proper connector (not supplied) into open ing, and route load leads through connector into junction box.
Strip approximately 3/4 inch (19 mm) of insulation from ends of terminals (see leads, and connect to proper load
Figure 5-3); tighten connections securely.
Reinstall cover onto junction box.
Reconnect negative () battery cable.
Close and secure left side door.
6-1.
AUXILIARY POWER GENERATORS
A.
Introduction
The auxiliary power generated from this unit is most commonly used in industrial, small business, and resi dential applications.
For industrial applications, this por table unit can be moved to the job site to power portable tools, lights, compressors, etc.
For small business and residential applications, the generator supplies standby power during power outages.
It is the installers .responsibility
to follow all applicable codes when installing an auxiliary power generator.
It is also the installers responsibility to determine if the gen erator is capable of supplying adequate power for a spe cific application.
The following sections provide some guidelines for the installation and operation of an auxilia ry power generator.
IMPORTANT: Consult qualified local personnel and fol low all applicable codes for safe and proper installation.
B.
Safety Considerations
Before this generator may be used to supply auxiliary power, the installer must first become familiar with and meet all codes applicable to the installation of an auxilia ry power generator.
It is the installers follow the responsibility to applicable rules from the National Electrical
Code (NEC), state, local, and OSHAcodesforthe instal
OM-458 Page 18
SECTION 6 EVALUATING AUXILIARY POWER REQUIREMENTS lation and use of auxiliary power generators.
The follow ing list includes major safety requirements of NEC for auxiliary power generator installation.
1.
Isolation is always required between a portable generator and other sources of electric power.
Proper isolation procedures prevent possible in jury due to feedback from the generator to the pri mary source of electric power. Consult qualified local personnel and follow all applicable codes for safe and proper installation.
2.
3.
Overcurrent protection
, such as fuses or circuit breakers, is required if a generator is supplying a permanent installation.
Overcurrent protection may not be required for generators supplying por table, cord-connected equipment through recep tacles mounted on the generator.
Overcurrent protection may be factory installed if the generator design and/or receptacle(s) require overcurrent and protection.
If the generator design receptacle(s) protect themselves from overcurrent conditions, circuit protection is not re quired and, thus, not factory installed.
Grounding requirements depend upon the op erating setup for the generator.
If the generator supplies only equipment mounted on the genera tor, or cord-connected equipment ator-mounted through gener receptacles, the generator frame
4.
does not require grounding.
If the generator is mounted on a vehicle, the vehicle and frames must be connected.
If the generator generator is supplying a permanent installation or some that does not meet the load mounting or receptacle connection exclusion, the generator frame and one of the supply conductors may have to be grounded (refer to local codes for specific require ments).
A grounding terminal is normally provided on the generator for grounding the generator case.
To ground the generator case, locate grounding ter minal, connect one end of ground cable to grounding terminal, and connect remaining end to a proper earth cable ground using adequate size
(refer to NEC for specific requirements).
When a conductor within the generator requires grounding, a grounding terminal is normally pro vided within the generator.
a.
Ground fault protection for personnel on con struction sites must be provided with one of the following methods:
Ground fault circuit interrupters (GFCIs) are required on all 15 and 20 ampere 120 volt recep tacles not part of permanent wiring, and on all receptacles with a grounded neutral conductor.
GFCIs are generally not required on portable and vehicle-mounted generators rated not more than 5 kW with circuit conductors isolated from the frame, and on generators not connected to
15 or
20 ampere, 120 volt receptacles.
6-2.
b.
An may assured equipment grounding program be used instead of GFCIs to provide ground fault protection for personnel on con struction sites. Refer to NEC for specific pro gram procedures.
LOAD EVALUATION (Tables 6-1 And 6-2)
Before connecting or operating the auxiliary power gen erator, the installer must determine if the generator is ca pable of supplying adequate power for a specific appli cation. Load and generator evaluation is essential for satisfactory generator and equipment operation (see
Table 6-1).
A.
Types Of Loads
Load requirements depend on the type of load con nected to the generator.
There are two types of loads, re sistive and non-resistive.
A resistive load, such as a light bulb, requires a constant amount of power from the gen erator. A non-resistive load, such as a portable grinder, requires variable amounts of power from the generator.
Because a grinder requires more power for motor start ing and is rarely used with a constant, even pressure, the load requirements can change greater than the oper ator anticipates.
The following sections provide information on how to de termine running load and motor-starting requirements
(see Sections 6-2B and C).
B.
Running Load Requirements
The total running load applied to the generator is calcu lated by adding up all the individual loads.
Some equip ment is ments rated in amperes, for most equipment others in watts.
The are provided on its require name plate.
EXAMPLE 1: If a drill requires 4.5 amperes at 115 volts, calculate its running power requirement in watts.
VOLTS x
AMPERES
=
WATTS (EQUATION 1)
(Equation 1 provides an actual power requirement for resistive loads, or an approximate running requirement for non-resistive loads.)
115V x
4.5A
=
520W
Therefore, the individual load applied by the drill is 520 watts.
EXAMPLE 2: If a flood lamp is rated at 200 watts, the individual load applied by the lamp is 200 watts. If three
200 watt flood lamps are used with the drill from Example
1, add the individual loads to calculate total load.
(200W
+
200W
+
200W)
+
520W
=
1120W
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.
C.
Motor-Starting Requirements
Starting amperage requirements are many times the running amperage of the motor.
Starting requirements must be determined to assure that the generator is capa ble of starting the motor without damaging it. This can be done by examining the motor nameplate and identifying the code letter specifying the starting kVNHP required.
Table 6-2 lists common motor start codes with their start ing kVAHP requirement.
If the kVNHP requirement, motor horsepower, and volt age rating are known, the starting amperage can be cal culated.
EXAMPLE 3: Calculate the starting amperage required for a
230V, 1/4 HP motor with a motor start code of G.
Calculate the equation: starting amperage using the following kVAIHP xHP x
1000
VOLTS
(EQUATION 2)
STARTING AMPERAGE
Volts
=
230
HP
=
1/4
Using Table 6-2, Code G results in kVNHP
=
6.3
6.3
xl/4 x
1000
230
=
6.85A
Therefore, starting the motor requires 6.85 amperes.
OM-458 Page 19
INDUSTRIAL MOTORS
Split Phase
Capacitor Start-
Induction Run
RATING
1/8 HP
I/S HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1
HP
1-1/2 HP
2HP
3HP
5 HP
APPROXIMATE
STARTING WATTS
800
1225
1600
2100
3115
2020
3075
4500
6100
8200
10550
15900
23300
Table 6-1. Power Requirements*
APPROXIMATE
RUNNING WATTS
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
FARM EOUIPMENT
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevalor
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std.
(e.g. Conveyora.
Feed Augera.
Air
Compressors)
A ING
1/4 HP
1/2 HP
3/4 HP
2 HP
Capacitor Start-
Capacitor Run
1-1/2 HP
S HP
7-1/2 HP
IOHP
8100
23300
35000
46700
2000
6000
8000
10700
High Torgue )e g. Barn
Cleanera. Silo Unloadera.
Silo Hoiata.
Bunk Feeders)
Fan Duty 1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1000
1400
1850
2400
3500
400
550
650
800
1100
3-1/2 Cu. Ft. Miaer
High Pressure 1.8
Gal/Mm
Wanher 2 Gal/Mm
2 Gal/Mm
.
CONTRACTOR
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compreaaor
Electric Chain Saw
Electric Trimmer
Electric Cuflivator
Elec.
Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 Gel.
Drum Miaer
Wet & Dry Vac
RATING
1/4
3/8
1/2
6-1/2
7-1/4
8-1/4
9
10
14
6
8
10
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12
2 HP, 14
Standard 9
Heavy Duty 12
1/3 HP
-
18
HtD
Metal Halide
Mercury
& Sodium
Vapor
400 GPH
900 GPH
3/4 HP, 16
1 HP, 20
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7
HP
2-1/2 HP
APPROXIMATE
STARTING WATTS
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
350
400
600
500
900
1400
4500
6300
400
125
313
APPROXIMATE
RUNNING WATTS
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
350
400
600
500
900
1400
1500
1800
Coffee Maker
Elec.
Range
Microwave
Television (Solid-Stale)
Radio
Rehig.
Or Freezer
Shallow Well Pump
Sump
RESIDENTIAL
Pump
Dishwasher
Clothea Dryer
Automatic Waaher
Gaa Or Fuel Oil
Furnace Blower
Central Air Conditioner
1000 1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
1000
200
500
1400
1800
950
1400
1600
700
900
1300
Garage Door Opener
Electric Blanket
Dehumidifier
Vacuum Cleaner
Lights
Toaster
Hair Dryer
Iron
Motors require up to two or three times their starling wattage when starting under load.
1/8 HP
1/8 HP
1/4 HP
1/3 HP
1/2 HP
10,000 BTU
20,000 BTU
24.000
BTU
32,000 BTU
40,000 BTU
1/4 HP
1/3 HP
Portable
Standard
Deluae
2 Slice
4 Slice
1/3 HP
1/2 HP
3/4 HP
1
HP
1-1/2 HP
2HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
1OHP
1/2 HP
500 PSI
550 P51
700 PSI
APPROXIMATE
STARTING WATTS
1000
1650
3400
4400
2900
10500
APPROXIMATE
RUNNING WATTS
1000
650
1000
1400
1100
2800
23300
35000
46700
3300
3150
4500
6100
1720
2575
4500
6100
8200
10550
15900
23300
8100
RAT ING
6 Element
8 Element
Oven
625W
B & W
Color
1/3 HP
1/2 HP
1/3 HP
1/2 HP
(Cool Dry)
(Hot Dry)
Gas
Electdc
APPROXIMATE
STARTING WATTS
1750
1500
2100
6000
2800
100
300
50-200
3100
2150
3100
2100
3200
2100
2850
2500
7550
3450
APPROXIMATE
RUNNING WATTS
1750 Typ.
1500
1000
800
1050
700
1450
700
5750
1150
2100
6000
2000
100
300
50-200
800
750
5800
8750
11500
13800
1650
2125
400
1450
800
1100
~
800
1250
1600
2100
3225
3700
1050
1850
300-1200
1200
300
500
600
700
875
1500
2500
3800
5000
6000
550
725
400
650
800
1100
As Indicated
On Bulb
1050
1650
300-1200
1200
2000
6000
8000
10700
1000
950
1400
1600
720
975
1400
1600
2200
2850
3900
6800
OM-458 Page 20
Table 6-2.
Single-Phase Induction Motor Starting
KVA/HP Requirements
Motor Start
Code Letter
N
~P
L
M
J
K
0
H
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
If a code letter is not present on the motor nameplate, ap proximate starting amperage is equal to six times run ning amperage. This is a reasonable approximation for all applications where the generator rated amperage is at least twice the motor requirement.
If the generator-tomotor-size ratio is less than 2:1, acquire the needed in formation to properly determine the motor-starting re quirement.
6-3.
GENERATOR CAPABILITY
A.
Auxiliary Power Output
Different types of loads require different types of output.
When a nonmotor load is applied, generator output goes to the ampere requirement of the equipment.
When a motor load is applied, the generator attempts to supply motor-starting amperage causing output to drop to a low voltage because the starting amperage is many times the running amperage.
The total load requirements must not exceed the gener ator capability.
When combining motor (non-resistive) and resistive loads, compare the total load required by the equipment to the generator output.
Limit load re quirements to the capabilities of the generator.
For best performance and load handling, only use approximately
90% of the available output.
The 10% margin allows for more satisfactory engine governor response to chang ing load situations. When loading the generator, always apply the largest non-resistive (motor) non-resistive loads in succession from load largest first, add to small est, and add resistive loads last.
B.
Operation
It is the installers responsibility to follow all applicable safety codes and guidelines for the installation and oper ation of an auxiliary power generator.
Always start engine and bring up to speed before starting any auxiliary equipment connected to the auxiliary power receptacles or junction box. Before stopping the engine, be sure to turn off the auxiliary equipment.
The installer should check for proper generator/load op eration.
If a motor does not start within 5 seconds, turn off power to it or the motor will be damaged.
This 5-sec ond-maximum-time rule should be applied to all motor starting situations to prevent damage to the start wind ing.
If 90% of rated voltage is present across the mo tor terminals when running under load, then it is safe to assume that it is properly running within the capabilities of the generator.
6-4.
STANDBY POWER CONNECTIONS (Diagram
6-1)
The block diagram shown in Diagram 6-1 includes the proper equipment and connections required for the gen erator to supply standby power during emergencies or power outages.
IMPORTANT: Consult qualified local personnel and fol low all applicable codes for safe and proper installation.
The following step numbers match the circled numbers within Diagram 6-1.
1.
2.
Locate the power company or service meter, dis connect switch, and main overcurrent protection.
If necessary, obtain and install a double-pole, double-throw transfer switch between the service meter and disconnect switch.
IMPORTANT: Double-pole, double-throw transfer switch rating must be the same as or greater than the main overcurrent protection.
3.
If necessary, obtain and install circuit breakers or fused disconnect switch to protect generator from overload conditions.
4.
5.
6.
7.
Select conductors of adequate amperage capac ity for the current rating of the generator and overcurrent protection (see Section 6-5).
Install terminals or plug of adequate amperage capacity onto end of cable.
Make connections safety practices.
according to all codes and
Turn off or unplug all auxiliary equipment con nected to generator before starting or stopping engine.
When starting or stopping, the engine has low speed which causes low voltage and frequen cy.
For best load to performance and load approximately handling,
90% of the available limit
Out put.
OM-458 Page 21
120/240 Volt
60Hz
Three-Wire
Service
I
Neutral Conductor
240V
Double-Pole,
Double-Throw
Transfer Switch
Load
Ground Conductor
Conductors Of
Extension Cord e
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
IMPORTANT: Circled numbers match steps in Section 6-4.
S-0405
Diagram 6-1.
Standby Power Equipment And Connections
OM-458 Page 22
6-5.
AUXILIARY POWER EXTENSION CORD
SELECTION (Tables 6-3 And 6-4)
Extension cords may be necessary if to tools or load a distance from the power is supplied generator.
Select cords of adequate amperage capacity, and use the fol lowing Tables 6-3 and 6-4 to select conductor size ac cording to cord length.
Use the shortest cords possible because cause excessive cord lengths may reduce output or unit overload due to added resistance.
Table 6-3.
Cord Lengths For 120 Volt Loads
4
Maximum Allowable Cord
For
Length In Feet (Meters)
Conductor Size (AWG)*
6 8 10 12 14
Current In
Amperes
5
Load In
Watts
600
7
10
15
20
25
30
35
40
45
50
840
1200
1800
2400
3000
3600
4200
4800
~
5400
6000
400
(122)
300
(91)
225
(68)
175
(53)
150
(46)
125
(38)
112
(34)
100
(30)
87
(26)
75
(23)
62
(19)
62
(19)
137
(42)
112
(34)
87
(26)
50
(15)
400
(122)
275
(84)
175
(53)
*Conductor size is based on maximum 2% voltage drop
87
(26)
62
(19)
50
(15)
50
(15)
37
(11)
350
(106)
250
(76)
175
(53)
112
(34)
225
(68)
150
(46)
112
(34)
75
(23)
50
(15)
37
(11)
37
(11)
137
(42)
100
(30)
62
(19)
37
(11)
30
(9)
100
(30)
62
(19)
50
(15)
30
(9)
OM-458 Page 23
Table 6-4. Cord Lengths For 240 Volt Loads
4
Maximum Allowable Cord
For
Length In Feet (Meters)
Conductor Size (AWG)*
6 8 10 12 14
Current In
Amperes
Load In
Watts
5 1200
7
10
15
20
25
30
35
40
45
50
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
300
(91)
250
(76)
225
(69)
200
(61)
175
(53)
800
(244)
600
(183)
450
(137)
350
(107)
800
(244)
550
(168)
350
(107)
150
(46)
125
(38)
125
(38)
100
(31)
275
(84)
225
(69)
175
(53)
*Conductor size is based on maximum 2% voltage drop
700
(213)
500
(152)
350
(107)
225
(69)
175
(53)
125
(38)
100
(31)
100
(31)
75
(23)
450
(137)
300
(91)
225
(69)
150
(46)
100
(31)
75
(23)
75
(23)
225
(84)
200
(61)
125
(38)
75
(23)
60
(18)
200
(61)
125
(38)
10
(31)
60
(18)
SECTION 7OPERATOR CONTROLS
IMPORTANT: Once a week move all controls and switches through their entire sequences. This procedure cleans switch contacts and provides better general performance and less downtime, especially in corrosive or dirty environments.
7-1.
PROCESS SWITCH (Figure 7-1)
SMAW
ALt~I,
______
GTAW
WARNING: ELECTRIC SHOCK
Do not touch live electrical parts.
OM-458 Page 24 can kill.
Do not touch weld contactor is output terminals when energized.
Do not touch electrode and work clamp at the same time.
Open-circuit voltage is present at the weld output termi nals whenever the engine is running and the Process switch is in the SMAW position or in the GTAW position and the contactor is
energized.
Placing the Process switch in the GTAW position pro vides high frequency, shielding gas, and contactor con trol with use of a
Remote Contactor Control Switch.
Placing the Process switch in the SMAW position allows use of the automatic idle circuitry and disconnects the high frequency, shielding gas control, and contactor con trol circuits.
AC/DC Selector
Switch
High-Frequency
Switch
Amperage And Voltage
Adjustment Control
Overload Breakers
(see Section 10-3)
Range Switch
Auto Idle Switch
Postflow Timer
Safety Shutdown
Switch
Ignition Switch
Battery Charging
Light voltmeter
Ammeter
Remote Amperage
Control Switch
Choke Control
IMPORTANT: For remaining front panel components, see Figure 4-2.
SB-086 842-B
Figure 7-1.
Front Panel Controls
7-2.
AMPERE RANGES SWITCH (Figure 7-1) ss
/
DO NOT SWITCH UNDER LOAD
The AMPERE RANGES switch provides five coarse ac and dc amperage ranges. The range of each switch po sition is displayed on the nameplate.
ARCING can damage switch a CAUTION: contacts.
Do not change the position of the AMPERE
RANGES switch while welding or under load.
Arcing causes the contacts to become pitted and eventually inoperative.
7-3.
AMPERAGE & VOLTAGE ADJUSTMENT
CONTROL (Figure 7-1)
AV
AMPERAGE & VOLTAGE
ADJUSTMENT
The AMPERAGE & VOLTAGE ADJUSTMENT control permits the operator to select a welding amperage and open-circuit voltage between the minimum and mum values of the course range selected by the maxi
Range switch.
The scale surrounding the AMPERAGE & VOLT
AGE ADJUSTMENT control is calibrated in percent and does not indicate an actual amperage value.
IMPORTANT: The AMPERAGE & VOLTA GEADJUST
MENT control may be adjusted while welding.
OM-458 Page 25
IMPORTANT: The AMPERAGE & VOLTAGEADJUST
MENT control must be rotated to the 100 (maximum) po sition whenever the 7.5
kVA,/kW ac power plant is used.
The AMPERAGE & VOLTAGE ADJUSTMENT control may be in any position when using the 120V 26A or op tional 240V 13A AC duplex receptacle.
7-4.
REMOTE AMPERAGE CONTROL SWITCH
(Figure 7-1)
REMOTE
AMPERAGE CONTROL a WARNING: ELECTRIC SHOCK can kill.
Do not use
AC output in damp areas, if move ment is confined, or if there is a danger of falling.
Use AC output ing process.
ONLY if required for the weld
If AC output is required, use remote output control.
Read and follow Safety Rules at beginning of this manual.
ION
Q
OFF
If remote amperage control is desired, make connec tions to the Remote Amperage Control receptacle (see
Section 4-9), and place the REMOTE AMPERAGE
CONTROL switch in the ON position.
The Remote Con trol adjusts output from minimum to maximum of the se lected range of the Ampere Ranges switch.
If remote amperage control is not desired, place the RE
MOTE AMPERAGE CONTROL switch in the OFF posi tion.
7-5.
REMOTE CONTACTOR CONTROL SWITCH a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not touch weld contactor is output terminals when energized.
Do not touch torch or clamp at the same time.
electrode and work
The Remote Contactor Control switch functions when the Process switch is in the GTAW position.
If remote contactor control is desired, make connections to Remote Contactor Receptacle (see Section 4-10), close the Remote Contactor Control Switch, and high frequency, shielding gas, and weld output are available.
When the Remote Contactor Control switch is opened, high frequency and weld output stop, and the POST-
FLOW begins to time.
7-6.
AC/DC SELECTOR SWITCH (Figure 7-1)
DC REVERSE
ELECTRODE POS.
DC
STRAIGHT
ELECTRODE
NEG.
AC damage switch a CAUTION: ARCING can contacts.
Do not change the position of the AMPERE
RANGES switch while welding or under load.
Arcing causes the contacts to become pitted and eventually inoperative.
The AC/DC Selector switch provides a means of select ing AC, DC STRAIGHT/ELECTRODE NEG.
polarity, or
DC REVERSE/ELECTRODE POS.
polarity output with out changing weld output cable connections. To ensure that weld output corresponds to the dc polarity positions, connect the electrode holder/torch connector to the
ELECTRODE terminal and the work cable to the WORK terminal..
7-7.
HIGH-FREQUENCY SWITCH (Figure 7-1)
High frequency is used during Gas Tungsten Arc Weld ing (GTAW) to aid in starting and maintaining the arc.
HIGH
FREQUENCY a WARNING: USING HIGH FREQUENCY WITH
THE SHIELDED METAL ARC WELDING
(SMAW) PROCESS can result in serious per sonal injury.
Place the HIGH FREQUENCY switch in the
OFF
Arc position before using the Shielded Metal
Welding (SMAW) process.
The attempted use of lish an arc with a high frequency to estab stick electrode could cause an arc to form between the electrode holder and op erator.
The HIGH FREQUENCY switch allows the operator to choose whether high frequency will be used or not and for how long.
This switch has four positions: START,
OFF, and CONTINUOUS.
DO NOT SWITCH UNDER LOAD
OM-458 Page 26
A.
START Position
!
START
High frequency is present from the time the contactor is closed until an arc is established.
Once an arc is estab lished, high frequency is no longer present.
High fre quency is present any time the arc is broken to aid in re starting the arc as long as the contactor is energized.
B.
OFF Position
0
OFF
High frequency is not present.
The HIGH FREQUENCY switch must be in the OFF position while doing Shielded
Metal Arc Welding (SMAW) or when high frequency is not desired.
C.
CONTINUOUS Position
CONT.
High frequency closed is present throughout the whenever welding the contactor is operation until the con tactor opens. When the contactor opens, high frequency is not present until the contactor closes again.
7-8.
POSTFLOW TIMER (Figure 7-1)
.
S
/t2
The POSTFLOW TIMER control provides 0 to 60 sec onds of gas flow after the arc is extinguished by opening the Remote Contactor Control. The scale surrounding the POSTFLOW TIMER control is calibrated in percent and does not indicate an actual time in seconds.
Rotat ing the POSTFLOW TIMER clockwise increases postflow time.
7-9.
METERS
The meters are tion.
provided to monitor the welding opera
They are not intended for exact amperage or volt age measurements.
nected to the output
These meters are terminals.
The internally con voltmeter indicates the voltage at the output terminals, but not necessarily the actual voltage at the welding arc
(due to cable resis tance, poor connections, etc.).
The ammeter indicates the amperage output of the unit.
7-10.
CHOKE CONTROL (Figure 7-1)
CHOKE
N
The CHOKE control varies the fuel-air mixture to the en gine.
When the CHOKE control is pulled fully out, very little air will be admitted to the engine through the carbu retor thereby supplying a richer mixture of fuel. This po sition is required if the engine is cold when started.
As the engine warms up, push the CHOKE control inward slowly as far as it will go.
When the CHOKE control is ful ly in and the engine is warmed up, the engine should be ready for loading.
7-11.
START PUSH BUTTON AND IGNITION
SWITCH (Figure 7-1)
~ON
~OFF
IGNITION
O
START a CAUTION: REENGAGING THE STARTER
MOTOR while flywheel Is rotating or
EXCEEDING RATED CRANKING TIME can damage starting components.
Do not reengage starter motor until starter pinion and flywheel have stopped rotating.
Placing the IGNITION switch in the ON position ener gizes the fuel system circuit. When the IGNITION switch is in the ON position, holding the Low Oil Pressure And
High Coolant Temperature Shutdown System Switch closed and depressing the START push button engages the starter motor and starts the engine.
Once the engine has started, release the START push button.
Placing the IGNITION switch in the OFF position shuts down the engine.
The IGNITION switch must be left in the OFF position when the engine is not running to pre vent the battery from discharging.
7-12.
LOW OIL PRESSURE AND HIGH COOLANT
TEMPERATURE SHUTDOWN
SWITCH (Figure 7.1)
SYSTEM
The Low Oil Pressure And
Shutdown
High Coolant Temperature
System Switch will automatically shut down the engine if oil pressure drops to an unsafe level or the coolant the temperature becomes too high.
When starting engine, depress the Low Oil Pressure And High
Coolant Temperature Shutdown System Switch and hold in until the engine starts and the OIL & TEMP.
light goes off.
OM-458 Page 27
This switch is of the switch protected by fuse F located on the bottom assembly directly behind the front panel.
Should this fuse open, the engine will not start.
See Sec tion 10-3 for fuse replacement procedure.
7-15.
ENGINE TEMPERATURE AND OIL PRES
SURE LIGHT (Figure 7-1)
7-13.
AUTO IDLE SWITCH (Figure 7-1)
AUTO
IDLE
The automatic idling device saves fuel by allowing the engine to idle when the welding generator is not loaded.
The AUTO IDLE switch controls the operation of this de vice. This switch~ has two positions: ON and OFF.
A.
ON Position
When the AUTO IDLE switch is in the ON position, the engine will remain at idle speed (1200rpm) until an arc is struck or load applied to the duplex receptacle.
When an arc is struck or load applied to the duplex receptacle, the engine speed will increase to weld/power rpm
(1850).
Approximately 10 seconds after the arc is broken or load is removed, the engine will return to idle rpm. This time delay is nonadjustable.
B.
OFF Position
OFF
When the AUTO IDLE switch is in the OFF position, en gine speed remains at governed weld/power rpm
(1850) when the generator is not loaded. This used when the 7.5
kVAJkW power position plant must be is used.
7-14.
BATTERY CHARGING LIGHT (Figure 7-1) t:~i
BATTERY
The BATTERY charging light turns on when the engine battery charge current is not flowing.
It is normal for the light to turn on when the IGNITION switch is in the ON position and the engine is NOT operating.
IMPORTANT: If this light comes on while the engine is running, immediately shut down the mine the cause.
Do not attempt to engine operate and deter the engine again until the trouble has been remedied.
OM-458 Page 28
OIL & TEMP.
The OIL & TEMP.
creases light turns on if the oil pressure de below 8 psi (55 kPa) or if the coolant tempera ture increases above 240F (116C).
Itis normal for the light to turn on when the IGNITION switch is in the ON position and the engine is NOT operating.
7-16.
ENGINE HOURS METER (Figure 7.1) t
ENGINE HOURS
The engine HOURS meter registers the total hours of engine operation.
This information is useful for routine maintenance on the engine.
7-17.
LOW CURRENT CONTROL (Optional)
The Low Current Control option provides selection of weld output from 5 to 40 amperes ac/dc in one of three current ranges. See
Volt-Ampere curves for Low Current
Control option (Chart 3-2).
The LOW CURRENT CONTROL is protected by a car tridge-type fuse F3 located behind the right side panel on the rear of the opens, weld high frequency control panel.
If the fuse output in the low current range stops.
See
Section 10-3 for fuse replacement procedure.
A.
LOW CURRENT CONTROL Switch
Place the LOW CURRENT CONTROL switch in the IN position to obtain the low current ranges. Place the LOW
CURRENT CONTROL switch in the OUT position to dis connect Low Current Control.
B.
RANGE SELECTOR Switch
ARCING can damage switch a CAUTION: contacts.
Do not change the position of the AMPERE
RANGES switch while welding or under load.
Arcing causes the contacts to become pitted and eventually inoperative.
IMPORTANT: if welding current in excess of 40 am peres is required, use the standard ranges available on the front panel.
When Range switch is in the Minimum position and LOW
CURRENT CONTROL switch is in the IN position, the
RANGE SELECTOR switch provides selection of weld output from 5 to 40 amperes ac/dc in one of three low current ranges. AMPERAGE & VOLTAGE ADJUST
MENT control provides adjustment of the amperage out put from minimum to maximum of each coarse low cur rent range.
7-18.
TACHOMETER (Optional)
The tachometer, located on the radiator enclosure, registers engine speed from 0-3000 rpm.
7-19.
OIL PRESSURE GAUGE (Optional)
The optional Oil Pressure gauge registers the system pressure in lubricating pounds per square inch
(psi).
The pressure registered by the gauge should remain constant for a given engine speed.
If the oil pressure fluctu ates or drops, stop the engine, and do not operate until the trouble has been corrected.
7-20.
TEMPERATURE GAUGE (Optional)
The Temperature gauge registers the coolant temperature and indicates when an abnormal condition occurs.
7-21.
AIR CLEANER SERVICE INDICATOR tional)
(Op
The air cleaner cleaner requires service indicator signals when the air servicing (see Section 9-2).
7-22.
FUEL GAUGE (Optional)
The FUEL gauge registers the amount of fuel remaining in the fuel tank.
SECTION 8 SEQUENCE OF OPERATION a WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Do not touch live electrical parts.
Stop engine, and disconnect negative ~ battery cable from battery before inspecting or servicing.
Keep away from moving parts such as fans, belts, and rotors.
Keep all covers and panels in place while operating.
Warranty is void if the welding generator is oper ated with any portion of the outer enclosure removed.
ARC RAYS can burn eyes and can damage hearing.
skin; NOISE
Wear correct eye, ear, and body protection.
If ventilation is breathing device.
inadequate, use approved
Use in open, well ventilated areas, or vent exhaust out of doors.
HOT METAL, SPATTER, SLAG,
EXHAUST can cause fire and burns.
AND
Watch for fire.
Keep a fire extinguisher nearby, and know how to use it.
Allow work and equipment to cool before handling.
FUMES AND GASES your health.
canseriously harm
Ventilate to keep from breathing fumes and gases.
If ventilation is breathing device.
inadequate, use approved
Use in open, well ventilated exhaust out of doors.
areas, or vent
HOT METAL, SPATTER, SLAG, AND
EXHAUST can cause fire and burns.
Watch for fire.
Keep a fire how to use it.
extinguisher nearby, and know
A//ow work and equipment to coo/before handling.
FUMES AND GASES can seriously harm your health.
Ventilate to keep from breathing fumes and gases.
ENGINE FUEL can cause fire or explosion.
Stop engine before checking or adding fuel.
Do not spill fuel; if spilled, wipe up.
Do not refuel if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill expansion.
tank to top; allow room for
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.
See Section
Arc
1-Safety Rules For Operation Of
Welding Power Source for basic welding safety information.
8-1.
1.
2.
GAS TUNGSTEN ARC WELDING (GTAW)
WARNING: Read and follow tion at safety informa beginning of entire Sections 5 and 8 before proceeding.
Install and connect unit as instructed in Section 4.
Install and connect the High-Frequency unit ac cording to its Owners Manual, if applicable.
Scratch start GTAW does not require the use of external high-frequency.
OM-458 Page 29
5.
6.
7.
8.
3.
4.
Select and obtain proper electrode
9-3).
(see Table
Prepare tungsten electrode according to Section
9-6, and insert into torch.
Wear dry and insulating gloves.
Connect work clamp to clean, bare metal at workpiece.
Place Process in the GTAW position.
Place AC/DC Selector switch in desired position
(see Section 7-6).
~
WARNING: ELECTRIC SHOCK can kill.
Do not use
AC output in damp ment is confined, or if there is a areas, if danger moveof falling.
Use AC output ONLYif required for the welding process.
If AC output is control.
required, use remote output
Read and follow Safety Rules at beginning of this manual.
9.
10.
11.
12.
13.
14.
15.
Place Range switch in desired position (see Section 7-2).
If remote amperage control is not used, place RE-
MOTE AMPERAGE CONTROL switch in OFF position and rotate AMPERAGE & VOLTAGE
ADJUSTMENT control to desired position (see
Section 7-3).
If remote amperage control is to be connections to used, make
REMOTE AM PERAGE CON-
TROL receptacle (see Section 4-9), set desired amperage, and place
CONTROL switch in ON
REMOTE position.
AMPERAGE
Place HIGH FREQUENCYswitch indesired position (see Section 7-7).
Rotate POSTFLOW TIMER to desired postflow position.
Start the engine as instructed in Section 8-5.
Connect desired auxiliary equipment to the
1 20V26A or optional 240V 1 3A AC duplex receptacle.
16.
17.
Energize the auxiliary equipment, if applicable.
Wear welding helmet with proper filter lens according to ANSI Z49.1.
Close Remote Contactor Control switch.
18.
19.
Turn on
High-Frequency unit, if applicable.
20.
Begin welding.
OM-458 Page 30
8-2.
7.
8.
5.
6.
1.
2.
3.
4.
9.
10.
GAS TUNGSTEN ARC WELDING
WITH
(GTAW)
LOW CURRENT CONTROL OPTION
WARNING: Read and follow tion at safety informa beginning of entire Sections 5 and 8 before proceeding.
CAUTION: contacts.
ARCING can damage switch
Do not switch change LOW CURRENT CONTROL position while welding or under load.
Install and connect unit as instructed in Section 4.
Install and connect the High-Frequency unit ac cording to its Owners Manual, if applicable.
Scratch start GTAW does not require the use of external high-frequency.
Select and obtain proper electrode
9-3).
(see Table
Prepare tungsten electrode according to Section
9-6, and insert into torch.
Wear dry and insulating gloves.
Connect work clamp to clean, bare metal at workpiece.
Place Process in the GTAW position.
Place LOW CURRENT CONTROL switch in the
IN position.
Place the RANGE SELECTOR switch in the de sired position.
Place AC/DC Selector switch in desired position
(see Section 7-6).
WARNING: ELECTRIC SHOCK can kill.
Do not useACoutput in damp areas, if movement is confined, or if there is a danger of fall ing.
UseAC output ONLY/f required forthe welding process.
If AC output is control.
required, use remote output
Read and follow Safety Rules at beginning of this manual.
11.
12.
13.
14.
Place Range switch in minimum range position
If remote amperage control is not used, place RE-
MOTE AMPERAGE CONTROL switch in OFF position and rotate AMPERAGE & VOLTAGE
ADJUSTMENT control to desired position (see
Section 7-3).
If remote amperage control is to be used, make connections to REMOTE AMPERAGE CON
TROL receptacle (see Section 4-9), set desired amperage, and place REMOTE AMPERAGE
CONTROL switch in ON position.
Place HIGH FREQUENCY switch in desired posi tion (see Section 7-7).
15.
16.
17.
18.
19.
20.
21.
22.
Rotate POSTFLOW TIMER to desired postflow position.
Start the engine as instructed in Section 8-5.
Connect desired auxiliary equipment to the
1 20V26A or optional 240V 1 3A AC duplex recep tacle.
Energize the auxiliary equipment, if applicable.
Wear welding helmet with proper filter lens ac cording to ANSI Z49.1.
Close Remote Contactor Control switch.
Turn on
High-Frequency unit, if applicable.
Begin welding.
8-3.
SHIELDED METAL ARC WELDING (SMAW) a WARNING: Read and follow tion at safety informa beginning of entire Sections 5 and 8 before proceeding.
1.
2.
3.
4.
5.
6.
Install and connect unit as instructed in Section 4.
Wear dry and insulating gloves.
Connect work clamp to clean, bare metal at workpiece.
Select proper electrode.
Place Process in the SMAW position.
Place AC/DC Selector switch in desired position
(see Section 7-6).
a WARNING: ELECTRIC SHOCK can kill.
Do not use
AC output in damp areas, if move ment is confined, or if there is a danger of falling.
Use AC output ONLY if required for the weld ing process.
If AC output is control.
required, use remote output
Read and follow Safety Rules at beginning of this manual.
7.
8.
9.
10.
11.
Place Range switch in desired position (see Sec tion 7-2).
If remote amperage control is not used, place RE
MOTE AMPERAGE CONTROL switch in OFF position and rotate AMPERAGE & VOLTAGE
ADJUSTMENT control to desired position (see
Section 7-3).
If remote amperage connections to control is to be used, make
REMOTE AMPERAGE CON
TROL receptacle (see Section 4-9), set desired amperage, and place
CONTROL switch in ON
REMOTE position.
AMPERAGE
Place HIGH FREQUENCY switch in the OFF p0sition (see Section 7-7).
Start the engine as instructed in Section 8-5.
12.
13.
14.
15.
16.
Place AUTO IDLE switch in the desired position
(see Section 7-13).
Connect desired
1 20V26A or auxiliary equipment to the optional 240V 1 3A AC duplex recep tacle.
Energize the auxiliary equipment, if applicable.
Wear welding helmet with proper filter lens ac cording to ANSI Z49.1.
Begin welding.
8-4.
7.5
KVA/KW POWER PLANT OPERATION a WARNING: Read and follow tion at safety informa beginning of entire Sections 5 and 8 before proceeding.
1.
2.
3.
4.
5.
6.
Install and connect unit as instructed in Section 4.
Make connections to the 120/240 volts ac termi nals as instructed in Section 5-5.
Rotate the AMPERAGE & VOLTAGE ADJUST
MENT control to 100 (maximum).
Start the engine as instructed in Section 8-5.
Place the AUTO IDLE switch in the OFF position.
Once the engine is operating at weld/power rpm, power may be obtained from the 7.5
kVAIkW pow er plant.
8-5.
STARTING THE ENGINE
IMPORTANT: Weld output is present whenever the en gine is running unless the Process switch is in the G TA W position and the Remote Contactor Control switch is open.
Auxiliary power output is present whenever the engine is running.
IMPORTANT: Read entire engine Owners Manual
(F- 163) before operating engine.
1.
Engine Prestart Checks a.
Oil Level
Check engine oil level.
If oil level is low, fill to mark on dipstick. (See engine manual for oil se lection.)
Fuel Level a WARNING: REMOVE FUEL CAP
FUEL SPRAY may cause be under pressure.
SLOWLY; injury; FUEL may
Rotate fuel cap stops before slowly and wait until hissing removing cap.
2.
Check fuel level.
If necessary, fill tank with fresh, clean fuel.
(See engine manual for fuel specifi cations.) c.
Coolant level
Check coolant level. If necessary, fill radiator with fresh coolant.
(See engine manual for cool ant specifications.)
Place Process switch in SMAW position.
OM-458 Page 31
3.
4.
5.
6.
Place the AUTO IDLE switch in the ON position.
This should be done to permit the engine to warm up at idle rpm.
Place IGNITION switch in ON position.
Choke engine as necessary
(see Section 7-10).
While holding Low Oil Pressure And High Coolant
Temperature Shutdown System switch closed, depress START push button.
_____
CAUTION: REENGAGING THE STARTER
MOTOR while flywheel is rotating or
EXCEEDING RATED CRANKING TIME can damage starting components.
Do not reengage starter motor until starter pinion and flywheel have stopped rotating.
Do not exceed engine manufacturers maximum cranking time.
Allow
tw~
minutes cooling time before attempt ing to restart engine.
7.
When engine starts, release START push button.
When OIL & TEMP light goes off, release Low Oil
8.
Pressure And down
High Coolant Temperature Shut-
System switch.
Allow the engine to run for a few minutes before applying a load.
This is necessary to enable the engine to properly warm up and ensure proper lu brication.
8-6.
1.
2.
3.
4.
STOPPING THE ENGINE
Stopweldingandallotheroperations,andturnoff all auxiliary equipment.
If applicable, place Process switch in SMAW posi tion and place the AUTO IDLE switch in the ON position.
Place Ignition switch in OFF position.
Turn off shielding gas supply, if applicable.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in use.
SECTION 9 MAINTENANCE
9-1.
ROUTINE MAINTENANCE (Table 9-1)
IMPORTANT: this unit for
Every six months inspect the labels on legibility.
All precautionary labels must be maintained in a when clearly readable state and replaced necessary. See the Parts List for part numbers of precautionary labels.
~
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from battery before inspecting, maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from belts, and rotors.
moving parts such as fans,
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and working on a hot engine.
clothing when
.
BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material.
Wear correct eye and body protection,
Maintenance to be performed only by qualified persons.
A.
Cables And Wiring a WARNING: Read and follow tion at safety informabeginning of entire Section 9-1 before proceeding.
Check interconnecting wiring and connections for tightness and flaws.
Be sure that the weld output cable
OM-458 Page 32 connections are clean and tight.
Check the insulation for breaks or other signs of damage. Repair or replace
Cables or wiring as necessary.
B.
Battery
WARNING: Read and follow tion at safety informa beginning of entire Section 9-1 before proceeding.
Inspect the battery for loose connections, cables, damaged corrosion, cracked case or cover, loose holddowns, and loose or deformed terminal posts.
Clean and tighten connections, replace cables, or replace battery if necessary.
C.
Oil And Filter a WARNING: Read and follow tion at safety informa beginning of entire Section 9-1 before proceeding.
The engine is equipped with a full-flow oil filter.
Change the oil and filter according to instructions on unit main tenance label and in engine Owners Manual (F-i 63 engine).
Use correct type and grade of oil as listed in in structions for expected temperature range before next oil and filter change.
IMPORTANT: This engine is equipped with a
LOW OIL
PRESSURE AND HIGH COOLANT TEMPERATURE
SHUTDOWN SYSTEM.
If engine shuts down, deter mine the cause, and make necessary corrections. Do not operate the been corrected.
welding generator until the trouble has
Table 9-1.
Maintenance Schedule
Frequency*
Every day.
Every
Every
100 to 150 hours.
200 hours.
Every 250 hours.
Every 1000 hours.
Maintenance
Check fuel, oil, and coolant levels (see Sections 4-4 and 4-5, and
Manual, F-163 engine).
engine Owners
Change oil and filter (see engine Owners Manual, F-163 engine).
Check cables, wiring (see Section 9-lA), and battery (see Section 9-1B).
Units in heavy service environments: Check labels; clean and inspect unit
(see Section 9-1).
Replace fuel filter (see engine Owners Manual, F-163 engine).
Clean spark arrestor carbon trap, if applicable (see Section
9-6).
Check brushes and slip rings (see Section 9-10).
Check all labels (see IMPORTANT block, Section 9-1).
Clean and inspect unit (see Section 9-1).
Check coolant system (see engine Owners Manual, F-163 engine).
Once a year.
*Frequency of service is based on unit operated 40 hours per week.
Increase ceeds 40 hours per week.
frequency of maintenance if usage ex
D.
Cleaning And Inspecting a WARNING: Read and follow safety information at beginning of entire Section 9-1 before proceeding.
When performing routine oil changes at intervals specified on the unit maintenance label, clean and inspect the unit as follows:
1.
Keep the inside of the welding generator clean by blowing out the unit with clean, dry compressed air.
2.
3.
Wipe oil and fuel spills from engine immediately to avoid accumulation of dust.
Check for fluid leaks indicating loose oil or fuel connections.
Tighten loose connections, and clean oil or fuel spills off engine.
IMPORTANT: See the engine Owners Manual (F-163 engine) for complete engine care.
9-2.
AIR CLEANER SERVICE AND OPTIONAL IN-
DICATOR (Table 9-2) a WARNING: Read and follow tion at safety informabeginning of entire Section 9-1 before proceeding.
~
CAUTION: DIRTY AIR can damage engine,
Do not operate element in place.
engine with dirty air cleaner
Do not operate engine without air cleaner element in place.
A.
Air Cleaner Service (Table 9-2)
The air cleaner is one of the most important parts of the engine from the standpoint of engine life.
If dirty air gets into the engine, it can cause major engine damage within afew operating hours.
on conditions,
Every 50 hours or less depending empty the dust cup, and inspect the ef e ment.
IMPORTANT: A dirty air cleaner element is usually ac corn panied by a loss of power and smoke in the engine exhaust.
When it becomes necessary to service the air cleaner in the field, follow the steps in Table 9-2.
Keep a spare ele ment on hand for replacement.
New elements are available from your welding equipment distributor.
B.
Air Cleaner Service Indicator (Optional)
The air cleaner service indicator, located on air cleaner hose adapter near intake manifold (behind right side ac cess door), signals when the air cleaner requires servic ing. During normal operation, a green band signals a properly functioning air cleaner. When a red band ap pears, the air cleaner element should be serviced.
Reset the indicator by pressing the end of the indicator marked PRESS TO RESET after servicing element.
IMPORTANT: Check the air cleaner seivice indicator before starting or stopping the engine.
See supplied in structions on indicator.
OM-458 Page 33
Follow
These
E asy
Steps:
,
.mpo
an1
Ho~ To
Clean
Elements
F or
R ~ e-use
Table 9-2. Air Cleaner Service
1.
Stop engine.
2.
Wipe off cover before opening air cleaner.
3.
Remove cover.
4.
Remove element.
5.
Wipe out element chamber with clean, damp cloth.
6.
Inspect new element and all gaskets for shipping damage before use.
1.
Dont attempt to service air cleaner with engine running.
2.
Dont blow out the inside of the air cleaner with compressed air.
Clean element by one of the following methods:
Compressed Air or
Washing.
Compressed air is recommended when element will be re-used immediately because a washed element must be dried before
3.
Dont leave open air cleaner to exposed blowing dust while you clean element,
Replace cover.
4.
If air cleaner is horizontally mounted, be sure that dust cup is positioned so arrows point up.
re-use.
However, washing does a better job and must be used when exhaust soot has lodged in fine pores of the filter media. Use Donaldson D-1400 detergent which contains a special additive for removing soot and carbon,
Replace element after 6 cleanings or annually, whichever occurs first.
7.
Reinstall element.
8.
Replace cover.
5.
For Donaclone air cleaners, dont blow out Donaclone tube section without element, cover and inner cover (if any) correctly installed or you will blow dust into the engine.
(When cleaning Cyclopac elements, do not remove plastic fin assembly backflowing with compressed air or washing will remove dust from beneath the fin assembly).
Compressed Air
Direct air through element in the direction opposite to normal air flow through the element.
Move nozzle up and down while rotating element.
Keep nozzle at least one inch from pleated paper. Maximum air pressure
100 PSI.
Washing
1.
Soak element 15 minutes or more in Donaldson D-1400 and water solution.
See carton for full instructions,
2.
Rinse until water is clear water pressure 40
PSI.)
(Maximum
3.
Air-dry or use warm
I 60 F.
flowing air, max.
Do not use compressed air or light bulbs.
Inspection
Place bright light inside element and rotate element slowly.
If any rupture, holes or damaged gaskets are discovered replace.
S-009114-89
OM-458 Page 34
9-3.
BATTERY REPLACEMENT PROCEDURE
(Figure 9-1) a WARNING: SPARKS OR FLAMES can cause
BATTERY GASES to EXPLODE; BATTERY
ACID can burn eyes and skin.
Stop engine before disconnecting or connect ing battery.
Keep sparks, flames, cigarettes, and other ig nition sources away from batteries.
Do notallowtoolsto cause sparks when work ing on a battery.
Always wear a face shield and proper protec tive gloves and clothing when working on a battery.
Use the following procedure to prevent sparks when re moving or instaUing a battery:
Be sure engine is fully stopped, and IGNITION switch is in the OFF position.
2.
3.
4.
5.
Locate battery in unit (see Figure 9-1).
Open door or remove panels as necessary.
Disconnect negative () battery cable first and positive (+) cable last.
Remove holddown device.
6.
7.
8.
9.
Remove battery.
Install new
(or charged) battery.
Reinstall and secure holddown device.
Connect positive cable last.
(+) cable first and negative ()
10.
Securely reinstall or close any doors or panels.
9-4.
MAINTENANCE-FREE BATTERY CHARGING
WARNING: CHARGING A FROZEN
BATTERY can cause the battery to explode and result in serious injury or damage to equipment; BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material; BATTERY GASES can explode and shatter battery.
Allowbatteryto warm up to 600 F
(160 fore charging if battery is frozen.
C)be
Wear a face shield, proper protective cloth ing, and remove all metal jewelry.
Do not spill or splash battery fluid.
Do not apply pressure to walls of filled battery use battery carrier, or place hands on oppo site corners when lifting battery.
Keep sparks, flames, cigarettes, and ignition sources away from batteries.
other
Use from enough ventilation to keep battery gases building up during and for several hours after battery charging.
Turn off battery charger before nections to battery.
making con
Do not touch or move connections on battery while battery charger is on.
Do not lean over battery when charging.
Be sure battery charger connections to battery are clean and tight.
Keep vent caps in place, and cover top of battery with damp cloth.
Be sure battery charger output matches battery voltage.
Turn off battery cha rger before disconnecting charger from battery.
Batlery
Access Door
Right Rear
Corner Of Base
Figure 9-1.
Battery Location
Battery
SB-138 751
Remove battery from unit, and place on a level worktable or other suitable surface.
2.
If battery has removable vent caps, check the condition of the electrolyte as follows: a.
Check electrolyte temperature in one of the cen ter cells with a battery thermometer. For each
10F (6C) increment above 80F (27C), a cor rection factor of 0.004
specific gravity must be added to the specific gravity reading taken in
Step 2b. For each 10F (6C) increment below
80F (27C), 0.004 must be subtracted from the reading taken in Step 2b.
b.
Check the specific gravity of each cell with a hydrometer.
(Draw in and expel the electrolyte two or three times from the first cell to be tested to adjust the temperature of the hydrometer to that of the electrolyte.)
OM-458 Page 35
c.
If a corrected specific gravity reading of 1 .225 at
80F (27C) is not obtained, replace the vent caps and recharge the battery following battery charger manufacturers instructions.
the
3.
a.
If the battery does not have removable vent caps, check the condition of the battery as follows:
Check the stabilized open-circuit voltage of the battery.
For a
12 volt battery, any reading below
12.4
volts indicates the battery needs charging.
Disconnect both battery cables from the battery, and allow battery voltage to stabilize for several hours.
4.
5.
6.
7.
8.
b.
If the stabilized
12.4
volts, open-circuit voltage is below charge the battery following the battery charger manufacturers instructions.
Remove damp cloth from battery.
Reinstall battery into unit.
Replace battery holddown, and
Do not overtighten.
tighten securely.
Connect positive (+) battery cable to positive (+) battery terminal.
Connect negative () battery cable to negative () battery terminal.
9-5.
TUNGSTEN ELECTRODE (Table 9-3, Figures
9-2 And 9-3)
Use Table 8-3 to select the correct size and type tung sten electrode.
Prepare the tungsten electrode using the following guidelines.
A properly prepared tungsten elec trode is essential in obtaining a satisfactory weld.
A.
For AC or
DC Electrode Positive Welding (Fig ure
9-2)
Ball the end of tungsten electrodes used for ac or dc electrode positive welding before beginning the welding operation.
Weld amperage causes the tungsten elec trode to form the balled end.
The diameter of the end should not exceed the diameter of the tungsten elec trode by more than 1-1/2 times.
For example, the end of a
1/8 in.
(3.2 mm) diameter tungsten electrode should not exceed a
3/16 in.
(4.8 m) diameter end.
.4
I1-1/2
Times
I I Electrode
Diameter
A IE_2.1~2
Times
Electrode
Diameter
AC And DC
Electrode Positive
bJ
DC Electrode
Negative
Figure 9-2.
Properly Prepared Tungsten
Electrodes
S~O161
B.
For DC Electrode Negative Welding (Figures 9-2
And 9-3) a CAUTION: HOT FLYING METAL PARTICLES can injure personnel, start fires, and dam age equipment; TUNGSTEN
TION can lower weld quality.
CONTAMINA
Shape tungsten electrode only on grinder with proper proper guards in a safe location wearing face, hand, and body protection.
Do not use same wheel for any other job, or the tungsten will become contaminated.
Shape tungsten electrodes on a fine grit, hard abrasive wheel used only for tungsten shap ing.
Grind tungsten electrodes so that marks run grinding lengthwise with the electrode. These procedures reduce the possibility of the tung sten electrode transferring foreign matter into the weld and help reduce arc wander and insta bility at low currents.
Grind the end of the tungsten electrode to a taper for a distance of2to 2-1/2 electrode diameters in length.
For example, the ground surface for a
1/8 in.
(3.2 mm) di ameter tungsten electrode should be 1/4 to 5/16 in.
(6.4
to 8.0
mm) long.
For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.
OM-458 Page 36
Table 9-3.
Tungsten Size
Electrode Diameter
Amperage Range
-
Polarity
-
Gas Type
Pure Tungsten
(Green Band)
DC-Argon Electrode
Negative/Straight Polarity
DC-Argon Electrode
Positive/Reverse Polarity
AC-Argon Using
High Frequency
AC-Argon Balanced
Wave Using High Freq.
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
1/4
2% Thorium Alloyed
Tungsten
(Red Band)
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
1/4
Uptol5
5-20
15-80
70-150
125-225
225-360
360-450
450-720
720-950
Upto25
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
*
*
*
10-20
15-30
25-40
40-55
55-80
80-1 25
*
*
*
10-20
15-30
25-40
40-55
55-80
80-125
Uptol5
5-20
10-60
50-100
100-160
150-210
200-275
250-350
325-450
Upto2O
15-35
20-80
50-150
130-250
225-360
300-450
400-500
600-800
UptolO
10-20
20-30
30-80
60-130
100-180
160-240
190-300
250-400
Uptol5
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
Zirconium Alloyed
Tungsten
(Brown Band)
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
1/4
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Upto2O
15-35
20-80
50-150
130-250
225-360
300-450
400-550
600-800
Uptol5
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
*NOT RECOMMENDED
The figures listed are intended as a guide and are a composite of recommendations from American Welding
Society (AWS) and electrode manufacturers.
S-000g/a-88
TUNGSTEN PREPARATION: IDEAL
Stable Arc
TUNGSTEN PREPARATION: WRONG
Arc Wander
Straight ~
Flat
(The Dia.
Of This
Flat Governs
Amperage Capacity)
Point
Figure 9-3.
Tungsten Preparation
Radial Ground
S-a 162
OM-458 Page 37
SERVICING THE SPARK ARRESTOR 9-6.
a WARNING: ENGINE EXHAUST SPARKS can cause fire.
Exhaust spark arrestor must be installed in accordance with local, state, and federal regulations.
Stop engine before cleaning spark arrestor.
Clean spark arrestor in a noncombu stable en vironment.
HOT ENGINE PARTS can cause severe burns.
The exhaust system must be cold when serv icing the spark arrestor.
A spark arrestor/muffler is provided for installation onto the engine exhaust pipe on this
Section welding generator (see
4-2). Aspark 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 or
California Public Resources Code).
For other ar eas, check your state and local laws.
Internal combustion engines operating in a highly com bustible environment are a common fire hazard. Glow ing carbon particles blown out with the exhaust can re tain sufficient heat to ignite materials. While no practical spark arresting device will stop all sparks, this device will minimize fire hazards solid by removing and trapping most particles provided that it is properly maintained.
The carbon trap should be serviced every 250 operating hours. The entire spark arrestor should be inspected ev ery
1000 operating hours or three times per season.
Removal of the device from the exhaust system is not necessary for servicing.
Proceed as follows to service the spark arrestor:
1.
Stop the engine and allow the exhaust system to cool.
2.
3.
4.
5.
Remove the cleanout plug from the bottom of the spark arrestor. If a crust has formed over the hole, break it loose with a screwdriver or similar tool.
Start the engine and run it at idle rpm to blow col lected particles out the cleanout hole.
If particles are slow to discharge, momentarily cover the end of the exhaust stack.
Stop the engine, and allow the exhaust system to cool.
Replace and secure the cleanout plug.
9-7.
SPARK GAPS (Figures 4-3 And 9-4) a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine before inspecting, maintaining, or servicing.
OM-458 Page 38
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and clothing when working on a hot engine.
Maintenance to be performed only by qualified persons.
It is necessary to readjust the spark gaps every three to four months or when intermittent operation occurs.
Nor mal spark gap setting is 0.012 in.
(0.304 mm).
High-frequency output varies with the spark gap setting.
When a great amount of high frequency is necessary, the spark gaps can be adjusted to 0.013 in.
(0.330mm).
This, however, increases high-frequency radiation which increases interference with communications equipment.
It is suggested that a minimum spark gap setting of 0.008 to 0.012 in.
(0.203
to 0.304
mm) be used.
IMPORTANT:
At
Spark gaps widen with normal operation.
regular inspections, check and maintain the spark gaps to ensure consistent welding results pliance with FCC radiation regulations.
and com
IMPORTANT: Do not clean or dress the points since the material at the tips is tungsten and is impossible to file.
The entire point should be replaced when the tungsten section has completely disappeared.
C
B A B s.oo~
1.
Figure 9-4.
Spark Gap Adjustment
This unit is provided with a spark gap assembly located behind the lower front panel access door (see Figure
4-3).
To adjust spark gaps, proceed as follows:
Open lower front panel access door.
2.
Loosen screws
A on both sides.
3.
4.
5.
6.
Place feeler gauge of proper thickness between points C.
Apply slight pressure against points so feeler gauge is held firmly in gap.
Tighten screws
A.
Close and secure lower front panel access door.
9-8.
CARBURETOR AIR TEMPERATURE SELEC
TOR (Figure 9-5) a CAUTION: IMPROPER AIR SELECTOR
TUBE ADJUSTMENT can damage engine.
Use proper carburetor air tor temperature position for ambient temperature.
selec
The air intake to the air cleaner is equipped with a selec tor tube which allows cool air to be drawn from the sur rounding engine compartment or heated air from around the exhaust manifold of the engine.
Heated air prevents carburetor icing in cold weather.
Figure 9-5 shows the selector tube in the cold weather position.
In cold weather, the tube must be approximate ly 1/2 in.
(13 mm) away from the air cleaner inlet.
For warmer weather, loosen the selector tube and slide it down against th~ manifold and retighten.
Air Cleaner
Air Inlet
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and working on a hot engine.
clothing when
Maintenance to be performed only by qualified persons.
A.
Weld Speed (1825 rpm) Adjustment
1.
2.
Shut down the engine.
Loosen the hardware linkage socket nuts and remove the securing the linkage socket to the gov ernor.
Rotate the linkage socket until the throttle stop stop.
plate is about 1/32 in.
(0.79 mm) from the
A clockwise rotation of the linkage socket will shorten the governor gap; a linkage and reduce the counterclockwise rotation of the linkage socket will lengthen the governor linkage and wid en the gap.
(In some cases it may be necessary to adjust the linkage itself to obtain the 1/32 in.
(0.79
mm) gap required.) Tighten nuts to lock the position of the the linkage linkage socket sockets.
IMPORTANT: Check the linkage for freedom of move ment throughout its entire travel.
If the linkage is binding due to the linkage sockets being out of properalignment, loosen the linkage socket nuts and rotate the socket slightly until unrestricted movement of the linkage is re stored.
Tighten the linkage socket nuts.
Manifold
Stove
Air
Selector
(Shown In Cold
Weather Position)
SA.144 987
Figure 9-5.
Carburetor Air Temperature Selector
3.
Recheck all connections.
Place the AUTO IDLE switch in the OFF 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.
4.
Loosen the governor speed adjustment screw se curing nut.
Adjust the governor speed adjustment screw until a speed of 1825 rpm is obtained.
Tighten the securing nut to maintain the governor speed setting.
IMPORTANT: Whenever the governor speed is ad justed, the governor sensitivity MAY need readjustment
(see Section 9-9C for procedure).
9-9.
AUTOMATIC IDLE CONTROL/GOVERNOR
LINKAGE ADJUSTMENT (Figure 9-6)
This welding generator was shipped fully adjusted and ready for use.
Should problems arise, select and per form the following procedure(s) to obtain proper engine idle and/or weld speed:
4~
WARNING: ELECTRIC SHOCK can kill.
_____
Do not touch live electrical parts.
Stop engine before inspecting, maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
B.
Idle Speed (1200 rpm) Adjustment
1.
Start the engine and allow it to reach normal oper ating temperature (about five minutes).
Ensure that the CHOKE control is pushed fully in. Place the AUTO IDLE switch in the ON position.
Adjust the carburetor low speed mixture as follows:
2.
Loosen solenoid screws, and allow solenoid to travel freely.
OM-458 Page 39
Idle Mixture
Adjustment
Screw
Idle Control
Solenoid
Governor
Spring
Governor
OPTIONAL
SC-080 519.8
3.
4.
5.
Pull the arm toward the front of the welding gener ator to the idle position.
Maintain pressure on the arm to butt against the idle screw throughout the following adjustments: a.
Rotate the idle speed screw to obtain 550 rpm.
Clockwise rotation of the screw will increase en gine rpm, whereas counterclockwise rotation of the screw will decrease engine rpm.
b.
Rotate the idle mixture adjustment screw coun c.
terclockwise until the engine begins to falter or roll; then rOtate the screw clockwise until the en gine operates smoothly. Rotating the screw clockwise restricts the fuel flow, making the airfuel mixture leaner.
Rotating the screw counter clockwise admits more fuel, making the air-fuel mixture richer.
When mixture is satisfactory, rotate idle speed screw to obtain 1200 rpm.
Loosen alignment screw and position the idle alignment clamp so that idle arm is positioned as shown in Figure 9-6.
Tighten alignment screw.
Maintain pressure on the arm to butt the stop against the idle screw.
Slide the solenoid plunger until fully bottomed in the solenoid body.
Tighten the two solenoid screws.
Recheck for 1200 rpm.
OM-458 Page 40
Figure 9-6. Idle Control/Governor Linkage Adjustment
IMPORTANT: Do not readjust the idle speed screw when adjusting the idle speed.
IMPORTANT: Check the idle movement linkage for freedom of throughout its entire travel, If the linkage is binding due to the linkage being out of proper alignment with the idle arm, adjust the idle alignment clamp until unrestricted movement of the linkage is restored. Re peat Steps 3, 4, and 5.
C.
Governor Sensitivity Adjustment
IMPORTANT: Before making any governor sensitivity adjustment, be sure that the carburetor and associated linkages have been completely adjusted according to
Sections 9-9A and 9-9B. If engine performance is still unsatisfactory, check and adjust the governor sensitivity as follows:
Check the governor engine regulation by applying and removing a load.
If the engine is slow to increase rpm or rpm drops exces sively under load, regulation range is too broad. Loosen one of two locking nuts, and decrease the governor spring tension by sliding the sensitivity, adjustment screw inward.
If the engine hunts or surges with or without a load, regu lation range is too narrow.
Loosen one of the two locking nuts and increase governor spring tension by sliding the adjustment screw outwards.
IMPORTANT: Whenever governor sensitivity is ad justed, governor speed (weld speed) must be readjusted
(see Section 9-9A).
Whenever the governorspeed (weld speed) is adjusted, governor sensitivity may need ad justment.
0.
HIgh Altitude Carburetor Main Mixture Adjust ment (Optional) (Figure 9-6)
The carburetor can be equipped with an adjustable main jet for high-altitude operation (above 4000ff.
or
1219 m).
Minor adjustment will be necessary for proper operation at a particular altitude.
Loosen the main adjustment screw locking nut.
Apply a near-full the main engine load to the welding generator.
Rotate adjustment screw clockwise until the engine begins to falter ~nd loose rpm. Rotate the main adjust ment screw counterclockwise until the engine operates smoothly; then continue counterclockwise rotation for
1/4 turn.
Rotating the screw clockwise restricts fuel flow, making air-fuel mixture leaner.
Rotating the screw coun terclockwise admits more fuel, making the air-fuel mix ture richer. Remove the engine load.
Tighten thelocking nut.
a CAUTION: ATOO LEAN AIR-FUEL MIXTURE can damage valves.
Do not restrict fuel flow to the point where the air-fuel mixture is too lean.
MOVING PARTS can cause serious injury.
Keep away from belts, and rotors.
moving parts such as fans,
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and clothing when working on a hot engine.
Maintenance to be performed only by qualified persons.
Brush life is very good under most operating conditions.
Inspect brushes and slip rings every six months or when ever excitation voltage is lost. Be sure that slip rings are clean and brushes are free to move.
If the welding gen erator has been operating under extremely dusty or dirty conditions, increase the frequency of inspection.
IMPORTANT: If the welding generator has not been used for an extended period of time, oxidation may form on the slip rings causing excitation voltage to be lost.
Under normal use, slip rings discolor to a dark brown.
Clean slip rings if a buildup of brush material is present.
Clean rings with a 220 or finer sandpaper, and polish rings with crocus cloth.
Never use emery cloth because part of the emery will embed itself into the turn, destroy the carbon brushes.
rings and, in
Replace brushes if they become chipped or broken or if less than 1/2 in.
(12.7
mm) of brush material will be left at next projected inspection interval.
1/2 in.
(12.7
Minimum
mm)l
9-10.
BRUSHES AND SLIP RINGS (Figure 9-7) a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from battery before inspecting, maintaining, or servicing.
Figure 9-7. Brush Replacement
S-0234
OM-458 Page 41
SECTION 10 TROUBLESHOOTING
10-1.
GENERAL
It is assumed that proper installation has been made, ac cording to Section 4 of this manual, the operator is famil iar with was the function of controls, the welding generator functioning properly, and the trouble is not related to the welding process.
10-2.
BOOSTER BATTERY JUMP STARTING
If it is necessary to jump start this unit, use the following safety precautions and the step-by-step procedures in order of appearance.
a
WARNlF~G:
BATTERY GASES OR A DAM
AGED BATTERY can explode thereby shat tering the eyes, other battery; BATTERY ACID can burn skin, destroy clothing, and damage material; MOVING PARTS AND IM
PROPER CONNECTIONS can cause serious personal injury and damage equipment.
Keep sparks, flames, cigarettes, and other ig nition sources away from battery.
Ensure that al/personnel are a safe distance from batteries and clear of moving parts while starting.
Do not jump start a frozen or completely dis charged battery.
Do not jump start a battery which has loose terminals or one having evidence of damage such as a cracked case or cover.
Be sure that vent caps are tight and level on both batteries and cover both batteries with a damp cloth.
Wear correct eye and body protection, andremove all metal jewelry.
Keep jumper cables clear of moving parts.
Ensure that both batteries are of the same voltage.
Do not jump start a trailer mounted welding generator with the towing vehicle battery un less the trailer is completely disconnected from the towing vehicle.
Do not jump start a vehicle mounted welding generator from the vehicle battery.
If booster battery is installed in vehicle, do not allow vehicle to make contact with welding generator case or frame.
Do not jump start by applying power to weld output receptacles or terminals.
Do not allow jumper cables to contact any other metal while attaching or removing ca bles.
OM-458 Page 42
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Use properly insulated jumper cables of ade quate size.
Connect ends of one cable to positive (+) termi nals of each battery.
Connect one end of other cable to negative () terminal of booster battery.
Connect erator remaining end of cable to welding gen engine block at least 18 inches (457 mm) from battery (do not connect to welding generator case, frame, or equipment grounding terminal as damage to equipment can result).
Wait at least one minute after connecting cables before starting engine.
Start engine
Section 8 following
(Sequence of procedures
Operation) outlined of this in manual and allow engine to return to idle speed.
If the unit does not start after cranking for twenty seconds, stop the jump starting procedure.
More than twenty seconds seldom starts the some mechanical adjustment engine is made.
unless
Remove jumper cable from engine block.
Remove other end of same cable from booster battery negative () terminal.
Remove other jumper cable from welding genera tor battery positive (+) terminal.
Remove remaining end of cable from booster bat tery positive (+) terminal.
Discard damp cloths.
10-3.
OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from battery before inspecting, maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
HOT ENGINE PARTS can cause burns.
severe
Wear protective gloves and working on a hot engine.
clothing when
INCORRECT FUSE can damage unit.
Use only replacement fuse of same size, type, and rating (see Parts List).
A.
Resetting Overload Breakers (Figure 7-1) a WARNING: Read and follow safety informa tion at fore beginning of entire Section 10-3 be proceeding.
The overload breakers are not automatic-trip type and are manually operable.
When the overload breaker but ton is in (ON position),the overload breaker is functional.
When the button is out (OFF position), the breaker is open.
If an overload breaker trips when equipment use begins, a fault is probably present in the equipment.
If a breaker trips after prolonged equipment use, an overload condi tion is probably present.
Should a breaker trip, proceed as follows:
2.
3.
Locate and repairfaultor reduce receptacle load.
Reconnect equipment to receptacle and start en gine.
Reset overload breaker (depress button); it may be necessary to allow a breaker can be reset.
cooling period before the
4.
Resume operation.
B.
Replacement Of 7.5
KVAJKW Fuses a WARNING: Read and follow tion at safety informa begInning of entire Section 10-3 be fore proceeding.
Proceed as follows to replace fuses Fl and/or F2:
1.
2.
3.
4.
5.
6.
Open left side doors, and secure in open position.
Remove cover from junction box.
Check fuses Fl and F2, and replace if necessary.
Replace junction box cover.
Reconnect negative () battery cable.
Close and secure left side doors.
C.
Replacement Of Low Oil Pressure And High
Coolant Temperature System Shutdown Fuse
4A WARNING: Read and follow tion at safety informa beginning of entire Section 10-3 be fore proceeding.
Proceed as follows to replace the fuse F on
MS1:
1.
Open right tion.
side doors, and secure in open posi
2.
3.
4.
5.
6.
7.
Remove right side panel.
Locate fuse Fon bottom of MS1.
Remove and check fuse, replace if necessary.
Reinstall right side panel.
Reconnect negative () battery cable.
Close and secure right side doors.
D.
Replacement Of Optional Low Current Control
Fuse a WARNING: Read and follow safety informa tion at fore beginning of entire Section 10-3 be proceeding.
Proceed as follows to replace the fuse F3:
1.
Open right side doors, and secure in open posi tion.
5.
6.
2.
3.
4.
7.
Remove right side panel.
Locate F3 on top of high frequency panel mount.
ing bracket.
Remove and check F3, replace if necessary.
Reinstall right side panel.
Reconnect negative () battery cable.
Close and secure right side doors.
10-4.
CIRCUIT BOARD HANDLING PRECAUTIONS j~ WARNING: ELECTRIC SHOCK can kill.
_____
Do not touch live electrical parts.
Stop engine, and disconnect negative () battery cable from batterj before inspecting, maintaining, or servicing.
MOVING PARTS can cause serIous injury.
Keep away from belts, and rotors.
moving parts such as fans,
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and working on a hot engine.
clothing when
Maintenance to be performed only by qualified persons.
a CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
Put on
BEFORE properly grounded wrist strap handling circuit boards.
Transport Circuit boards in proper staticshielding carriers or packages.
Perform work only at a static-safe work area.
INCORRECT INSTALLATION or plugs can damage circuit board.
misaligned
Be sure that plugs are properly installed and aligned.
EXCESSIVE PRESSURE can break circuit board.
Use only minimal pressure and gentle move ment board when disconnecting or connecting plugs and removing or installing board.
If any circuit board is not working, follow the preceding precautions, and contact nearest Factory Authorized
Service Station.
OM-458 Page 43
10-5.
TROUBLESHOOTING (Tables 10-1,10-2, And
10-3)
4~
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
_____
Stop engine, and disconnect negative () battery cable from batten, before inspecting, maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans, belts, and rotors.
HOT ENGINE PARTS can cause severe burns.
Wear protective gloves and clothing when working on a hot engine.
Troubleshooting to be performed only by qualified persons.
The following table is designed to diagnose and provide remedies for some of the troubles that may develop in this welding generator.
Use this table in conjunction with the circuit diagram while performing troubleshooting procedures.
If the trouble is not remedied after performing these proce dures, contact the nearest Factory Authorized Service
Station.
In all cases of equipment malfunction, strictly follow the manufacturers procedures and instructions.
Table 10-1.
Weld/Power Troubleshooting
WELDING TROUBLE PROBABLE CAUSE REMEDY
No or low weld kW output; 3 kVAJ auxiliary power available.
Loose or poor electrical connections.
Check internal and external connections to weld output terminals.
Process switch S12 in wrong position for welding process.
Place S12 in SMAW position for Shielded Metal
Arc Welding; place in the GTAW position for Gas
Tungsten Arc Welding.
REMOTE AMPERAGE CON-
TROL switch S5 is in ON position with no remote control connected.
Place S5 in the OFF position, or connect a re motecontroItotheREMOTEAMPERAGECON
TROL receptacle RC3.
RANGE switch S3 is between positions.
Be sure
S3 is properly positioned.
Control
Control relay CR1.
relay CR3.
Check and replace CR1 if necessary.
Check and replace CR3 if necessary.
Loworhighopen-circuitvoltage at weld output terminals.
Incorrect engine speed.
Check and
Section 9-8.
adjust engine speed according to
Erratic weld output.
~
Loose or dirty connections; imconnection to workproper piece.
Range switch S3.
Checkconnectionsbothinsideandoutsideweld ing generator.
Clean and tighten connections as necessary.
Check and replace S3 if necessary.
Erratic weld and power output.
Poor contact between and brushes.
slip rings Clean slip rings and replace worn brushes if necessary (see Section 9-7).
No optional Low Current Control weld output; output available.
regular weld
Range switch S3 is between ranges.
Fuse F3.
Place S3 in Minimum
7-17).
position (see Section
Check and
10-3).
replace F3 if necessary (see Section
LOW CURRENT CONTROL switch Sii in the OUT or position,
Sli not operating properly.
RANGE SELECTOR switch
Si 4.
Place Si 1 in the IN position, or check and replace
Sil if necessary.
Check and replace Si 4 if necessary.
OM-458 Page 44
Table 10-1.
Weld/Power Troubleshooting (Continued)
WELDING TROUBLE PROBABLE CAUSE REMEDY
No weld or
3 kVA/kW auxiliary power output.
Poor contact between brushes and slip rings.
Clean slip rings and replace worn brushes if necessary
(see Section 9-7).
Tungsten electrode oxidizing and not remaining bright after conclusions of weld.
Water in torch.
Refer to torch parts list for part or parts requiring replacement, and repair torch as necessary.
Loose gas fittings on regulator or gas line.
This will draw air into the weld zone.
Check and tighten all gas fittings.
Insufficient postuiow time.
Drafts blowing gas shield away from tungsten.
Increase postilow time.
Shield weld zone from drafts.
Wandering arc; poor control of direction of arc~
Use of tungsten considerably larger than recommended.
Use proper size tungsten (see Table 9-3).
Improperly prepared tungsten.
Prepare tungsten as instructed in Section 9-6.
Gas flow rate too high.
Reduce flow rate.
Lack of high frequency; difficulty in establishing a
GTAW arc.
Use of tungsten larger than recommended for welding amperage.
Use proper size tungsten for
(see Table 9-3).
welding amperage
Dissipation of high frequency from torch or work cable.
Check that torch or work cables are not near any grounded metal.
Weld cable leakage.
Improper spark gap G.
Check cables and torch for cracked or deterio rated insulation or bad connections.
Repair or re place necessary parts.
Check G, and adjust if necessary (see Section
9-5).
No high frequency.
HIGH FREQUENCY switch S4 in OFF position, or
S4 not operating properly.
Place S4 in the desired position (see Section
7-7), or check and replace S4 if necessary.
Improper spark gap G.
Check G, and
9-5).
adjust if necessary (see Section
.
Control relay CR2 if HIGH FRE.
QUENCY switch S4 is in the
START position.
Check and replace CR2 if necessary.
Capacitor C2.
Transformer Ti or
T2.
coupling coil
Check and replace C2 if necessary.
Check and replace Ti or
T2 if necessary.
High Frequency Start Control
Board PC2 if HIGH FREQUEN-
CV switch S4 is in the START position.
See Section 10-4, and contact rized Service Station.
Factory Autho
OM-458 Page 45
Table 10-2.
Auxiliary Power Troubleshooting
AUXILIARY POWER
PROBABLE CAUSE REMEDY
No 3 weld kVA/kW power output available.
output; OVERLOAD BREAKER CB1 or
CB2 open.
Reset CB1 or
CB2 (see Section 10-3).
Receptacle or receptacle wiring.
Check er receptacle RC1 or optional RC2 for prop connections (see Section 5-5). Replace re ceptacle if necessary.
No 7.5
kVA/kW power plant Output; weld output available.
Improper connections.
Check connections according to Section 5-4.
Fuse Fl or
F2.
Low or high 3 kVA/kW auxiliary power output.
Incorrect engine speed.
Check and
Section replace Fl or
F2 if necessary
(see
10-3).
Check and
Section 9-8.
adjust engine speed according to
No weld or
3kVNkW auxiliary power output.
Poor contact between brushes and slip rings.
Clean slip rings and replace worn brushes if nec essary (see Section 9-7).
OM-458 Page 46
Table 10-3.
Engine Troubleshooting
ENGINE TROUBLE PROBABLE CAUSE REMEDY
Engine dc~s not crank.
IGNITION switch S7.
Start switch PB1.
Battery.
Check S7, and replace if necessary.
Check PB1, and replace if necessary.
Inspect the electrical system (see Section 9-1).
Test the battery and recharge it if necessary
(see
Section 9-9).
If the battery does not recharge, re place the battery.
~
Starter solenoid.
Jump start the engine employing approved safe ty practices and booster.
Jump starting instruc tions provided in Section 10-2.
See Engine Owners Manual (F-163 Engine).
Engine cranks but fails to start.
Fuse F on
Low Oil Pressure
And High Coolant Temperature
Shutdown System Switch MS1 open.
Check and replace fuse F on
MS1 if necessary according to
Section 10-3.
Engine problems.
See Engine Owners Manual (F-163 Engine).
Engine ran fine but slowly stopped; unable to start engine.
Fuel tank cap vent in CLOSED position.
Examine inside of fuel tank cap, and rotate valve to the OPEN position.
Out of fuel.
Engine suddenly shuts down;
OIL & TEMP warning light on.
Low oil or coolant level (other probable causes can be found in the engine manual).
Add oil or coolant.
Highcoolanttemperatureorlow oil pressure.
Correct coolant problems temperature or oil pressure
(see Section 10-3).
BATTERY warning light on.
Fill fuel tank with fresh, clean fuel (see F-i 63 En gine).
Loose or dirty electrical connection.
Inspect ignition system.
Clean and tighten con nection.
Battery uses.
Alternator/regulator.
Check and replace alternator/regulator (see En gine Owners Manual, F-i63 Engine).
discharges between IGNITION switch S7 left in ON position,
Be sure
S7 is left in the OFF position when the unit is shut down.
Buildup of acid on top of battery
(white-grayish substance).
Clean battery with soda solution; rinse with clear water.
Battery.
Engine remains at weld/power rpm when AUTO
S2 is in the ON
IDLE position switch and no load is applied.
AUTO IDLE switch S2.
Check battery, and replace if necessary.
Check S2, and replace if necessary.
Throttle solenoid TS1.
Auto Idle Board PCi.
Check TS1, and replace if necessary.
See Section 10-4, and contact rized Service Station.
Factory Autho
Engine remains at idle rpm when AUTO IDLE switch S2 is in the ON position and an arc is struck.
Current transformer CT2 Check CT2, and replace if necessary.
Auto Idle Board PCi.
See Section 10-4, and contact rized Service Station.
Factory Autho
OM-458 Page 47
r
SECTION 11 ELECTRICAL DIAGRAMS
Gb
T
0
27
0
J
0
19
0
12
LP GAS KIT
I~TI~AL)
I
I
C
NO.
MANIFOLD
VACI_A.~))I SW.
SQ.ENOID
VALVE
L
12 VOLT
BATTERY
C20
TACHOIETER
(OPTI~AL)
Diagram 11-1.
Circuit Diagram For Welding Generator
OM-458 Page 48
C
LOW CI.~RENT
CQITROL
(~TIONAL) I
I
1.
r
2~OVOLT
RECEPTACLE KIT
(~TID~1AL)
I~TEI 3
<
-i
I
B
L~1~ff:i
SC I
-<W
12V.
Lp<
hELD
NEUTRAL GROU~C AS
NATIONAL AIC L~AL
RE~JIRED BY
ELECTRIC C~ES so
57 54 5~ dQ 4/
/454 s4~
54J7
--.3~I
FRONT
IAC
VIEW
2X REVERSE
3X STRAIGHT
Circuit Diagram No. SD-i 36 407-A
OM-458 Page 49
DIODE
ISOLATED D
RESET
POSITIVE B
OUTPUT
(DELAY OFF)
C
RESET ~
BURDEN
RESISTOR
E
CT
F
H
NEGATIVE U
Circuit Diagram No. SA-071 600-A
Diagram 11-2.
Circuit Diagram For Automatic Idle Control Board PCi
D
E
OM-458 Page 50
Circuit Diagram No.
SA-084 076-A
Diagram 11-3.
Circuit Diagram For HF Start Control Board PC2
SECTION 12 CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
12-1.
GENERAL
The following information is necessary to make a proper installation of the high-frequency arc welding equipment described in this instruction manual. In order to comply with Part 18 of the Rules and Regulations of the Federal
Communications Commission (FCC), the certificate in the front of this manual must be filled in completely and signed after the unit has been correctly installed. The certificate must be kept WITH THE EQUIPMENT AT
ALL TIMES to comply with the regulation.
The manufac turer of the equipment covered herein has conducted approved field tests and certifies that the radiation can be expected to be within the legal limits if the correct in stallation procedures, as outlined, are followed.
The im portance of a correct installation cannot be overempha sized since case histories of interference due to high-fre quency stabilized arc that in most cases, an welding equipment have shown inadequate installation was at fault.
In the event that interference with authorized FCC services occurs, the user is required to take suitable steps to clear the situation. The ment
Factory personnel will assist the user
Service by supplying
Depart techni cal information.
Instead of complying with the installation requirements and the certification of each individual installation, the user may elect to certify the entire plant by having a qualified engineer make a plant radiation survey.
In such cases, these instructions could serve as a guide in mini mizing interference that might be caused by the high-fre quency arc welding equipment.
Many processes and applications of processes require open-circuit voltages sufficient to jump from the elec trode to the work without making direct contact.
The maximum open-circuit voltage (OCV) of a welding power source is not sufficient for this.
In the Submerged
Arc Welding (SAW) process, granules of flux often get between the electrode and the workpiece making start ing of the arc difficult at normal open-circuit voltages.
A higher voltage is also required to start and maintain a stable arc in processes like the Gas Tungsten Arc Weld ing (GTAW) process. In these cases it will take several thousand volts to cause an electrical spark to jump this gap between the electrode and the work, creating an in itial path of ionization that the arc current can follow with out the hazards that would be present at power fre quency.
In order to provide these higher voltages, it is common practice to the superimpose a high open-circuit voltage on output of a welding power source by using high-fre quency techniques.
The high-frequency voltage can be a source of interference and will be discussed in this sec tion.
12-2.
DEFINITIONS
A.
High-Frequency Assisted Arc Welding Power
Sources
In the arc welding process, high frequency may be used for initiating an arc or stabilizing the arc once it is struck, or for both functions.
The energy from the high-frequency source must flow to the welding electrode via a good quality, low impedance, and well insulated connecting cable.
B.
Welding Circuit
The welding circuit consists of all attachments con nected to the welding terminals.
C.
Welding Terminals
Welding terminals are the terminals which provide weld ing power and high-frequency energy to the arc.
D.
Electrode Terminal
The electrode terminal is the terminal to which the elec trode cable or welding torch is connected.
E.
Welding Torch
A device used in the Gas Tungsten Arc Welding (GTAW) process to control the position of the electrode, to trans fer current to the arc, and to direct the flow of shielding gas.
F.
Work Terminal
The work terminal is the terminal to which the welding workpiece is connected.
-
G.
Welding Zone
The welding zone is the space within 50 ft.
(15 m) in all directions from the midpoint between the power source and the welding arc
(see Figure 12-6).
H.
Bonding
Bonding refers to connecting metallic objects together to cause the objects to be at the same potential regardless of any currentflow between them (see
12-4).
Figures 12-3 and
I.
Grounding (Earthing)
Depending on the practices within jurisdictions, one of these terms is commonly used to indicate the connec tion, or bonding, of parts of the apparatus to the earth.The
terms may be used interchangeably.
J.
Receiver
A receiver is any device normally used for receiving elec tromagnetic energy and converting itto useful communi cations purposes.
K.
Conduction
Conduction is the transmission of high-frequency en ergy via an electrical conductor or conducting medium.
OM-458 Page 51
L.
High Frequency
High frequency is radio frequency energy, either con tinuous or pulsed, used to start or stabilize a welding arc.
M.
High-Frequency Assisted Arc Welding
High-frequency assisted arc welding refers to any of the arc welding processes requiring high frequency.
N.
Interference
Interference is the unwanted and problematic reception of high-frequency energy.
0.
Radiation
Radiation is the transmission of high-frequency energy through space.
12-3.
HIGH-FREQUENCY RADIATION
Installations using high frequency, either as an integral part of the power source or as an accessory unit, will pro duce some high-frequency radiation. Such radiation, if the signal strength is sufficient at the receiving device, can cause an inconvenience or disruption of communi cations or can cause malfunction in sensitive electronic controls and systems.
The four major causes of high-fre quency radiation are as follows:
A.
Direct Radiation From The Power Source Or
High-Frequency Accessory Unit
Direct radiation is that radiation emanating directly from the power source or accessory unit. Radiation from the power line and welding power source accessories is not considered to be direct radiation from the power source or accessory unit.
B.
Direct Radiation From The Welding Circuit
Any attachment to the output terminals of the high-fre quency source radiating is capable of acting as an antenna and high-frequency energy.
Attachments include weld cables, torches, worktables, etc.
Since direct radia tion from the welding circuit is the major source of radia tion, it is important to keep attachments to a minimum.
C.
Conduction And Radiation From The Power
Line
Most power lines are capable of conducting high-fre quency energy which may cause interference directly or by reradiation from these power lines.
Normally such ra diation is small when compared to that caused by radia tion from the weld cables.
D.
Reradiation
Radiation from the welding circuit can be picked up by ungrounded metal objects or unshielded wiring in the im mediate vicinity, conducted some distance, and reradiated. This can be a troublesome source of interfer ence.
OM-458 Page 52
12-4.
LOCATION
Locate the high-frequency power source as close to the welding process as possible.
Also consider the near ness of a suitable ground connection when selecting a site for the installation of the power source.
Ideally, the high-frequency power source should be located in an area where there is a limited amount of miscellaneous wiring (lighting, power, telephone, communications, other unshielded conductors) located within the and welding zone.
Ungrounded, metallic conductors in the welding zone can act as antennas which will pick up, conduct, or reradiate the high-frequency energy transmitted by the welding circuit.
All miscellaneous wiring in the welding zone should be enclosed in grounded, rigid metallic con duit, copper braid, or some other material equivalent shielding efficiency, and having grounded an at 50 ft.
(15 m) intervals (see Figure 12-1).
Shielded Wire
\
Is
/
Ground At 5Oft.
/
(15 m) Intervals
~rI
Work Clamp
/
Ground
High-Frequency ~
Welding
Power Source
~
Keep all unshielded and ungrounded wires out of the welding zone.
/
I)
Figure 12-1.
Requirements To Minimize Reradia tion Pickup In The Vicinity Of The Welding Zone s.0017
12-5.
GENERAL INSTALLATION PROCEDURES
A.
Weld Cables
Keep the weld cables as short as possible and do not ex ceed 25 ft.
(8 m) in length.
Position the cables as close together and as close to the floor or ground plane as pos sible.
If the welding operation must be carried out at a point far ther than 25 ft.
(8 m) from the welding power source, use a portable high-frequency source and locate the port able unit within 25 ft.
(8 m) of the welding electrode.
B.
High-Frequency Assisted Arc Welding Power
Sources
When the high-frequency assisted arc welding power source is in operation, all service doors and covers must be closed, securely fastened, and adequately bonded to ensure good contact around the entire perimeter of the opening. Except for changes and adjustments allowed by the manufacturer, the high-frequency assisted arc welding power source should not be modified.
Place leads on floor or on boards and keep 3/4 in.
(19 mm) to 1 In.
(25 mm) apart.
Electrode
Holder
Electrical
Input
Supply
Ground
7
Work Clamp S -00 18
Figure 12-2.
General Rules For Welding Leads
C.
Grounding (Earthing) The Weld Cables
Be sure that the enclosure of the high-frequency power source is firmly ~rounded to the WORK terminal. If the high-frequency power source is not labeled as being in ternally high-frequency grounded, then this ground must be made by grounding the enclosure tothe WORKtermi nal with No. 12 AWG gauge or smaller wire.
Connect the ground wire to a driven ground rod or to a water pipe which enters the earth within 10 ft.
(3 m) of the high-fre quency power source.
D.
Metal Buildings
Installation of a high-frequency power source within a suitably bonded and grounded (earthed) metal can be an effective means of building reducing high-frequency radiation.
Wherever possible, install high-frequency power sources in such places.
Grounded
Copper Screens
However, when the high-frequency power source is in stalled within a metal building, precautions must be taken to be sure that the building is properly bonded and grounded (earthed).
This can be accomplished by plac ing several good electrical ground rods around the pe riphery of the building. During the construction of a new building of any type having metal in the structure, be sure that all the reinforcing and structural steel is bonded to gether (as by welding each piece of metal to all other ad jacent pieces).
For metal buildings, adjacent metal pan els should be bolted or welded together at frequent inter vals.All windows and doorways should be covered with grounded copper screen or galvanized hardware cloth of not more than 1/4 in.
(6.4 mm) mesh.
E.
Shielding Of Miscellaneous Wiring In The Weld ing Zone
Ungrounded, metallic conductors in the welding zone can act as antennas which will pick up, conduct, and/or reradiate the high-frequency energy transmitted by the welding circuit located within or near the welding zone.
This means that all ungrounded water pipes must be grounded, and that all lighting, power, telephone, com munications, and other conductors within the welding zone must be enclosed in grounded, rigid metallic con duit, copper braid, or some other material having an equivalent shielding capability (spirally wound, flexible, metallic conduit is not suitable).
Shielding of the miscel laneous wiring in the welding zone must be grounded at
50 ft.
(15 m) intervals.
Excellent low resistance electrical connections must be maintained between conduit sec tions (see Figure 12-4).
Copper
S-0020 rounding Wire
Metal Panels
Bonding Of Metal Panels
Figure 12-3.
Grounding And Bonding
Panels Of Metal Building
S.001 9
Figure 12-4.
Bonding Method For Poor Conduc tors
F.
Power Service
The high-frequency power source should be connected to the line input power supply as instructed in this man ual. If the unit is equipped with a power cord, the supply conductors should be serving the high-frequency power source completely enclosed in solid metallic conduit, or in equivalent shielding, up to the point of connection with the power cord.
The solid, metallic conduit, or equivalent shielding, should extend the entire distance from the power entrance location in the building to the high-frequency power source.
Shielding should be elec trically continuous throughout its length and should be connected so that good electrical contact is provided be tween the shield and the high-frequency power source.
OM-458 Page 53
Line
Power input
Supply
High-Frequency
Welding Power Source a.
Have all unshielded power, lighting, munication wires within the and welding com zone placed in the grounded welding zone.
shields or relocated outside b.
Ground all large metallic objects, long guy wires, or support wires within the welding zone.
c.
Be sure that there are no external power or tele phone wires, which may be off the immediate premises, within the welding zone.
Ground
Line Fuse And Switch Box
Or Receptacle
Figure 12-5.
Installation Of High-Frequency
Stabilized Arc Welding Power Source
S-0021
12-6.
GUIDELINES FOR INSTALLATION OF HIGH-
FREQUENCY ASSISTED ARC WELDING
POWER SOURCES
1.
2.
3.
Locate the the equipment so that the ground wire of high-frequency power source can be kept as short as possible.
Shield the line input power leads up to the point of connection with the enclosure of the high-fre quency power source as factures specified requirements (see section by the manu
12-5F).
Be sure that there is good electrical contact made at the enclosure of the high-frequency welding power source, through the conduit, and back to the service box.
Be sure that the conduit system is continuous to a point at least 50 ft.
(15 m) from the equipment, and that the conduit system is one complete run within the high-frequency zone.
If rigid, metallic conduit is not used, be sure that the shielding used has equivalent shielding effi ciency. Copper sleeving, lead covered cable, or the equivalent, is satisfactory.
Spirally flexible, metallic conduit is not suitable.
wound,
4.
5.
6.
7.
Keep WORk and ELECTRODE cables as short and straight as possible.
Keep weld cables to a maximum length of 25 ft.
(8 m).
Keep weld cables as close together and as close to the ground plane as possible.
Adjust spark gap setting to the minimum setting given in this manual.
8.
Secure all service and access doors before oper ating.
9.
Visualize the welding zone as a sphere with a
50 ft.
(15 m) radius centered on a point between the power source ure and the electrode holder
12-6), and proceed as follows:
(see Fig
OM-458 Page 54 center Point
Figure 12-6.
WeldIng Zone
S.0022
10.
11.
12.
Use driven ground rods which enter the ground
10 ft.
(3 m) or less from the ground connection, or cold water pipes, as the ground for the high-fre quency welding power source.
Be sure that all ground connections are clean and tight.
If the high-frequency welding power source is op erated within a metal building, be sure that the building is properly grounded.
12-7.
INSTALLATION GUIDELINES CHECKLIST
All items may not be necessary or practical for each in stallation.
Complete the necessary items to eliminate in terference with authorized FCC services.
1.
2.
3.
4.
5.
Is equipment properly located?
(See Sections 12-4, 12-5D, 12-5E, 12-6.1, and
12-6.9.)
Are ac input power connections properly made?
(See Sections 12-5B, 12-6.2, and 12-6.3.)
Are weld cables and equipment properly in stalled?
(See Sections 1 2-5A, 12-6.4, 12-6.5, and 12-6.6.)
Are ground connections properly made?
(See Sections 1 2-5C, 12-6.1, 12-6.6, 12-6.11, and 12-6.12.)
Is equipment properly set up and adjusted?
(See Sections 12-6.7
and 12-6.8.)
SECTION 13 PARTS LIST
OM-458 Page 55
-S -L N)
-s -t -s
11
(0
-s ~
O~a Ce)
-s -S Ci)
-S -s A
11
-s
(a
~s~0 C~
Ci) I~)
-s 0 N) -5 0 -5
(SI
-s 0
(0 -J
(0 (0 Cal (0 A (0 -S (0 0
0(0
/
/
I
0 1%)
0 -S
N) Ce)
N) A
N) (Ji
-n
(a C CD
-& Ci) -I
0I 0 0 CD 3
0
C
37
26 41
32
75
76
80.
79
78
71
Fig 13-8
34
70
69
60
61
62
57
56
55
54
64
65
66
67
63
68 53 52 51 50
48
49
SD-088 637-E
43
44
OM-458 Page 57
Item
No.
Dia.
Mkgs.
1
2
3
3
4
13
14
15
16
17
18
19
20
21
22
23
24
25
8
9
10
11
12
5
6
7
30
31
32
33
34
35
36
37
38
39
26
27
28
29
40
41
42
AC-Z
DC-Z
NEG
POS
BAT
43
44
45
46
47
48
48
49
OM-458 Page 58
Part
No.
Description
Figure 13-1.
Main Assembly
089 517
134 771
030 194
053 664
115000
125 756
020 108
118 066
602 938
097 507
010 869
096 439
084 173
107 816
047 420
605 288
084 479
STRAP, fuel tank
PLUG, protective .640sq (used as
TANK, fuel (consisting of) engine door bumpers also)
TANK, fuel (consisting of)
~CAP,fueltank
SENDER, fuel gauge
FLANGE, fuel gauge
GUAGE, fuel elec 12V neg
FITTING, pipe-plug sq hd grd
.125NPT
STRIP, rbr adh back .125
x
1.000
x
20.500
FITTING, pipe brs bushing 1/4 x
VALVE, ball .125-27NPTF inlet x
1/8NPT
.25Otbg
CLAMP, hose .460-.545
cip dia
HOSE, SAE .250
ID x
.500 OD (order by ft)
FILTER, fuel inline
FITTING,
FRAME, pipe galv plug sq hd
.25ONPT
mtg-reactor/stabilizer
REACTOR 003 135
003097
017 479
092 097
108 081
047 812
023 626
010 954
134779
071 678
STABILIZER
SEAL, weather-lift eye
FRAME, center/lift eye base
TERMINAL PROTECTOR, battery post
CABLE, bat neg
CABLE, bat pos
WASHER, flat stl .406 ID x
1.250
OD
HOLDDOWN,battery
BATTERY, stor 1 2V 55Ocrk 1 65rsv
134 782 BATTERY BOX
082 672 BOLT, L stl .312-18 x
6.375
604 433 NUT, stl
018 765 AIR slflkg hex hvy .312-18
CLEANER, intake (consisting
018859 ~CAP,dust of)
008 698
021 117
BAFFLE, dust cap
NUT, wing
+017 309
.
ELEMENT
000 272
.
CLAMP ASSEMBLY
031 868
010861
018 365
003 075
010 875
BRACKET, mtg air cleaner
CLAMP, hose 1.312-2.250clpdia
HOSE, air cleaner intake
PANEL, side LH
CLAMP, muffler 2.000dia
107 632
090 656
035 968
108 487
004 130
MUFFLER, exhaust spark arrestor
COVER, top
WASHER, flat rbr 3.625
ID x
5.875 OD x
.O62thk
LABEL, warning falling equipment can cause serious etc
BRACKET, support door
+090 699
+090 700
DOOR,
DOOR, engine cmpt RH engine cmpt LH
121 509
053 430
LABEL, warning do not run engine
LABEL, diesel engine maintenance (LH
090628 LATCH engine door)
089 947
605 982
028 089
+003 559
+003 648
011 198
RADIATOR w/SHROUD, (consisting
CAP, rdtr pressure 7 lb
DOOR, access rdtr
ENCLOSURE, rdtr
ENCLOSURE, rdtr w/tachometer
LABEL, warning fan of)
Quantity
2
6
1
1
1
1
1
2
1
1
1
1
3 ift
1
1
1
2
1
1
1
1
1
I
1
2
1
1
1
1
2
1
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
74
75
76
77
78
79
69
70
71
72
73
63
64
65
66
67
68
80
81
82
83
84
85
86
87
88
Sb
89
ALT
TEl
Item
No.
Dia.
Mkgs.
56
57
58
59
60
61
62
50
51
52
53
54
55
94
95
96
97
89
90
91
92
93
SR1,2
98
99
100
R2
R3
CT1
Part
No.
Description
Figure 13-1.
Main Assembly (Continued)
Quantity
123 504
006 015
010861
091 418
017 363
123505
090 690
000 302
089 343
003 631
088 781
062 263
136404
006 014
111 851
005 772
005 373
010837
010493
047 474
071 194
017 594
020 365
Fig 13-8
071 731
601 945
114 772
025 474
025 473
136 268
007 894
134 948
007 025
602 218
085 980
010 146
603 107
038 621
038 620
035 131
053 967
081 499
035 860
035 704
031 926
601 851
083476
071 730
071 890
+085 439
083 030
601 836
030 060
128 862
036611
GUARD, fan RH
FITTING, pipe brs drain cock 1/4NPT
CLAMP, hose 1.312-2.25oclpdia
HOSE, rdtr lower
HOSE, rdtr
GUARD,fanLH
PANEL, side generator
PANEL, side RH
RIVET, truss hd 1 in
PIPE, exhaust
FAN,
BELT, engine 15.500
COW rotation
(included w/engine)
ENGINE,gas
FITTING, brs flrd invt elb M 1/4 x
1/8NPT
LINE,fuel
CONTROL, weld/idle (consisting of)
SOLENOID, 14VDC .52A
PIN, spring CS .093
x
.625
BUSHING, snap-in nyl .625 ID x
.875mtg
hole
BRACKET, mtg idle device
STRIP, mtg throttle
CLAMP, manifold stove
STOVE, manifold
GENERATOR
WASHER, flat stl .656 ID x
2.250 OD x
.l87thk
SCREW, cap stl hexhd .625-18 x
4.000
STARTER, engine 12V (included w/engine)
SWITCH, thermo temp
SWITCH, pressure oil
BRACKET, mtg alternator (included
ALTERNATOR, 42A 12V neg w/engine grd w/pulley see engine parts
(included w/engine) list)
STRIP, adj-alternator (included w/engine see
PULLEY, (included w/engine see engine parts engine list) parts list)
MOUNT, engine
BASE
SCREW, cap stl hexhd .625-11 x
1.250
WASHER, lock sti split .625
NUT, stl hex full fnsh .625-11
CLAMP, nyl .625
HOSE, nprn slit bk
.156 ID x
.343
OD
BLOCK, term 30A 4P
(order by ft)
LINK, jumper
CONNECTOR, blk 30A 45
INSULATION, rect deg
BRACKET, mtg-term strip
RECTIFIER, (consisting of)
RECTIFIER, integ 40A 800V
HEAT SINK
NUT, stl slflkg hex reg
.625-18
TUBING, nprn .875
ID 2.500
OD x
2.000
TUBING, stl .875
OD x
1 2ga wall x
2.375
RETAINER, mount
FRAME, upright base front
STUD, brs grd .250-20 x
1 .750
NUT, brs hex .250-20
RESISTOR, WW jam hvy adj 375W 20 ohm
RESISTOR, WW adj 375W 50 ohm
TRANSFORMER, current 500/5
2
2
2
2
2
4
4
1
2
2
1
1
1
6
I
1
1
6
I
3
OM-458 Page 59
2
2
1
1
1
1
1
1
1
1
1
I
1
1
Item
No.
Dia.
Mkgs.
110
111
112
113
114
115
101
102
103
104
105
106
107
108
109
Fl ,2~
C5/Dl
D10
Part
No.
Description
Figure 13-1.
Main Assembly (Continued)
+113038 DOOR,accessfrontlower
134 792 LABEL, warning general precautionary
Fig 13-2 PANEL, front lower w/components
Fig 13-7 PANEL,frontupperw/components
084 771 PANEL, control HF (Fig 13-4)
057 358
048489
BUSHING, snap 1
.000
ID x
1
CLAMP, nyll.000 clamp dia
.375mtg
601 158 BLANK, snap-in metal .875mtg
hole
134 903 FUSE BOX hole
026 947
039 169
+132 116
044 383
*012 625
601 165
070 010
085 323
059389
STAND-OFF, instil .250-20 x
1.000
lg
HOLDER, fuse-cartridge 60A 250V
COVER,junction box
LABEL, warning 1 20/240V volt junction box
FUSE, cartridge 45A 250V
BLANK, snap-in metal 1.000mtg
hole
BOLT, J .250-20 x
2.312
CAPACITOR/DIODE
DIODE,3A1000VSP
Part of Optional 041 713 Fuel
*Recommended Spare Parts.
+When ordering a component
Gauge.
originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
I
1
2
OM.458
Page 60
Item
No.
Dia.
Mkgs.
10
11
12
7
8
9
13
2
3
4
5
6
13
14
15
16
17
010,11
06
GS1
Part
No.
Description
Figure 13-2.
Panel, Front Lower w/Components (Fig 13-1 Item 103)
020 279
085319
010 006
108 321
085 436
085321
039 047
601 976
039 049
601 880
039044
601 879
085437 iii 784
010 222
010 296
003 207
003538
CLAMP, stl cush .75Odia
x
CAPACITOR
.28lmtg
hole
TUBING, stl .625
OD x l2ga wall
HF PANEL, (Fig 13-3)
BRACKET, mtg HF
CAPACITOR panel
TERMINAL, pwr output red (consisting of)
SCREW, cap stl hex hd .500-13 x
1.500
TERMINAL BOARD, red
NUT, stl hex jam .500-13
BUS BAR, term bd
NUT, stl hex full fnsh .500-13
PANEL, front lower
PANEL, front lower w/LCC
CONNECTOR, rect cell
FITTING, hose brs elb M 1/4NPT x
.625-18RH
BRACKET, mtg solenoid
VALVE, 115VAC 2 way 1/41P5 port 1/8 cr1
Quantity
2
1
1
1
1
1
4
1
1
1
1
1
1
2
1
1
1
2
Fig 13-3
4
17
6
I
1211 10 98
7
1615 14 13
Figure 13-2.
Panel, Front Lower w/Components
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
SC-088 175-C
OM-458 Page 61
8
9
10
11
12
2
3
4
5
6
7
13
14
15
16
17
18
19
20
21
22
23
G
T2
Ti
R4
R6
C3
R7
C2,4
Item
No.
Dia.
Mkgs.
Part
No.
Description
108 321 Figure 13-3. HF Panel (Fig 13-2 Item 4)
020 623
*020 603
020 622
095 621
601 835
010 886
016601
038 887
602 042
033 373
601 838
074398
603 737
605 742
083 784
030965
081 291
081 282
007 532
059 887
030603
010885
096 761
SPARK GAP ASSEMBLY,
POINT, spark gap
HOLDER, point
BASE
(consisting of)
NUT, hex-regular 10-32
STRIP, conductor
MOUNTING BOARD
STUD, primary board brs 10-32 x
1 .375
SCREW, brs-rd hd 10-32 x
1.000
COIL, coupling-air
NUT, brs hex .375-16
TRANSFORMER,
HV 115V
SCREW, mach brs rdh .375-16 x
1.750
CLIP, mtg-resistor .500
ID
RESISTOR, WW fxd 100W 10 ohm
RESISTOR, WW fxd 100W 100 ohm
CAPACITOR,
STRIP,
(consisting of) mtg-capacitor
CLAMP, 1.000dia
CAPACITOR, MF lOuf22OV
RESISTOR, WWfxd lOW lOKohm
STRIP, conductor 5-3/8 in Ig
CAPACITOR, mica .OO2uf
10,000V
Quantity
1
1
4
1
1
2
1
6
1
1
3
2
1
2
1
2
8
1
1
4
4
1
11
12
22
23
22
Figure 13-3. HF Panel
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-458 Page 62
SC.005 561-B
Item
No.
Dia.
Mkqs.
1
2
3
4
7
8
5
6
9
10
11
12
13
CR3
CT2 iT
PC2
TD1
CR2
CR1
Cl
PCi
R5
14
15
SR6
C21-24
Part
No.
084 771
Description
Figure 13-4.
Panel, Control-HF (Fig 13-1 Item 105)
034 856
084 536
059 712
123794
095 042
038621
080 509
072 255
000769
059267
044588
053296
071 609
072635
007080
072 633
035704
110960
RELAY, 11OVDC SPST
PANEL, mtg-HF components
CLIP, component
.437dia
EDGE TRIM, (order by ft)
TRANSFORMER, control-idle
BLOCK, term 30A 4P
GROMMET, scr
No.
8/10 .312sq
CIRCUIT CARD, output-current detector
TIMER, delay 0-100 sec
12OVAC
RELAY, end
1 2VDC DPDT w/flange
RELAY, end
1 2VDC 3PDT flanged
(Fig 13-6)
CAPACITOR, ignition .5uf
CIRCUIT CARD, weld/idle control (Fig 13-5)
RESISTOR w/BRACKET, (consisting of)
RESISTOR, WW fxd 25W 50 ohm
BRACKET,
RECTIFIER, mtg-resistor integ 40A 800V
CAPACITOR ASSEMBLY
Quantity
1
1
1
1
1
1
1
2ft
1
3
Fig 13-5
12.
7 Fig 13-6
SC.084
549
Figure 13-4.
Panel, Control-HF
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-458 Page 63
Dia.
Mkqs.
-
PCi
C50,54
C51 52
C53
050,54
D51-53,56,57
D55
050
Q51
R50,53
R51,56
R52
R54
R57
R58
R59
*
R60
R61 62
R63
R64
SCR5O,51
SR5O
Part
No.
071 609
Description
Figure 13-5.
Circuit Card, Weld/Idle Control (Fig 13-4 Item 12)
035 522
045 868
080 507
070 250
026202
037 243
000 088
039 355
000 039
605 919
605916
035 824
052 146
053 572
052 138
035 822
030 026
003 272
071 595
080 508
021 939
CAPACITOR, polye film .047uf bOy
CAPACITOR, elctlt 1 OOuf 25VDC
CAPACITOR, tantim 22uf 1 5V
DIODE, rect 3A 600V SP
DIODE, rect 1A400VSP
DIODE, zener 18V 1W
TRANSISTOR, NPN 800 MA 40V
TRANSISTOR, ujt 15 MA 40V
RESISTOR, C 2W 680 ohm
RESISTOR, C .25W
47 ohm
RESISTOR, C .25W 1K ohm
RESISTOR, CF .25W 270 ohm
RESISTOR, MF .25W6l9Kohm
RESISTOR, MF .25W 12.1K ohm
RESISTOR, MF .25W 20K ohm
RESISTOR, CF .25W 10 ohm
RESISTOR, C .5W 560 ohm
RESISTOR, CF .25W
1 meg ohm
RESISTOR, CF .25W 22 ohm
THYRISTOR, SCR 8.5A 200V
RECTIFIER, integ 1 .5A 400V
Quantity
2
1
1
2
1
1
1
2
2
2
5
1
1
2
1
1
1
1
2
1
1 n
P61
D54
D52
FIgure 13-5.
Circuit Card, Weld/Idle Control PCi
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-458 Page 64
SA-090 506-D
Dia.
Mkgs.
PC2
C50-52
C53,54
D50
D51
0C50
Q50
R50
R51
R52
R53
SR5O
Part
No.
Description
072 255 Figure 13-6. Circuit Card, Output-Current Detector (Fig 13-4 Item 7)
031 670
000 859
037 449
026 202
000 041
005274
030630
039 106
074 111
605 912
021 939
CAPACITOR, cer disc .O5uf
500VDC
CAPACITOR, elctlt 220uf 35VDC
DIODE, zener
15V 1W SP
DIODE, rect 1A 400V SP
IC, interface 4N32
TRANSISTOR, NPN 1OA8OVNPN
RESISTOR, WWfxd 11W 100 ohm
RESISTOR, CF .25W
470 ohm
RESISTOR, C 2W 47 ohm
RESISTOR, C .25W 4.7K ohm
RECTIFIER, integ 1 .5A 400V
Quantity
1
1
1
1
3
2
1
1
1
1
I
ASSEMBLY
2~i____
.2~
+
0
R52~
R51
0C50
D50
~.-
Q50
0
C51
051
9
A
9B Uc RD 9E
0
SB.108 87~.C
Figure 13-6.
CIrcuit Card, Output-Current Detector PC2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-458 Page 65
5 6 r
37
21
22
32
31 30 29 28
27
26 25 24
20
19 18
17
16
SD-086 638-B
Figure 13-7.
Panel, Front-Upper w/Components
8
9
OM-458 Page 66
Item
No.
Dia.
Mkgs.
4
5
6
1
2
3
7
8
9
10
S12
RiO
S4
Si
Ri
S3
CB1,2
S2,7
RC1
31
32
33
34
35
36
37
20
21
22
23
24
25
26
27
28
39
30
10
18
19
RC2~ ii
12
13
14
15
16
17
P1
P2
D2
MS1
F
PB1
C16,17
RC4
07-9
RC3
S5
A2
Vi
PL1,2
HM
Part
No.
041 329
604103
025 234
025 704
025 703
070 250
011 072
*048 317
046 433
085 320
039 602
039 618
085 324
039 615
039621
011 611
010647
044328
039618
009835
604 525
019790
084 246
021 385
025623
044335
602592
082789
*048 155
082 788
145247
097922
019602
602 178
011 622
030686
011 610
085 363
084578
605960
044 353
139266
011 609
604176
073 690
083 030
601 836
Description
Figure 13-7.
Panel, Front-Upper w/Components (Fig 13-1 Item 104)
Quantity
SWITCH, tgl 3PDT 15A 125V
POTENTIOMETER, C iT 2W 2
SWITCH, meg ohm tgl SPDT 15A 125VAC center off
PANEL, front-upper
SWITCH, polarity
RHEOSTAT, WW 300W 34 ohm
SWITCH,
CIRCUIT range
BREAKER, man reset iP 15A25OVAC
SWITCH, tgl SPDT 15A 125VAC
RECEPTACLE, str dx grd 2P3W 1 5A 1 25V
CAP, P&S 5266 DF
AUXILIARY POWER, 240V (consisting of)
RECEPTACLE, str dx grd 2P3W 15A 250V
PLUG, str grd 2P3W 1 5A 250V
FILTER, HF AC/DC volt and DC amp meter
FILTER, HF AC amp meter
DIODE, 3A 600V
SWiTCH, magnetic w/adj plate and clamp (consisting of)
FUSE, mintr gI 14A 32V
SWITCH, PB MC NO 36VDC black
CAPACITOR
RECEPTACLE, twlk 2P2W 20A 250V
CAP, Arrow Hart 9102N
CAPACITOR
RECEPTACLE, twlk 4P4W 20A 250V
CAP, Hubbel 7411C
SWITCH, tgi DPDT i5A 125V
PIN, spring 5/32 x
1-1/4
HANDLE, switch
CAP, twlk 2P2W 20A 250V
SWITCH w/LEADS
CABLE, No. 18 2/c
CONTROL,
(order by ft) push/pull
CAP, switch-dust/weather proof black
BOOT, tgl switch lever
METER, weld 0-500 scale
METER, volt AC/DC 0-100 scale
KIT, shield-meter
LENS, Iignt-red
BULB, incandescent-flanged base 1 2V
HOLDER, light-indicator
METER, hour 4-4OVDC
KNOB, pointer (RiO)
KNOB, pointer (Ri)
SCREW, set skt .250-20 x
.375
NAMEPLATE, (order by model and serial number)
STUD, brs grd .250-20 x
1.750
NUT, brs hex .250-20 jam hvy
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
5
1
3
2
1
1
2
1
21ff
1
1
1
1
1
1
1
1
2
2
1
Optional
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-458 Page 67
1
23
22
17
*Does not reflect actual part.
16
15
14
6
Figure 13-8. Generator
OM-458 Page 68
SD-086 774-C
8
9
10
11
4
5
6
7
1
2
3
12
13
23
24
25
26
27
14
15
16
17
18
19
20
21
22
SR3
C14,15
06,8
R11,VR1
SR3
C12,13
D5,7
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 13-8.
Generator (Fig 13-1 Item 71)
049 650
018 614
BRACKET,
BRUSH mtg-brushholder
SET, (consisting of)
BRUSH *044 755
600 270
018 665
013 367
085 274
.
HOLDER, brush
CAP, brushholder
LABEL, warning moving parts can cause serious injury
GUARD, generator
+137 733
039 207
.
STATOR,
BAFFLE, generator (consisting of) air-generator
089 736 ROTOR, generator (consisting of)
024617
053390
RING,retaining-ext
BEARING,baIl
089 737
.
035 776
.
044 374
FAN, rotor
KEY, 3/8 x
3/8 x
2
STATOR, excitor
049 235
106424
106 429
048420
106425
ENDBELL, generator
BARREL, rect
DIODE ASSEMBLY, (consisting of)
CAPACITOR,cer.O1uf500VDC
INSULATOR
037 956
.
DIODE, 275A 300V SP
046819 ~SUPPRESSOR
106426 INSULATOR
106 440 BUS BAR, rect
106428
048420
.
DIODE ASSEMBLY, (consisting of)
CAPACITOR, cer
.O1uf500VDC
037 957
.
DIODE, 275A 300V RP
106425 INSULATOR
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
1
1
1
2
1
1
1
1
1
1
2
2
I
2
2
1
2
2
1
I
2
1
1
1
1
1
1
OM-458 Page 69
Dia.
Mkqs.
TAC
C20
F3
R13
Sli
S14
SR4
Zi
Part
No.
Description
Parts For Optional Equipment
042 564
047 841
047 842
137 825
602 946
041 179
010 429
020325
041 329
042 566
105738
003 648
106632
027 735
010021
042 023
011 116
111 782
030647
111 779
112018
035704
111 790
059 866
097922
111 783
010647
070 220
041 713
ENGINE METER KIT, (consisting of)
GAUGE, temp
GAUGE, pressure 5-100
KIT, oil line 54.000
1/4NPT x
1/8NPT
FITTING, pipe-brs tee B 1/8NPT
ELEVATION MODIFICATION, (consisting of)
JET, carburetor high altitude
LABEL, high-altitude operation
AUXILIARY POWER, 24V (see Fig 13-7)
TAC-8 TACHOMETER, (consisting of)
TACHOMETER, 0-3000RPM
ENCLOSURE, rdtr
CAPACITOR
HANDLE
CLAMP, stl cush .562dia
x
.343mtg
hole
LOW CURRENT CONTROL, (consisting of)
FUSE, mintr gI slo-blo 7A
HOLDER, fuse mintr
RESISTOR, WW adj 240W 10 ohm
SWITCH, polarity
SWITCH, rotary
RECTIFIER,
REACTOR integ 40A 800V
HANDLE, switch
KNOB, pointer
CHANNEL,mtg
PIN, spring .156x 1.250
TUBING, .500
OD x
GAUGE, fuel l7ga waIl 2.125
(Fig 13-1)
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
OM-458 Page 70
OPTIONS AND ACCESSORIES
RHC-3GD25B
(#004735)
Remote hand amperage control.
Furnished with 20 ft.
(6 m) cord and plug.
RFC-23GD25A
(#004 737)
Remote foot amperage and contactor control. Furnished with 20 ft.
(6 m) cord and plug.
LOW CURRENT CONTROL
(#042 023 Factory)
(#042 024 Field)
Provides 0 to 40 amperes of ac or dccurrent.
240 VOLT AUXILIARY POWER
RECEPTACLE KIT
(#041 329 Factory)
(#041 330 Field)
Required to reconnect auxiliary power from 120 to 240 volts.
LP GAS CONVERSION KIT
(#041 504 Factory)
ENGINE GAUGE KIT
(#041 526 Factory)
(#041 606 Field)
Mechanical gauges for oil pressurewater temperature in addition to standard indicator lights.
TACHOMETER TAC.7
(#041 591 Factory only)
Electronic type.
Mounted inskle on radiator shroud.
FA-1 LOCKABLE FLAME
ARRESTOR FUEL CAP
(#041 056 Field only)
COOLANT SYSTEM HEATER
(#040 878 Field only)
ALTITUDE MODIFICATION KITS
When operating above 4000 ft.
(1219 m).
(#041 395
(#041 396
Factory)
Field)
NO. 4WA WELDING
ACCESSORI ES
(#040 045)
35 (10.7
m) No. 2/0 electrode cable with electrode holder and lug, 30 (9 m) No. 2/0 ground cable with lugs attached, welding helmet and wire scratch brush.
RADIATOR 1 (115 volt)
(#041 398)
RADIATOR 2 (230 volt)
(#041 399)
Water coolant system for water cooled hG torch.
Mounting Kit For 4 Wheel Trailer.
(#041 544)
2/89
OPTIONS AND
ACCESSORIES
NO. 3000-4 FOUR-WHEEL
TANDEM TRAILER
(#041 015)
Tandem axle design enables this trailer to ride smoothly over rough terrain. The unit is equipped with fenders, lights, a leveling jack, 2
(50 mm) bail hitch and safety chains.
The two wheel self-actuating hydraulic brake system operates automatically as pressure is put against the tongue of the trailer.
Another feature is a breakaway device which would automatically lock the brakes should the trailer become loose.
A hand operated parking brake is standard.
Specifications
Total Width 72-1/4 (1.8
m)
Tread 63 (1.6 m)
Length 163-1/2 (4.2 m)
Height of Bed 19 (480 mm)
Road Clearance 10 (254 mm)
GVWR 3000 lbs.
(1360 kg)
Shipping Wt.
757 lbs.
(343 kg)
EDT 2400-2 TWO WHEEL
TRAILER
(#041 722)
A 2100 lbs.
(953 kg) capacity trailer with welded structural steel frame, heavy duty axle with roller beating hubs and leaf spring suspension.
Mounting holes for all large Miller engine driven welding generators are prepunched.
Hardware for mounting is provided.
Also included is a jack stand for raising and lowering the tongue, safety chains and universal tongue mounting for optional hitches.
An optional fender and light kit is required when trailer is used on the highway.
NOTE: Hitch must be ordered separately.
SpecIfications
GVWR: 2400 lbs.
(1087 kg)
Trailer weight: 300 lbs.
(136 kg)
Trailer capacity 2100 lbs.
(953 kg)
Total Width (without optional fender kit) 62 (1.6 m)
Total length (wftout optional hitch)
96 (2.4 kg)
Width of bed 40-1/2 (1029 mm)
Track Width 53-1/2 (1359 mm)
Height of Bed 21 (533 mm)
Tire size P205D-1 4
Shipping Wt.
300 lbs.
(136 kg)
The EDT 2400-2 traIler when equipped with fender and light kit and 2 (50 mm) ball hitch and the
No. 3000-4 trailer conform to all appilcable U.S. Federal Motor
Vehicle Safety Standards In effect on date of manufacture.
311(80 MM) DIAMETER LUNETTE
TOWING EYE
For use with No. 3000-4 Trailer.
(#041 628 Factory)
For use with 64X and 74X Trailer.
(#040 697)
FENDER AND LIGHT KIT
(#041 723)
Includes fenders, harness and lights, wiring mounting hardware.
Shipping weight 50 lbs.
(23 kg)
HITCHES
2 (51 mm) BALL
(#041 724)
Shipping
weight 5 lbs.
(2 kg)
CLEVIS
(Not for highway use)
(#041 726)
Shipping weight 11 lbs.
(5 kg)
2-1/2 (64 mm) LUNNETTE EYE
(#041 725)
Shipping weight 9 lbs.
(4 kg)
TOOL BOX
(#040 638)
For use with 4 wheel trailer only.
Keeps tools handy. Sturdy steel construction with hinged cover.
Five inch (130 mm) high divider in center of box. Attachment hardware included.
Height 11 (280 mm),
Depth 10 (254 mm), Length 44
(1120 mm).
NO. CC-4 CANVAS COVER
(#040 144)
Heavy-duty, olive drab, waterproof and mildew resistant.
CRT CYLINDER RACK
(#040 543)
Two racks included.
(For use with 4 wheel trailer only)
NO. 74X FOUR-WHEEL TANDEM
TRAILER
(#041 086)
For off the road use only.
The tandem axle design enables this trailer to ride smoothly over rough terrain. The unit is equipped with fenders, 12 volt stop, directional and tail-lights and leveling jack.
A bolt on clevis hitch and 2 (50 mm) ball hitch are also included.
Tire Size F78-14
Tread 62 (1.6 m)
Total Width 72 (1.8
m)
Road Clearance 11 (280 mm)
Shipping Wt. 790 lbs.
(358 kg)
NO.64 X TRAILER
(#041 223)
Same as
74X but without fenders and lights. Weight 710 lbs.
(321 kg)
Shipping Wt. 740 lbs.
(336 kg)
When the ordering off-road trailers purchase order must include the statement, For off the road use only.
2/89
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