Miller BIG 40 Owner Manual

July 1973 FORM: OM-450
Effective with serial No. HD690740
CE 7; _
MODEL STOCK NO.
BIG 40 900955
MODEL /STOCK NO, SERIAL/STYLE NO.
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO, 4579
———"——— TABLE OF CONTE NTS scene
Paragraph No. Page No.
SECTION 1 —~ SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE
General oot ee ee eee ee ee ea
Welding Cables... ..... i i ee ee
Electrode Holder o.oo ott ee iit aa ea aa REKEN Le
Code Conformance ..........eeecreesererereereore ee. ace Lee»
Parallel Connections ......202020 0004 410 ae 14 1 0 8 4 a 4 0 0 8 0 a a ona.
. Power Disconnect Switch .........-eeederoreroererecam. aaa.
. Polarity Switch .........._eeorearenrorearyrereoncorererare ce.
. Range Switch 1.022020 0440126 4 84 8 a a a a ea ee a ee 100 eee
Exhaust Gases oo. tte tt it itt terete ee aaa
Power Circuit Ground ..,........eee-esrararereneravrorareero eno.
Containers Which Held Combustibles .................... eae
Hollow Castings (Welding of)... ovine ieee
Explosion Hazards . ........ citi aie ii eee aaa о
Ventilation © ott es te ee ee eee RR RK aa
Solvents... .............. i tea eater eae 6
. Fire Hazards .. 111100220244 4 14 110 4 4 0 4 a ee 4 8 0 0 4 a 0 0 4 0 8 8 a ee +0
. Electrical Shock-Voltage .......0222000 0000404 aa 0 ea a eee aa ae La ee 0
1-18. Electrical Shock-Dampness ......2242042 0004 0e 40 4 a 0 0e aa en eue aa ann 0
1-19. Starting Under Load .......24000 020040 es a a ee a a a 14 11 ee eee 12200
1-20. Face Protection .........oecoreenvesnmoenmarerearaceameorerearero
1-21. Eye Protection .........eemerorrarariorarrecrererermecoerea—
1-22. Clothing ...........ee0seereone rv eorocrarierrenarrearenaremA.
1-23. Hot Metal Burns ........oe.eraenverraoradoordorerdearoredaac cana
1-24. Grinding and Chipping ......000000 040 es aa 4 aa eee 4 a ee de ae неее
1-25. Compressed Gas Cylinder ......2200 0822244 a ee a a a ae 0 2 11 KH
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SECTION 2 — INTRODUCTION
2-1. General 1.111.211 24422414 4 4 a 4 0 0 4 4 4 0 a 4 40 0 0 ea a ee a 0 0 00 8 11 02 200
2-2. Receiving-Hand!ing .. 222222000004 ea 0 a aa ee 0 Pr
2-3. Description ......22000 042040040400 4e eee sa ea a a a акк 2 11 1 000 0 5
2-4. Safety ....... eneddariardoredvereravarecoearerecrannarecoo |
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SECTION 3 — INSTALLATION
3-1. Location ....... eo ear erdoreadonearecmerodudorrarvar0rarev e nao
3-2. Weld Qutput Connections ....... —.evmerrerarrvrrrecr eae
3-3. Generator Chassis Ground .... 1.222000 2221 4 a 22 24 4 0 4 4 0 0 ee ae 0 a 0
1 3 O
SECTION 4 — OPERATION OF GENERATOR CONTROLS
120 Volt AC Receptacie ...........esorererece:eereeare rmac.
Range Switch ........oeocereororesrorerearerrecmareocare e.
Fine Current Control .........._eememorerooaerenamenorentene 0
Volt-Ampere Curves .......erremecncorareea0rarearereerearere.
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SECTION 5 — GENERATOR OPERATION
5-1. Shielded Metal-Arc Welding (SMAW) {Stick Electrode) ................ 8
SECTION 6 — GENERATOR MAINTENANCE
6-1. Сепега!| .............. eee ie 0 8 4 a a a era ee a a Se ea Les 6 .. 8
6-2. Collector Ring Brushes .........eesxvacorerrarerecrorrervodrere. 8
6-3. Welding Cables ..........e.mrereve cerca rerrere orar eta. 8
Paragraph No.
SECTION 7 — ENGINE PREPARATION
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SECTION 9 — ENGINE OPERATION
Lubrication .....22 2000042444 4 0 ee 4 4 4e ea 4 1e ea a 1 4 4 0 4 4 0 a 84 6
Coolant System ........o..e.
Readying New Battery For Service
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Air Cleaner © i tt tt tee eee eee tt eter ee terre ee ai aaa
FU Le ee ee ee tei e eee eee eee eee eae
Choke Control . «cv ttt it 4 442 4 4 4e 4 4 4 0 a 0 4 0 4 0 a 4 0 8 000 00 0
Starter Switch .....222002 00220 4 0e ee tee ee eee eae
Automatic Idie Control eee eee exareurecooreroaa nene»
Oil Pressure Gauge ........e.- _onvarorecorearreróarercoereerecsaao
Engine Ammeter ...... _..e.ermererrerecoreeoe.. eh eee
Temperature Gauge .........0ee_ererearoreoerveroorcerencsverde:
Carburetor Air Temperature Selector ..... cv iii iii iii iene
9-1. Preparing To Start And Starting The Engine ................ ........
9-2. Engine Shut Down ..........
SECTION 10 — ENGINE MAINTENANCE
10-1. Lubrication ...........222044
10-2. Coolant System .......2200 0204 6 4e 0 a 4 a Le sa a a 0 0 a es a 0 a a 0 aes
10-3. Governor Service ............
10-4. Carburetor Float Setting ......
19-5. Vacuum Circuit Air Filter .....
10-6. Air Cleaner Service ..........
SECTION 11 — TROUBLESHOOTING
11-1. Engine Troubleshooting.......
11-2. Engine/Generator Troubleshooting
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== SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE ===
1-1. GENERAL
These rules apply to ac and dc welding generators, ac trans-
former and ac/dc welding machines, and de transformer recti-
fier welding machines.
In arc-welding operations, where electrically energized parts
are exposed, observe the following safety rules to insure max-
imum personal safety and protect nearby persons,
Failure to observe these safety precautions may expose not
only you, but fellow workers as well, to serious injuries, Once
these rules are learned and kept in mind, proceed with maxi-
Mum assurance.
1-2. WELDING CABLES
DON'T overload cables, (Figure 1-1)
Figure 1-1. Don't overload cables
NEVER use welding cables at currents in excess of their rated
capacity. It will cause overheating and rapid deterioration of
the insulation. It is also uneconomical.
DON'T use worn or poorly connected cables, {Figure 1-2)
Figure 1-2. Don’t use worn or poorly connected cables
Inspect the cables frequently. Immediately repair all breaks
in the insulation with rubber and friction tapes. Tighten all
cable connections and adequately insulate any joints where a
connector may have an exposed conductive part. In addition
to the potential hazard to life, a hazard occurs when exposed
sections of cable come in contact with grounded metalic
objects, causing an arc. Unprotected eyes may be injured and
fire may result if combustible materials such as oil or grease
are in the vicinity. The efficiency and quality of welding will
be improved by elimination of these dangerous grounds, and
by keeping connections tight.
. ELECTRODE HOLDER
DON'T use electrode holders with defective jaws. (Figure
1-3)
Keep the jaws of the electrode hoider tight and the gripping
surfaces in good condition to provide close contact with the
electrodes. Defective jaws will permit the glectrode to wob-
ble, making control of the welding operations difficult.
Figure 1-3. Don’t use Electrode Holder with defective jaws
DON'T use electrode holder with loose cable connections.
Keep the connections of the electrode lead to the holder
tight at all times.
Use only fully insulated electrode holders {and without pro-
truding screwheads.)
Never touch two electrode holders from two separate welding
machines at the same time.
. CODE CONFORMANCE
The machine and its equipment must be installed and main-
tained in accordance with the National Electrical Code and
local requirements.
PARALLEL CONNECTIONS
See diagrams in the instruction manual applying to the weld-
ing machine.used.
. POWER DISCONNECT SWITCH
if the welding machine does not include a power disconnect
switch, install one at or near the machine,
. POLARITY SWITCH
DON'T operate the polarity switch under load.
The polarity switch {when supplied} is provided for changing
the electrode lead from positive {reverse polarity) to negative
(straight polarity}. Never move it while under the load of a
welding current. Operate this switch only while the machine
is idling and the welding circuit is open. The potential dan-
gers of opening the circuit while carrying high current are:
1. An arc will form between the contact surfaces of the
switch and severely burn them,
2. The person throwing the switch may receive a severe burn
from this arcing.
. RANGE SWITCH
DON'T operate the range switch under load.
The range switch (when supplied) is provided for obtaining
required current settings. |t must never be operated while the
machine is under the load of welding current. Operate the
range switch only while the machine is idling and the welding
circuit is open. The potential danger of switching the circuit
while carrying high current is the formation of an arc be-
tween the contact surface which will severely burn them,
Repeated occurrences of this arcing wiil eventually prevent
operation of the contacts.
. EXHAUST GASES
DON’T use gas engine units in confined spaces without vent-
ing the exhaust gases. (Figure 1-4)
if gasoline or other fuel driven welding machines are operated
indoors, provide means to pipe the exhaust gases to the out-
side air to avoid carbon monoxide poisoning.
OM-450 Page 1
1-10.
Figure 1-4. Vent exhaust gases
POWER CIRCUIT GROUND
DON'T use welding machine without grounding frame or
case, (Figure 1-5)
Figure 1-5. Ground frame or case
Ground the ground cable of every power circuit to prevent
accidental shock by stray current. The potential danger 1s
that development of a stray current may give a fatal shock
should a person, for example, place one hand on the welding
machine and the other on the switch box, or other grounded
equipment. Do not ground to pipelines carrying gases or
flamrnable liquids and conduits carrying electrical conduc-
tors. Be sure conductors can safely carry the ground current.
When connecting the welding machine, properly ground the
machine frame or case.
1-11. CONTAINERS WHICH HELD COMBUSTIBLES
Page 2
DON'T weld on containers which have held combustible or
flammable materials or materials which, when heated, give
off flammable or toxic vapors without proper cleaning, purg-
ing, or inerting.
Welding containers which have hetd flammable or combust-
ibie materials may be extremely dangerous. To prevent a fire
or explosion of the container, follow the recommendations
of the American Welding Saciety Pamphlet A6.0 “Welding or
Cutting Containers Which Have Held Compbustibies”.
DONT depend on your eyes or nose to decide if 1t is safe to
weld on a closed container.
Find out what was in the container or use an explosimeter. A
very small amount of residual flammable gas or tiquid can
cause a serious explosion.
NEVER use oxygen to ventilate a container.
When you know the container held a gas or liquid which will
readily dissolve in water:
1. Flush out with water several times and then fill with
water as far as work permits, positioning container to
permit introduction of as much water as possible.
2. Before welding be sure there is a vent or opening to рго-
vide for release of air pressure.
1-12
1-13.
1-14.
When you know the container held a gas or liquid which wil
not readily dissolve in water:
1. Clean out thouroughly with steam or a cleansing agent
and purge alt air or inert with a gas such as carbon dioxide
or nitrogen before repairing. Carbon dioxide is heavier
than air and will tend to remain in the container if the
opening is at the top.
2. Use steam to clean out light material,
3. Use a strong caustic soda solution to clean out heavy oils
ог grease.
4. Be sure to purge ali air or inert with a gas, such as nitro-
gen or carbon dioxide, no matter how well you have
cleaned. There may still be traces of oil, grease, or other
readily oxidizable material under the seams.
Be careful when cleaning with steam or caustic soda wear
goggles and gloves.
DON'T clean where there is poor ventilation.
Ventilation is necessary to carry away harmful or explosive
vapors.
DON T clean where there are open flames.
When scraping or hammering to remove heavy sludge or scale,
use a spark resistive too! and keep it wet to avoid sparks.
Keep your head and arms as far away from your work as
possible.
HOLLOW CASTINGS
DONT weld on hollow {cored) castings that have not been
properly vented. The casting may explode. {Figure 1-6)
Figure 1-6. Don’t weld on hollow {cored} castings
EXPLOSION HAZARDS
NEVER weld in or near explosive atmospheres. Such atmos-
pheres can be created by flammable gas leaks or by vapors
from flammable liquids (gasoline, alcohol, etc.) or by com-
bustible dusts.
VENTILATION
DON'T weld in confined spaces without adequate ventilation.
When welding in confined spaces, provide ventilation in
accordance with United States of American Standard 249.1,
1967. Always provide adequate ventilation by blowers, air
lines, or other acceptable means. Never use compressed ox-
ygen. The depletion of the oxygen suppiy, the heat of weld-
ing, and the fumes given off may cause severe discomfort or a
serious iilness.
When toxic fumes from lead or cadmium bearing materials or
any other substances are present in harmful concentrations,
always use an air supplied respirator.
1-15. SOLVENTS
1-17.
Do not weld where chlorinated hydrocarbon vapors from de-
greasing, cleaning, or spraying may reach or be drawn into air
surrounding the welding operation. The heat of the arc can
decompose solvent vapors to form phosgene, a highly toxic
gas and other irritating decomposition products.
Do not weld where ultraviolet light from the electric arc can
penetrate air containing even minute amounts of vapors from
solvents such as trichloroethylene or perchioroethyiene. Ul-
traviolet light can decompose the vapors to form phosgene, a
highly toxic gas and other irritating products.
. FIRE HAZARDS
DON'T weld near flammable or combustible materials.
Fires can be caused by the arc, by contact with the heated
metal, by slag, or sparks. Keep combustibles at least 35 feet
from the arc or suitably protected. If welding must be done
in a particular area, move the combustibles away. If they
cannot be moved, cover them completely with fire resistive
screens, Cover cracks or openings in floors or walls; sweep
floor free of combustibles and wet down, if wood, being sure
welder wears insulation shoe coverings. Avoid welding on par-
tition walls in contact with combustibles. Heated metal on
the other side of partition wall being welded upon can ignite
combustibles in contact with the partition. Where other than
a minor fire might develop, have a fire watcher stand-by with
suitable fire extinguishing equipment for at least one-half
hour after the welding is completed.
ELECTRICAL SHOCK-VOLTAGE
OPEN power circuits before checking machines.
Before working on the wiring, switches, controls, etc, open
the power line disconnect switch. fn most welding shops the
power supply used for arc welding machines is 230 or 460
volts. Open circuit voltages are usualiy less than 100 volts and
welding or arc voltage drops are still lower. However, all of
these voltages are capable of developing a harmful or fatal
current to the body.
DON'T touch electrically "hot" parts.
NEVER touch any exposed or non-insulated part of the
cables, cable connectors, clamps, electrode holders, elec-
trodes, or the power supply equipment to prevent harmful or
fatal electric shock or burns.
. ELECTRICAL SHOCK-DAMPNESS
NEVER work in a damp area without suitable insulation a-
gainst shock, Keep hands, feet, and clothing dry at all times.
To prevent harmful body shocks, keep hands, feet and cloth-
ing dry. Never stand or tie in puddles of water, damp ground,
or against grounded metal when welding without suitable in-
sulation against shock. Always find a dry board or rubber
mat to stand on when water, moisture, or perspiration cannot
be avoided. Dampness between the body and an energized or
grounded metallic part lowers the resistance to the passage of
current to the body which may produce a harmful or fatal
shock. Salt in perspiration or sea water dangerously lowers
contact resistances.
Figure 1-7. Don’t leave electrode in contact with grounded
metallic surface,
1-19. STARTING UNDER LOAD
DON'T leave an uninsulated electrode holder, or a “live”
1-20,
1-21.
electrode on the table top or in contact with a grounded
metallic surface. (Figure 1-7)
When it is not in use, never place an electrode holder in
contact with the tabletop or other metalic surface in contact
with welding ground. Provide an insulated hook or holder for
the electrode holder. À potential danger is that a holder in
contact with the ground circuit provides a dead short circuit
on the welding machine, If the machine should be started up,
this short circuit would cause an excessive load on the ma-
chine and may damage the insulation.
FACE PROTECTION
DON'T use cracked or defective helmets or shields,
Keep the helmet, hand shields, or face shield in good condi-
tion. If cracks occur in the fibre material, replace the shield,
since the leakage of arc rays may cause serious burns.
EYE PROTECTION
NEVER under any circumstances, look at an_eiectric arc
without eye protection.
Make sure that flash goggles are used under the weld-
ing helmet at all times, particularly while gas shielded-
arc welding.
In some type of arc welding, such as gas shieided-arc welding,
ultra-violet and infra-red radiation from the arc is particularly
intense and requires constant attention to avoid arc flashes to
the welder when striking an arc and to avoid exposure to
other welders.
NEVER strike an arc without ascertaining that nearby per-
sons either have the necessary protective equipment or are
looking in the opposite direction.
For welding operations in open areas, provide portabie, non-
reflecting screens to shield persons nearby from the rays of
the arc. Eye burns from the arc, through not generally per-
manent injuries, are exceedingly painful. Such burns fre-
quently referred to as “flashes”, feel like hot sand in the eye,
If the eye is focused on the arc without filterglass protec-
tion, infra-red radiation can cause retinal scarring and tm-
paired vision. For eye burns consult your first aid station or
doctor.
NEVER use cracked, dl-fitting, or defective plates,
The fiiter glass plate provided in the helmets and shields must
be of reputable manufacture conforming to the latest Ameri-
can National Standards Institute, Standard Z2.1. Replace
cracked or ill-fitting filter plates promptly.
NEVER use filter plates without a protecting cover glass.
OM-450 Page 3
Keep a clean cover glass in front of the filter plate for the
protection thereof. Frequent renewal of these cover glasses is
necessary, since they become covered with spatter, reducing
vision,
1-22. CLOTHING
NEVER use poor, inadequate, or worn-out clothing. Wear
heavy shoes, tightly laced. Keep clothing dry.
Proper and dry, oil-free clothing is essential for the welder’s
protection. Clothing must not only keep off the spatter and
molten particles, but must also obstruct the rays of the arc
and, when necessary, insulate the body from harmful electri-
cal currents,
Wear leather or asbestos gloves at all times to protect the
hands and wrists. Dark colored shirts are preferred to light
ones because light ones reflect arc rays to exposed parts of
the body. In the case of gas shielded-arc welding, light colors
are more reflective and may cause eye burns due to the in-
tense ultra-violet rays given off by the process, Avoid cotton
fabrics when gas shielded-arc welding,
An arc burn on the skin resembles a sunburn, except that it is
usually more severe, Clothing can be made flame resistant by
treatment with a solution of 3/4 pound of sodium stannate in
1 gallon of water, then wrung out and dipped in a solution of
1/4 pound ammonium sulphate per gallon of water. Don't
wash clothing so prepared in water, but dry clean,
When welding operations are to be performed in vertical and
overhead positions, leather sieevelets, aprons, and in some
cases leggings and ear plugs should be used to prevent severe
burns from spatter and molten metal.
1-23. HOT METAL BURNS
NEVER pick up hot objects. (Figure 1-8)
Figure 1-9. Never pick up hot objects
NEVER pick up pieces of metal which have just been welded
or heated, or the stub ends of electrodes which have been
discarded.
1-24. GRINDING AND CHIPPING
NEVER do any chipping or grinding without protective
goggles. (Figure 1-10)
Figure 1-10. Never do any chipping or grinding without
protective goggles.
Page 4
1-25.
Whenever it is necessary to grind or chip metal, wear protec-
tive goggles specifically designed for this purpose. Serious eye
injuries may result from failure to wear protective goggles.
COMPRESSED GAS CYLINDERS
NEVER strike an arc on a compressed gas cylinder, Always
observe the following precautions in regards to compressed
gas cylinders:
1. Avoid accidental contact of the electrodes, electrode
holder, or other electrically energized parts with a
compressed gas cylinder or any other pressure vessel.
Serious accidents or fires may result,
2. Use |.C.C.or D.O.T. cylinders. They are manufactured
and maintained in accordance with D.O.T. require-
ments and are safe so long as they are properly
handled. Don’t drop cylinders,
3. Identify gas content by the name marked on the cylin-
der. If the cylinder is unmarked, do not use it. Return
it to the supplier. Do not rely on a color code.
4, Never use a cylinder or its contents for other than
intended purposes.
5, Keep oil and grease away from oxygen cylinders and
cylinder valves.
6. Keep cylinders away from exposure to sparks, hot
slag, open flame and ail possible sources of ignition or
excessive heat,
7. Be careful that cylinders are not placed so as to be-
come a part of an electrical circuit. Avoid third rails,
wires and electric welding circuits.
8. When transporting cylinders by crare, use cradle plat-
form or other suitable support.
9. Never lift the cylinders by slings, by the caps or by
electric magnets.
10. Never use cylinders as supports or rollers.
11. Never try to mix any gases in a cylinder.
12. Never try to refill a cylinder.
13. Mark or tag empty cylinders “Empty” or “MT”.
14. $Send “Emptys” back to the supplier promptly. 15,
15, Keep ‘’Emptys’’ and “Fulls” separate,
16. Never tamper with or alter cylinder numbers or other
markings. This is not only foolish but may be illegal.
17. Do not tamper with or change fittings on cylinders.
18. If valves cannot be opened by hand, do not use ham-
mer or wrench, Notify supplier.
19. Protect cylinder valves from bumps, falls, falling ob-
jects, and from weather. Keep them covered with
cylinder caps when moving cylinders.
20. Keep vaives closed on empty cylinders,
21. See that your cylinders are clear of passageways and
active work areas and that they are secured against
falling.
22. if adapter is required between cylinder and regulator,
always use a standard adapter. These may be obtained
from your supplier, Where right and left hand threads
are used on adapter, use two wrenches to insure leak
proof connections.
23. Do not store cylinders in unventilated areas.
SECTION 2 - INTRODUCTION
Welding Welding Current Ranges Open Circuit Power Overali Weight
Rated Current In Amperes Voltage While Dimensions (Pounds)
Output Range Coarse Ranges Fine Range Range Welding (inches) Net [Ship
MIN. - 65 Mi 5 3kva
300 Amps 45 65 - 100 From in. 5 120 Volts AC | Length - 63”
At To 100 - 175 To Max. Of © 60 Hertz AC | Width - 24-3/4" | 1397 | 1443
40 Volts DC | 400 Amps | 125-250 Bach Course S ос Weld Depth - 41-1/2"
225 - MAX. ange olts Speed
Figure 2-1. Specifications
115 VOLT AC
RECEPTACLE J
2-1.
3-1.
ENGINE AL . EXCITER FINE CURRENT MAIN REVOLVING
EXCITER RECTIFIER CONTROL FIELD
| RANGE MAIN |
STATOR SWITCH RECTIFIER STABILIZER
WELD
TERMINALS
Figure 2-2. Block Diagram
GENERAL
This manual! has been prepared especially for use in familiar
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment,
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
- Or damage that may have occurred in transit must be filed by
the purchaser with the carrier. À copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Designation and/or Stock Number and
Serial (or Style) Number of the equipment be supplied.
. DESCRIPTION
This welding generator is designed for use with the Shielded
Metal-Arc Welding {SMAW) {Stick Electrode} process.
Welding power is furnished by a three phase main generator
which is fed through the necessary siope or range transformer
to a Range Switch. This switch controls the alternating cur-
rent value fed to the main power rectifier, which rectifies
alternating current to direct current for welding.
The main generator which is fed through the necessary slope
or range transformer to a Range Switch. This switch controls
the alternating current exciter generator. The exciter current
is rectified to direct current, which in turn is regulated
through the FINE CURRENT Control to the main generator
revolving field. The FINE CURRENT Control determines the
amount of exciter current in the main generator revolving
field. This control aliows fine current adjustment within each
LOCATION
Good installation is essential if the generator and engine are
to provide satisfactory and dependable service. Tilting not 10
exceed 15 degrees in any direction is considered standard
industrial engine specifications.
Mounting holes are provided in the welding generator base
for machines that require mounting. Figure 3-1 gives the
overall dimensions and base mounting hole layout of the
unit
2-4,
SECTION 3 - INSTALLATION
one of the five coarse current control ranges. The alternating
current exciter also provides up to 3kva of 120 volts ac, 60
Hertz auxiliary power, available at the duplex receptacle on
the front panel of the unit, when the welding generator is
operating at weld speed.
SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completeiy.
This wili help avoid possible injury due to misuse or improper
welding applications.
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Installation, operating, and maintenance procedures,
practices, etc., which will result in personnel injury or
| loss of life if not carefully followed. 1
IMPORTANT
Installation, operating, and maintenance procedures,
practices, etc., Which will result in damage to equip-
ment. |
installation, operating, and maintenance procedures,
I practices, etc., which it is essential to emphasize. i
If this unit is to be operated indoors, it should be
located in a place where. the exhaust fumes from the
engine can be vented out of the building. Failure to
comply with proper venting may result in serious
bodily injury or loss of life.
OM-450 Page 5
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LENGTH 102”
HEIGHT 58"
TREAD WIDTH 62”
TOTAL WIDTH 71"
NOTE: DIMENSIONS OF UNIT MOUNTED ON
OPTIONAL 6B OR 7B TRAILER.
ENGINE END
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AC-900 955-1
Figure 3-1. Dimensions And Base Mounting Hole Layout
3-2. WELD OUTPUT CONNECTIONS
The POSITIVE and NEGATIVE Weld Output Terminals are
located behind the lower front access panel. In order to gain
access to the weld output terminals, remove the two 5/16
inch bolts from the bottom edge of the lower access panel
and raise the panel in an upward direction.
Once the weld output cables have been connected to the
weld output terminals, the cables are to eXit from behind the
lower front access panel through the two openings provided
on the extreme lower left and right corners of the lower front
access panel. (See Figure 3-2}.
A. Welding Cables
If welding cables were not ordered with the welding genera-
tor, the following instructions should be followed to ensure
the best welding generator performance,
AB-900 955-11
Figure 3-2. Weld Output Connections
Page 6
1. Use Table 3-1 as a guide for selecting correct cable size for
the anticipated maximum weld current which will be
used, Table 3-1 shows total cable length, which includes
the electrode and work cable. Example: If the electrode
holder cable is 75 feet long and work cable is 25 feet long,
select the size cable that is recommended for 100 feet at
the maximum weld current that would be used.
2. Do not use damaged or frayed cables.
3. Fdltow the electrode holder manufacturer's instructions
-— for installing the electrode holder on the electrode cable.
4. Use correct lugs on weld cables to connect grounding
clamp and to connect the cable to the welding generator
weld terminals.
5, Make sure all connections are clean and tight.
Table 3-1. Weld Cable Size
Weiding *Total Length of Cable {copper) in Weld Circuit
Amperes{ *50 | 100 | 150 | 200 | 250 | 300 | 350 | 400
100 |4 4 т 2 2 1 1/0] 1/0
150 | 2 2 2 1 1/0 2/01 3/01 3/0
200 |1 1. 1 1/0| 2/0: 3/01 4/0| 4/0
250 1/0] 1/0] 1/0) 2/0) 3/0) 4/0) 4/0j2-2/0
300 2/0| 2/0| 2/0] 3/01 4/0] 4/0|2-2/0|2-3/0
350 3/0] 3/0| 2/0| 4/0: 4/0|72-2/0|2-3/0|72-3/0
400 3/01 3/0| 3/01 4/0|2-2/0|2-3/0|3-2/012-4/0 9
AA-901 181-10
NOTE: *A. 50 feet or less
- *B. (Cable size is based on direct current (de),
100% duty cycle and either a 4 volts or less
drop or a current density of not over 300
circular MILS per amp.
*C. Weld cable insulation with a voltage rating to
withstand the open circuit voltage {OCV} of the
welding generator must be used. While most
welding generators have an open circuit voltage
of less than 100 volts, some welding generators
of special design may have higher open circuit
voltage.
3-3. GENERATOR CHASSIS GROUND
; EQUIPMENT
Normaily engine driven welding generators are not required ; GROUNDING
to be grounded. However, this machine has auxiliary power ! TERMINAL
plant capabitity, therefore grounding of the frame and case is
recommended. For this reason a convenient grounding ter-
minal is provided on all welding generators/power plant units.
For detailed grounding instructions consult your local or
state codes or the latest issue of the National Electrical Code.
4-1. 120 VOLT AC RECEPTACLE (Figure 4-1)
Up to 3kva of 120 volts 60 Hertz power is available at this
duplex receptacle for operating 120 volt ac or 120 volt uni-
versal power tools etc. when the welding generator is being
operated at weld speed. Since the engine used to power this
generator is equipped with an automatic idling device, care
must be taken in the use of the 120 volt receptacie. The
voltage at this receptacle will drop below 120 voits when
engine speed is reduced to idling rpm. The low voltage may
damage the 120 volt electrical equipment connected to this
receptacle.
SECTION 4 - OPERATION OF GENERATOR CONTROLS
Figure 3-3. Generator Chassis Ground
The Range Switch permits selection of five different amper-
age ranges. Each of the five switch positions has its amperage
range indicated at the top end of the Range Switch Handle.
Fine amperage adjustment of the coarse range selected may
be obtained by utilizing the FINE CURRENT Control, the
function of which will be explained in section 4-3.
. FINE CURRENT CONTROL (Figure 4-1)
The FINE CURRENT Control permits the aperator to select
an exact amount of welding amperage. This control allows
adjustment of the welding amperage from minimum to maxi-
mum of the coarse amperage range that was selected by the
Range Switch,
IMPORTANT
The scale surrounding the FINE CURRENT Control is cali-
brated from O to 100 percent in increments of ten. Due to
this percentage calibration, it should be noted that if the
operator is using this scale to select a fine amperage setting,
the operator is selecting a percentage of the coarse range
selected and not an actual amperage value.
Ensure that the IDLE CONTROL Switch, located on
the front control panel, is in the LOCKED QUT posi-
ton when electrical equipment is being operated from
the 120 VOLT AC Receptacle. See the OPERATION
OF ENGINE CONTROLS Section for complete in-
structions on the operation of the Automatic Idling
i Device. I 4-4. VOLT-AMPERE CURVES {Figure 4-2)
FINE CURRENT CONTROL 100
#
\ |
) Ns
; i {
RANGE /
SWITCH ; и
Ç =
3 o
= =
/ 7 u
IDLE 120 VOLT a
CONTROL | RECEPTACLE
SWITCH |
о 100 200 300 400 500 600 700 800
D C AMPERES B-002 189
NEGATIVE
WELD TERMINAL POSITIVE
WELD TERMINAL Figure 4-2, Volt-Ampere Curves
Figure 4-1. Generator Controls
. AB-900 955-2A
The Volt-Ampere curves show the output voltage and current
of the welding generator available at any point fram the mini-
mum to maximum of each coarse current range, The FINE
CURRENT Control, controls the output between the mini-
mum and maximum curves of each coarse current range that
is shown, a
4-2. RANGE SWITCH (Figure 4-1)
IMPORTANT
Load voltage is predetermined to a large extent by the arc
characteristics. With the use of the Volt-Ampere curves it is
possible to determine what the weld current will be at a
particular arc voltage. Remember, the Voit-Ampere curves
show the minimum and maximum curves of each coarse cur-
rent range. When the FINE CURRENT Control is adjusted,
the Voit-Ampere curve will fall between the minimum and
maximum curves of the particular coarse current range in use.
Do not operate the Range Switch whiie welding.
Movement of the switch while under load will cause
arcing across the switch contacts and thus cause the
contacts to pit. Repeated arcing wili cause the con-
tacts to become completely deteriorated and thus
I cause the unit to become inoperative. I
OM-450 Page 7
Never operate the unit with the hinged side panels
. open or removed. If the sides are left open or re-
CAUTION. |
moved, a safety hazard exists to personnel from
moving and electrical components. Also, weather pro-
tection to the internal components of the unit will be
greatly reduced.
5-1.SHIELDED METAL-ARC WELDING (SMAW)
(STICK ELECTRODE)
1. Connections for Direct Current Straight Polarity (DCSP).
a. Connect the electrode cable to the negative weld ter-
minal on the welding generator.
b. Connect the work cable to the positive weld terminal
on the welding generator. ;
2. Connections for Direct Current Reverse Polarity (DCRP).
a. Connect the electrode cable to the positive weld ter-
minal of the welding generator.
b. Connect the work cable to the negative weld terminal
— of the welding generator:
IMPORTANT
Do not operate the Range Switch while an arc is
established. Arcing caused by opening a switch carry-
ing high current will severely burn the contact surfaces
of the switch. This burning of the contact surfaces will
decrease the maximum current carrying capacity of
the switch and possibly cause the switch to become
inoperative.
SECTION 5-GENERATOR OPERATION sess se——
3. Place the Range Switch and FINE CURRENT Control to
the desired position.
4. Ensure that the engine has been prepared for operation as
stated in Section 7.
5. Start the engine. Refer to section 9 for proper engine
starting procedures. :
6. After the engine is operating properly, welding may com-
mence.
IMPORTANT
Whenever starting the welding generator or operating
it at idle rpm, it is essential that all electrical equip-
ment connected to the 120 VOLT AC Receptacle be
turned off. Failure to comply may result in damage 10
the electrical equipment. Damage may be incurred be-
cause the welding generator is putting out a voltage
and frequency far below 120 volts 60 Hertz when
i operating at idle speed. B
7. The FINE CURRENT Control may be adjusted while
welding.
8. After the welding operation has been completed, allow
the engine to idle for a few minutes before shutting it
down.
6-1. GENERAL
Page 8
Economical operation and trouble-free service of this welding
generator are based upon regular inspections and reasonable
attention.
Occasional blowing out of the unit with clean dry com-
pressed air is recommended, This should be performed
periodically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere.
IACI |
® If any work is to be done on the armature of the
' generator, remove the spark plugs from the engine.
This will prevent engine compression from turning the
armature and catching the repairman’s hand between
the armature fan casting and the stationary adapter
casting,
This welding generator is equipped with hinged side panels to
permit easy access when performing inspection and mainten-
ance functions on the generator and engine. :
. COLLECTOR RING BRUSHES
The brushes should be inspected periodically to ensure their
proper function. The brush life is very good under normal
conditions. !f the generator has been operating in an ex-
tremely dusty or dirty place, a close check of the brushes for
freedom of movement and cleanliness should be made
weekly. Under normal use the commutator and slip rings will
discolor to a dark brown. If it should become necessary to
clean the slip rings or commutator, use a 3/0 or finer sand-
paper followed by a crocus cloth. Never use emery cloth as
part of the emery will embed itself into the exiter or collec-
tor rings and in turn destroy the carbon brushes.
. WELDING CABLES
Check connections periodically for tightness, The cabies
should be inspected frequently and all breaks in the insula-
tion should be repaired with electrical insulating tape or the
cables replaced.
A SECTION 7 - ENGINE PREPARATIÓN ==—————Ñ=Ñ——"""]""""
7-1.
See the Engine Manufacturer's manual (F-163 Engine)
| for complete engine care. I
- LUBRICATION
This engine was shipped from the factory with its crankcase
filled with the correct amount and type of break-in oil unless
otherwise ordered. Check the oil level before attempting to
operate the engine. it should be up to the full mark on the
bayonet type indicator. Add a quality brand of detergent oil
if the ail level is low. See the oil selection chart, Table 10-1,
in Section 10.
ml
À
=
b. 2 KEEP CRANKCASE OIL
/ AT THIS LEVEL
NEVER OPERATE ENGINE
a WITH OIL BELOW THIS LEVEL
< AA-900 033-314
Figure 7-1. Oil Level indicator
IMPORTANT
New engines have very close clearance between their
moving parts. Thus, it is recommended that [loading of
the engine be kept to a minimum during the first 50
hours of operation. Be sure to check the oil level
several times each day during the engine break-in
period. This engine requires about 50 hours of running
| time before it will be fully broken in. |
After about 50 hours of running time, drain the break-in oil
and change. the oil filter. See the oil selection chart, Table
10-1, in Section 10 for correct oil type and grade to use after
the break-in oil is drained.
. COOLANT SYSTEM
The liquid capacity of the coolant system in this welding
generator is 11 quarts (US measure). This unit is shipped
from the factory with the proper amount of water and anti-
freeze to permit operation of the unit at temperatures dowr *
to —15°F.
IMPORTANT
If this welding generator is to be operated in tempera-
tures which are below —15°F, additional anti-freeze
will have to be added to the coolant system or the
liquid in the system will freeze and thus cause the
engine 10 overheat.
The coolant system is equipped with a 180°F thermostat. If
the thermostat should become defective, be sure the replace-
ment is of equal temperature rating.
IMPORTANT
Do not run the engine with a defective thermostat or
without one. If this is done, the engine will run cold
and develop excess carbon accumulation and the oil
wil} become contaminated with excessive studge and
dirt.
The radiator for this engine is equipped with a pressurized
cap which is rated at 7 psi. If this cap is ever replaced, ensure
that the replacement cap has a rating of 7 psi.
7-3.
7-4.
7-5
RT ito
Caution should be exercised at all times when re-
moving the radiator pressure cap. The cap will turn to
an almost full open position, at which point a provi-
sion has been made to permit venting built up pressure
within the radiator. Allow the pressure to escape be-
fore completely removing the cap from the radiator
neck. When removing the cap, it is recommended that
a glove or rag be used to protect the operator's hand
| from possible exposure to extremely hot coolant. |
READYING NEW BATTERY FOR SERVICE
This battery is shipped from the factory in a dry state. A
sufficient amount of electrolyte is shipped along in separate
containers to activate the dry charge battery. To prepare the
new battery for operation, proceed as follows:
CAUTION |
Put on protective eye cover and ciothing prior to pour-
| ing the electrolyte solution, 1
1. Remove the battery from the unit and place it on a level
work table or other suitable area.
2. Fill the battery cells to the required level with electrolyte.
Do not dilute this electrolyte as it is pre-mixed to the
I required strength. i
3. Place a battery thermometer in one of the center cells and
check the specific gravity of each cell with a battery
hydrometer.
4. The battery temperature must be above 80°F and the
specific gravity reading above 1.240 prior to installation.
IT both conditions are not met, charge the battery follow-
ing the below instructions:
"a. Use an automotive type battery charger. This battery
should be charged at about a 3.5 ampere rate until
correct electrolyte conditions are met. Lower charging
rates can be used. However, the time to obtain the
correct electrolyte conditions will be longer.
b, When the battery is charged, remove tt from the
charger and re-check the electrolyte level. Add if
necessary.
с. Rinse out the empty electrolyte containers with water
before discarding. Since battery acid is corrosive to
metals, do not pour into a metal sink or drain. Rinse
and mutilate the empty electrolyte container before
discarding. If acid has accidentally spilled on the
battery or work area during filling or charging, flush
off with clear water and neutralize with soda or
ammonia solution. Use the same procedure if acid is
spilled on clothing.
5. Re-install the battery in the unit making sure that the
negative (—) terminal of the battery is connected to the
ground cable,
AIR CLEANER
The air cleaner this engine is equipped with, is a dry element
type with a replaceable filter element. The air cleaner re-
quires no initial service.
. FUEL
Use a good grade of “regular” gasoline, rated at least at 85
octane, for this engine. Fuels of lower octane ratings may
cause detonations {knocking} which could result in damage
to the engine bearings and head gasket. The fuel capacity of
the fuel tank is 16.5 gallons (U.S. Measure).
OM-450 Page 9
The fuel tank is equipped with a trap area in the bottom of
the tank. As a result, the tank will not go completely dry.
The purpose of this trap area is to hold water and dirt back
from the engine. A drain plug is located on the left, bottom
of the tank to drain water and dirt from the tank if it should
become necessary.
RII
ь О
Never allow the fuel to drain on the engine, the gener-
ator, or other components, Arrange provisions for.
catching the fuel when being drained and if the tank
must be drained frequently, install a valve and drain
line in the tank. When filling the fuel tank, do not fill
completely full. The reason being that the cold fuel
will expand due to engine heat and the outside air
when operating in a warm climate. If the tank is too
full, it will overflow causing a potential fire hazard.
Also, do not attempt to fill the fuel tank with the
engine running, always shut the engine down first.
A fuel consumptian chart is shown in Figure 7-2 to give an
idea of the fuel consumption of this engine under load. The
figures given on this chart will vary from one engine to
TEMPERATURE
GAUGE
N |
Lo STARTER
| ~~ SWITCH
|
|
QiL ) |
PRESSURE + ~~ CHOKE
J CONTROL
8-1.
Page 10
BATTERY
AMMETER
Figure 8-1. Engine Controls
CHOKE CONTROL (Figure 8-1)
A CHOKE Control for varying the fuel-air mixture to the
engine, is provided on the front control panel of the welding
generator. When the CHOKE Control is pushed fully out,
very little air will be admitted to the engine thru the car
buretor thereby supplying a richer mixture of fuel. This posi-
tion is required if the engine is cold when started. As the
engine warms up it will be necessary to push the CHOKE
Control inward slowly until itis pushed in as far as it will go.
When the CHOKE Control is fully in, the engine should be
ready-for operation.
. STARTER SWITCH (Figure 8-1)
A key actuated Starter Switch is provided on the front panel
for starting and stopping the engine. Rotating the key fully
clockwise wil! engage the starter motor and start the engine.
Once the engine has started, releasing the key will auto
matically return the Starter Switch to the On position. To
stop the engine, rotate the key fully countercl ockwise to the
Off position.
. AUTOMATIC IDLE CONTROL (Figure 8-1 8 8-2)
This engine is equipped with an automatic idíing device as
standard equipment. When the Idle Control is being employ-
ed, the engine will remain at idle mm when the generator is
not loaded, thus saving fuel etc.
The Idle Control uses a combination electric-vacuum control,
An IDLE CONTROL switch, located on the generator con-
LITERS /HR
IMP. GALS./HR.
7.57170
5.67125
3.78 .83
198 40
SECTION 8 - OPERATION OF/ ENGINE CONTROLS
another. Also, different brands of fuel, operating conditions,
condition of the engine, and numerous other conditrons will
determine the fuel usage of this engine.
+
U.S. GALS./HR.
ы
5
1.0
59
o 100
200
AMPS AT 100% DUTY CYCLE
рв-900 955-1
Figure 7-2. Fuel Consumption Chart
300
tro! panel, allows control over the operation of the automatic
idling device. The IDLE CONTROL Switch is labeled LOCK
IN - LOCK QUT. The LOCK IN position allows the engine to
idie until an arc is struck. The LOCK OUT position of the
switch is used whenever it is necessary or desirable to operate
the engine at constant weld rpm (1800), which would be the
case when 120 volt ac power is required from the 120 volt
receptacie.
The IDLE CONTROL Switch LOCK IN position would
usually be used when Shielded Metal-Arc Welding (SMAW-
Stick) is being done as this process does not require a con-
stant speed, This only holds true if the 120 volt ac receptacie
is not being used. In event accessory power tools are to be
operated from the 120 volt ac receptacles, place the iDLE
CONTROL Switch in the LOCK OUT position.
IMPORTANT
“If 120 volt ac power equipment is going to be oper
ated from the 120 volt ac power receptacle, be sure
the equipment is “off” until the engine ts operating at
full speed (1800 rpm}. The same holds true when
returning the engine to idle. If power tools are oper-
ated while the engine is idling, low voltage and -fre-
quency {resulting from the lower engine idling rpm) at
the power receptacle may cause damage to the 120
I volt equipment. I
IN ENGINE COMPARTMENT
„=
5 INTAKE MANIFOLD
SCREW “A™
ADJUST CLOCKWISE 1/8"
TURN AT A TIME TO IN-
CREASE IDLE TIME DE-
LAY.
— — — —_—e —,__—
Figure 8-2. {dle Control Time Delay Adjustment
Operation of the idling device is automatic when the IDLE
CONTROL Switch is in the LOCK IN position. When the
engine is started, engine speed will remain at idle until an arc
is established, at which time the engine immediately comes
up to weld speed. When the arc is broken, a time delay will
exist before the engine begins to return to idle speed. The
tength of this time delay is controlled by the setting of Screw
“A” in Figure 8-2. This screw is located on the vacuum line
fitting going into the Intake Manifold of the engine. Figure
8-2 shows the adjustment of this screw.
8 - 4. OIL PRESSURE GAUGE (Figure 8-1)
The Oil Pressure Gauge registers the lubricating system pres-
sure in pounds per square inch. Normally, the pressure regi-
‘stered by the gauge should remain constant for a given engine
speed. Should the pressure fluctuate or drop, stop the engine
and do not operate the engine again until the trouble has
been remedied.
8-5. ENGINE AMMETER (Figure 8-1)
The Engine Ammeter, located on the front control panel,
registers the charging current which is being supplied to the
battery by the charging generator. 1t also registers a discharge
equivalent to the amount of current being used by the engine
electrical system when the generator is not charging.
8-6. TEMPERATURE GAUGE (Figure 8-1)
The Temperature Gauge registers the coolant temperature
and will indicate when an overheated condition occurs.
8-7. CARBURETOR AIR TEMPERATURE SELECTOR
{Figure 8-3)
The air intake to the air cleaner is equpped with a selector
tube which allows the air to be drawn either from the sur-
rounding engine compartment air or heated air, drawn from
around the exhaust manifold of the engine. Heated air will
prevent carburetor icing in cold weather.
Figure 8-3 shows the selector tube in the cold weather oper-
ating position. When the tube is in this position, it must
remain about 1/27 away from the air cleaner inlet.
For warm weather operation, loosen the selector tube and
slide it all the way down against the manifold and re-tighten,
AIR CLEANER
AIR INLET
Y
1/2"
À
_ AIR SELECTOR
d— (Shown in cold
weather position)
MANIFOLD STOVE
AA-900 955-4
Figure 8-3. Carburetor Air Temperature Selector
—. os o — SECTION 9 - ENGINE OPERATION "A segmm
9-1. PREPARING TO START AND STARTING THE EN-
GINE
IMPORTANT
Check the engine oil level and radiator coolant level.
Make sure no loose parts etc. are laying in the unit,
Make the necessary connections to the generator
before attempting to start the unit. Fill the fuel tank
with the correct grade and type of fuel.
1. Make all necessary electrical connections to generator for
the particular application it is to be used for.
2. Place the IDLE CONTROL Switch in the LOCK IN posi-
tion. This should be done in order to allow the engine to
warm up atidle speed.
3. Choke the engine as necessary.
4. Rotate the Starter Switch fully clockwise.
10-1. LUBRICATION
This engine will require at least 50 hours of running time to
become fuliy broken in. During this period, the load on the
engine should be kept as light as possible. The oil leve! should
be checked a number of times during an operating day, as
some engines will use oil during the break-in period. After
about 50 hours of running time on the break-in oil, drain the
oil. Premium heavy duty oil, manufactured by any one of the
IMPORTANT
Always ensure that the starter pinion and flywheel
‘have stopped rotating before re-engaging the starter
motor, otherwise the ring or pinion may be damaged.
5, When the engine starts, release the Starter Switch. As the
engine warms up, slowly push the CHOKE in,
9-2, ENGINE SHUT DOWN
1. Remove the load on the generator.
2. Allow the engine to ¡dle for a few minutes, allow a longer
length of time if the engine has been operating at full
load. This idling time is to ensure that the internal engine
temperature has a chance to equalize.
3. Place the Starter Switch in the OFF position.
SECTION 10 - ENGINE MAINTENANCE m========—==—=—e
major oil companies, should be used as a replacement oil.
Table 10-1 gives a list of recommended grades and types of
oil to use to keep oil level up during break-in and to use after
the break-in oil is drained. The capacity of the engine with a
filter change is 4-1/2 quarts, without a filter change, 4 quarts.
Check the dip stick to make sure oil level Is up to the re-
quired operating level.
In normal operation, oil should be changed after about 50
OM-450 Page 11
10-2.
10-3.
10-4.
Page 12
hours of operation with a filter change every 150 hours. The
oil should be drained after the engine has been warmed up to
normal operating temperature, thus promoting foreign parti-
cle suspension in the oil and thereby removal when the oil is
drained. Foreign particles tend to settle at the bottom of the
crankcase when the oil is allowed to cool, thereby avoiding
removal and thus contaminating the new oil added.
Table 10-1. Oil Selection Guide
Above 90 degrees Fahrenheit
Not lower than 32 degrees
SAE 30 or TOW-30
SAE 20 or 20W
10W-30 or 10W-20
As low as 10 degrees
above zero Fahrenheit
SAE 20W
~ 10W-30 or 10W-20
As low as 10 degrees
below zero Fahrenheit
SAE 10W
TOW-30 or 10W-20
Lower than 10 degrees
below zero Fahrenheit
SAE 5W or 5W-20
COOLANT SYSTEM
If the engine is to be operated in a temperature below
—159F, make sure a good grade of anti-freeze is added to the
coolant system. Change the coalant solution as often as nec-
essary. The coolant system capacity is 11 quarts (US, Mea-
sure).
During the break-in period of a new engine, one of the
greatest dangers is over-heating. There are several possible
causes of over-heating, but the basic items for consideration
are engine lubrication and coolant circulation.
At the first sign of over-heating, shut the engine down and
make a thorough check to determine the cause.
Temperature of the engine coolant is regulated by a thermo-
static valve located in the outlet at the front of the cylinder
head. This unit retards the flow of coolant until a predeter-
mined temperature is reached, usually varying between
17G°E and 180°F. When the desired temperature is achieved,
the valve opens and free circulation of the coolant through
the system begins.
If the thermostat valve becomes faulty and does not open at
the correct temperature, the thermostat should be removed
and a replacement installed immediately.
GOVERNOR SERVICE
The governor speed setting and sensitivity setting are factory
set to obtain correct weld speed (1800 rem) and engine re-
sponse to changing load conditions. The governor speed con-
trol setting is factory locked with a lead seal. Do not remove
this seal unless absolutely necessary.
The governor, as used in conjunction with this engine,
does not have a “No Load Surge” adjustment as de-
j scribed in the Engine Manual. |
The engine is factory set to operate at 900 rpm idle speed
and 1800 rom when it comes up to weld speed. For informa-
tion concerning governor adjustment, refer to the Engine
Manual, Page 41, paragraph entitled “Pierce Governor”.
CARBURETOR FLOAT SETTING
To ensure correct fuel level in the float chamber, check dis-
tance {dimension A, Figure 10-1} from top of floats to
machined surface of throttle body (no gasket} with throttle
body inverted. This dimension should be 1-5/32 inches plus
or minus 1/32 inch. To increase or decrease distance from the
top of the float bodies to the machined surface, use a long
nose pliers and bend the float lever at a point close to the
float body.
TT
À
kh —>—
- AA-300 955-9
Figure 10-1. Carburetor Float Setting
Do not bend, twist or apply pressure on the float
bodies. The float bodies when viewed from the free
end of the bodies must be centered between and at
right angles to the machined surface and must move
i freely on the float axle. i
10-5. VACUUM CIRCUIT AIR FILTER
In order to provide clean air for the vacuum circuit, a brass
fitting type air cleaner is provided on the underside of the
idle control valve. See Figure 10-2 for location on the engine.
This brass fitting will have to be removed and cleaned in
gasoline or a suitable solvent periodically to ensure proper
engine operation,
N »
В
7
BRASS FITTING LOCATED
ON UNDERSIDE OF IDLE
CONTROL VALVE.
AA-900 955-10
Figure 10-2. Vacuum Circuit Air Filter Location
10-6. AIR CLEANER SERVICE
A. Daily Service
1. Open the engine compartment door nearest the air
cleaner.
2. Make certain that the screen on the weather cap is free of
dirt and foreign material.
B. Weekly Service
Service paper element once every week under normal condi-
tions or when loss of power is noted. Servicing element is
accomplished in the following manner:
1. Remove filter element lock assembly and seal.
2. Inspect the gasket on the end of the element for damage,
Wipe out inside of air cleaner housing before installing
element. Do not use the element if the gasket is damaged
or missing.
3. It is recommended that the element should be replaced
after ten washings or at the end of the season, whichever
comes first,
When it becomes necessary to service the air cleaner in
the field, follow the procedure outlined in Figure
10-3. It is recommended that a spare element always
be kept on hand for replacement. New elements are
E available from your distributor. I
For a temporary expedient
in the field, the element
can be cleaned by tapping
the side or the end care-
fully against the paim of
the hand.
CAUTION: Do not tap ele-
ment against a hard surface.
The element may be damaged
by doing so.
ALA
ERRANTE
пре ев ВЕ
Ah ft DAP
>=
+ =>
a Fa
3x3 F 393 >
551235556950
23 BFF a > 3B
TF FFE DTT
2779 2755 457
Fy 3 33
>> 5537»
5. |
Compressed air, not to ex-
ceed 100 Ibs. of pressure
can clean the element. in-
sert nozzle inside the ele-
ment and blow out dust.
Clean dust from the out-
side of the element by
holding the nozzle at least
6 inches from the ele-
ment.
If compressed air is not
available, or if soot, oily
vapor, or any dirt is pres-
ent which cannot be re-
moved by compressed air,
then the element is to be
washed, Agitate element
in warm water containing
a non-sudsing detergent.
CAUTION: Do not use water
hotter than the hand can
stand; solvents or oil; fuel oil,
or gasoline,
7.
Reverse flush with clean
water to thoroughiy rinse
all loosened foreign ma-
terial from the filter.
)
+ к =
aga © & & = цоя 4 он Е 4
Г
ча 4 бана с НН
ded с & со бб к LE
BELL ELCCOÉLECtAD
act di REEL Lec
Arlt ote cola
+4 E BL Lod ELE
Shake out excess water from the
element and allow to air dry,
CAUTION: Do not attempt to remove
excess water by using compressed air.
An even fine pattern of light
through the element, when a
light is held inside the element,
indicates that the element is
clean. Any large spot of light in-
dicates that the element is dam-
aged and, therefore, is unfit for
further use. Replace the element.
Figure 10-3. Air Cleaner Service
To minimize down time, created
by waiting for the element to dry,
it is suggested that the newly
cleaned filter be replaced by a
similar standby unit.
OM-450 Page 13
Tomas SECTION 11 - TROUBLESHOOTING sm anna mme que
11-1. ENGINE TROUBLESHOOTING
| FAILURE TOSTART |
|
CARBURETION IGNITION [compression]
Poor grade Restricted air cleaner, Plugs wet Breaker points pitted [Cylinders dry.
of fuel Fuel pump diaphragm or dirty. ar fused, Sticking valve.
Water Choke Condensation | [Spark plug insuiation bad.| | Loose or broken spark plugs.
in fuel Flooded — on electrodes. | {Breaker arm sticking. Cylinder head gasket leaking.
Gum Dirt or gum holding Weak battery | |Improper timing. Piston rings stuck.
in fuel float needle valve Broken ignition cables. Warped or broken valves,
Dirt Damaged HS needle valve. Ignition cables
in fuel Fuel line clogged. disconnected.
improper Air vent filler cap plugged. Wires to wrong plugs.
volatitity Manifold gasket leak.
No fuel Muffler clogged.
| «mocking |
(CARBURETION] | MECHANICAL | | IGNITION | [OVERHEATEO|
Poor grade of fuel Heavy load at slow speed, Breaker points No coolant in radiator,
Octane rating to low Carbon or lead deposits ir too far advanced Blocked radiator air flow,
cylinder head. Thermostat defective.
Loose connecting rod,
Loose main bearings.
Burned out connecting rod.
Warn or loose piston pin.
Worn or loose timing gears,
Improper piston fit.
Valve lash too great.
Y alves stick ing.
| MISSING |
Water in fuel Scored cylinders. Improper heat range in plug.
Gum in fuel Improper valve lash, Loose plug.
Improper needle valve. Stick ing valves, Poor insulation on plug.
improper carburetor Loose or broken spark plugs. Spark plug gap incorrect.
Dirty fuel system. Cylinder head gasket leaking, Worn and leaking ignition cables,
Improper fuel mixture, Piston rings stuck. Weak spark.
Inoperative fuel pump Warped or broken valves. Loose electrical connections,
(Dirt or mechanical]. Sand hoie in casting. Breaker points pitted or worn.
Air leaks in system. Valve springs weak or broken, | | Breaker points sticking.
Defective float mechanism Improper tension of breaker point
inoperative choke control spring.
Vapor lock, Improper breaker point gap.
Bad condenser.
Weak coil,
Worn out plugs.
Defective ignition switch,
Grounding of ignition acessories.
Moisture
Defective distributor cap,
| OVERHEATING |
1
L L Д L 1
CARBURETION) {LUBRICATION | [MECHANICAL] [| IGNITION | [COOLANT SYSTEM
- ] | | | |
Low grade of fuel, Cil supply low, Engine overloaded, Timing Restricted radiator air
Engine operated while Dirty Of MCONFect Carbon deposits in INCOTect, floue.
detonating, due 10 grade of oil. engine. Low coolant level,
tow octane fuel or Plugged lubricating Restricted exhaust. Inoperative coolant
heavy load. system. Choke control partially pump.
Improper carburetor Bad oil pump. pulled out, inoperative thermostat.
setting, Worn parts in Valves leaking.
Plugged air filter, lubricating system, Restricted air cleaner.
Leak in intake system. Recirculation of hot air.
Impraper break -irt,
| SURGING |
CARBURETION GOVERNOR
Carburetor flooding. Sticky controls
Improper adjustment, Improper lubrication.
intake leaks. y
Page 14
17-2. ENGINE/GENERATOR TROUBLESHOOTING
TROUBLE
PROBABLE CAUSE
REMEDY
No output at 120 volt ac
receptacle.
Poor contact between slip rings
and brushes.
Clean the slip rings with 3/0 sandpaper and if necessary,
Install new brushes.
Defective diode in rectifier SR1.
Replace defective rectifier.
120 vac available at receptacle but
no output at weld terminals.
Poor contact between slip rings
on welding generator.
Clean slip rings with 3/0 sandpaper and if necessary, install
new brushes.
Defective Fine Current Control
rheostat (R1).
Check for open winding in RT with ohmmeter.
Defective stabilizer (£2).
Remove both leads from Z2 and check for open or grounded
coil.
Defective diode in rectifier SR2.
Replace defective rectifier.
Erratic weld current
Damp or defective electrodes.
Try other electrodes.
Loose or dirty connections.
Check connections both
generator.
inside and outside of welding
Check ieads and contacts of the
Range Switch.
Discoloring of brass contacts could indicate heating caused
by loose connection, Replace contact or switch plate.
Defective diode in rectifier SR3.
Disconnect one lead on diodes D2 thru D7. Set ohmmeter on
x1 range and check across diode for continuity. Diode should
conduct in one direction and not in other. Replace if pre-
vious step is not true,
Engine speed remains at idle rpm
when arc is struck.
Magnetic field not closing reed
switch (CR1).
Replace CR1
Coil of solenoid burned out.
Apply 12 vdc to solenoid coll €: check for proper operation.
Filter on solenoid plugged.
Clean filter. See paragraph 10-5 for cleaning procedure.
Engine will not return to idle rpm
when arc is broken,
Idle control valve closed.
Open valve by turning in a counterclockwise direction.
idle control valve plugged.
Remove and clean.
Leak in vacuum line.
Check Line.
Shorted Idle Control Switch ($4).
Check switch with ohmeter.
REAR VIEW
Tr-TOTAL TIME METER
‘а МСТ
ВАТТЕР У |+
«НИНЕ
ные |
OPTIONAL?
| 4
GY EE GAOUNS STRAP MUST BE
INSTA LED BETWEEN ENSINE
FRAME aI WELDER FRAME
om
- 4 PHASE
5 | 13.6 CHMS AT TQ WELD GEM.
* USED ONLY IF REQUIRED TO
COMPENSATE FOR VARIATIONS
IN IRON CHARACTERISTICS
Gh? m
|
i
1
EZ VÈLTS SC PHASE TS PHASE | =
AT RATED FIELD CUFRENT-60H7 3
6
an
— az 27 03
ey” pr ние,
Fi PTS
в
Ja SAA 272
EQUIPMENT > > |
| GROUNS vy De
+ 20
Meal 1
"То "Тот
fit
NEGATIVE POSITIVE
Circuit Diagram No. CB-900 955-1K
Figure 11-1, Circuit Diagram
OM-450 Page 15
July 1973 FORM: OM-450
Effective with serial No. HD690740
MODEL STOCK NO.
BIG 40 900 955
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
FL LL
!
NWSA CODE NO, 4579
Figure A — Main Assembly
OM-450 Page 1
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OM-450 Page 2
Page 3
Item Dia, Factory
No. Mkgs. PartNo. Description Quantity
Figure A Main Assembly
1 017430 STRAP, holddown - fuel tank 1... 122224444444 0 4 4 4 4 aa 4e 4114 14 4 3 a es ae 000 2
2 010 434 STRIP, rubber 1/2 x 2x 4-1/8” it i ete eee eee 0 2
3 017 168 TANK, fuel (consisting of} ......... ee ee re eee eee ea 1
4 018858 .CAP ...r.recerereconaadererarererrercacenaderararereercerarecez 1
602 938 PLUG, galv pipe 1/8 MPT (used on bottom of fuel tank) .................. . 1
5 017 456 BRACE, support-fueltank ........... iri tiie, 1
6 018 158 FUEL LINE (consisting of) 1.241424 440 44045404 114 101 00e 0 eee ean 1
7 010870 NIPPLE, brass 1/8 MPT 1.121210 0 444444 44e 4e 44 aa 4 a a a 0 4 0 1 aa 0 ea en 0 1
8 010 318 VALVE, shut off .... i i eee cetera, 1
9 010867 .ELBOW, brass - street 90 degree 1/8 PT ee ea eee se 1
10 010 289 .CONNECTOR, brass 1/4 TBG 1/8 PT ............o.erecccsamoreoereeoeo. 2
11. 010 387 LINE, fuel ...102 240400440424 it i tite 0 1
12 017479 SEAL, liftmg eye ........eé_eereecaroceraernmenencenedarnzorooréaarare, 1
13 031868 BRACKET,mtg-aircleaner......2200 4000544 4 ee ae 0 1 a 4 4 aa 8 a a ee a ee 400 1
14 018 765 AIR CLEANER, intake (consisting of) ......... oii iii, 1
15 018 859 .CAP .....iececdorrvrandaramnarverarenvonrenaenoorarvrerzcvernvev. 1
16 010 433 .NUT, wing .....oeesvordrereronrrredraaneonacrvrsenecanvora ve narnia 1
17 *018 860 ELEMENT .....r.e.nadrrareraraneorererearendarcanrorerorsareerneo, 1
18 018861 .BODY ........ te eee ee eee ea a е неко. 1
19 010861 CLAMP, hose 20er it it et tt ate ee te tt treats meas, 6
20 018 365 HOSE, intake - ai. .......e.eorerrrornescene vrernrevenerererangararcare, 1
21 023 626 CABLE, battery - positive .... 111224444044 0 4e 6 4 a 4 a 0 4 4 4 40 a ea 1e sa sa 01e 0 1
22 022 899 TDOOR, access - battery .......222004 400444 4 a 8 ee 2 a 4 0 6 a 4 a a a a es ea ea 1408 1
23 017421 CATCH,door ................. PEO ananmeroecarrererverecde nee, 2
24 010515 BOLT, J5/16-18 ....... iin. a eee eee 4
29 017481 DOOR, side «o.oo KK 2
26 015684 GROMMET, rubber 4-3/167 ID .............esesrrereorereacirererevo, i
27 017485 COVER ..........eesrcedcererereovraanearoonaoredeerdmaanonrv ocean 1
28 604 559 PIN, cotter 1/4-3-1/27 ee ee ee eae 6
29 012 487 LABEL, pushdown touniatchdoor. .......... iin, 2
30 027572 GUARD, fan-lefthand ....... ie i eae iia 1
31 *О17 363 HOSE, radiator - Upper .........ocee.erervosiicoronorroerorerenmerenva, 1
32 028 404 RADIATOR (consisting of) ..........eem0oeneroaranavarnvereoracorvenea 1
33 081254 CAP, radiator .... ci eee KR a aa eee 6 1
34 019231 ENCLOSURE, radiator........... eee eee eee eee ara, 1
35 027 573 GUARD, fanrighthand .......... KK 1
36 010386 COCK, brass - radiator drain .... 112120420044 a 44 04 44 1 0 0 0 ea a 0 a sa 04000 A 1
37 *017 362 HOSE, radiator-lower .. 1.122210 4044244 4 44 0 4e 4 ea a a 4 4 ee 4 0 ra a 4 a ann, 1
38 BLADE, fan (included with engine-see engineparts hist) , ................... 1
39 BELT, V (included with engine-see engine parts list) ...................... 1
40 031 980 ENGINE, gasoline (consisting of) ...... iii ieee. 1
41 018 757 .CONTROL, weld & idle vacuum (See Fig. B Page 5) ..................... 1
42 020 365 .STOVE, manifold...........o..eomresemaererereerereanearoreorerarnazoen, 1
43 017594 CLAMP, stove... vivir iii eisai cena RAA AAA AS 1
44 025 453 SENDER, temperature ,.... Canedo ee eee 4 4e 4e aa a ee 0 1
45 025 884 ‚SENDER, oil pressure... 122220444044 464 40 0 8 4 a 4 40 4 0 sa a a ae se sea 22e 6 1
46 025 182 .BRACKET, mtg -alternator ........e.wc«eeceererderor -rervarener0cócarno, 1
7 695 429 | ALTERNATOR, 35 ampere 12volt een a ea aa 04 22000 0 1
48 605 430 PULLEY, single belt... .. ie eee eens eee 1
49 025 181 . TUBING, steel 5/8 OD x 12 ga wall x 1/27 iii 1
50 027541 PIPE, exhaust .. oo oti teat eae ieee 1
51 017389 CAP, weather NO. 4 oo i i it tte ett teeter ae 1
52 Figure C GENERATOR ASSEMBLY (SeePage 6) ........ cian. 1
53 017477 X%ROoOPD, bholddown - battery ........o_ceceere=resoncarrecsrsedvda correo 2
54 Batt 2015709 BATTERY, 12 volt 53 ampere hour ... 1.222444 44004444 a 4e a a a sa ea es ee 1
55 023 641 CABLE, battery - negative 1.104440 4 4000 44 4 0 4 a 4 0 4 i ie eee 1
56 017431 HOLDER, battery ......12242004 041400 48 4 4 8 es 0 a ea a es ee ae a es a 0010 40 1
57 023 892 CABLE, ground -engine ...1.0220 4004004 140 1e 4 a a a ea a ca a ea es ea 8000 1
58 MOUNT, engine (included with engine-see engine parts list} . . ............... 1
59 010 266 SPRING ........eoerceorararerrereveroeeoovereyenaaone aro roerecra, 2
60 017420 LATCH,door ................ a eee ee eee 2
61 22 027 982 STABILIZER ...22444 1004414 44 a 4 4 44 a 4 ee ee 4 aa ea a ee a 0 4e 14 a 1 ea ea en à 1
62 010679 MOUNT, rubber - generator . .... oii iit ir cs iit einen 2
63 031961 INSULATION, rectifier ......... Li ities 1
64 031888 RECTIFIER ASSEMBLY ,.......ce.ereerrreeoadiderooereoranaro rorerca 1
65 037 346 .RECTIFIER, integrater 6.5 ampere 400 volt ........... co. oii 2
66 031926 HEAT SINK i 0 4 a 4 4 a 4 4 4 4 a 0 4 0 LK RR 0 1
67 027951 BASE ......2120 4444 LL 1011440 44 44 4 44 44 8 a a 4 A 4 4 ee a ee a A a aa ea ee m0 4 0 1
68 027 957 FRAME, upright-base front .........—e-—e_—reserarvorerseadnrarvvroco ara 1
Item Dia. Factory
No. Mkegs. Part No. Description Quantity
Figure A Main Assembly {Cont.)
69 Figure D PANEL, front with components (See Page 7) .....r..e.eereeoeveoreeeerones.
70 027 846 PANEL, hinged - lower front ........_.--errearecrvervrceracrreer E
ral R2 030 060 RESISTOR, WW adj 375 watt 20 ohm ......... 0 ceria,
72 Z1 086 259 REACTOR 1.222000 042244 444 44 44e 4 a a a es a ee Se a 1 ea 880 1e 1 011 00 0
73 028 218 FRAME, mtg -stabilizer & reactor .... irri se ca 101 4000
74 VS1 025 932 SUPPRESSOR, 0.75 ufl0ochmw/leads ....... coins.
75 027 105 STRIP, cotton 1/8 x 1 x 20” iii iia eee 06 eee heen
024 480 KIT, label (includes all labels) ..............r_essnervrsroresarereerev..
+028 262 MUFFLER, exhaust .........eo_eeeoraredosreravcrrecrrereórercarer,
+010875 CLAMP, muffler 2” dia ........—_—eeesxdxcerervorrecarere racer oteacane
+015 700 BRACKET ASSEMBLY, mtg- muffler ........eeeexcororvecareerererA.
+027 564 SPACER, anti-noise - mtg muffler .........rc_eexeereovoverecaaro rr.
T025 663 METER, amperage de 0-400 .............e-ecemervecrcerecareareróe..
+026 943 INSULATOR, ammeter .........ee.eoocorenverervenecereerere ree.
+025 638 METER, voltage de 0O-100............ececeenermervesaierare ver ere
TT +025 718 METER, hour 12 volt de ..........oreeserecerereeroracesrervereóne G
+028 653 BRACKET, mtg-hourmeter .......... cc. aie,
TAC +027 491 TACHOMETER, electric 12volt ........... civ es a 0000
+017 390 BRACKET, mtg-tachometer ........... Lirias
+020 374 BRACKET, mtg - tachometer fo engine ............ oii.
52 +011 620 SWITCH, toggle SPST 16 ampere 125 volt (remote current control) ......... .
RC2 17039631 RECEPTACLE, twistlock 2P2W (remote current control) ...........e.e....
HH H ta a pa Ha HA AA DD AIHIhHhH
*Recommended Spare Parts.
TOptional Equipment.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 4
Item Dia. Factory
No. Mkes. PartNo. Description Quantity
Figure B 018757 Control, Weld & Idle Vacuum (See Fig. A Page 3 Item 41)
92 017 417 LINKAGE ASSEMBLY ........ .eecononecreraoroerererr rec ereeaane. 1
93 604 393 RECEPTACLE, screw 8/16” dia ..........oeesrerera—o eee eae 1
94 604 392 RIVET, round head 3/16 x 3/45 111221011122 .mecrecareceorvereca.re. 1
95 603 931 RECEPTACLE, screw 1/47 dia .......... oe e ..es-aranvereaeenvaceore. 1
96 603470 VALVE, needle -shut off ....2202200 12004 24 La 42 4 8 44 8 8 4 4 a 4 ii ii eee 1
97 010869 BUSHING, brass 1/4 MPT 1/8 FPT ..................... ee eee 2
G8 020963 TUBING, copper 3/16 OD x 18-1/27 1g 20er EEG 1
99 018 097 CHAMBER, vacuum ...... _eoorrornecocenceartareraoendeneorerearoras 1
100 020 962 HOSE, rubber 7/64 TD x 27/64 OD x 4” lg ........esenra0savaerrv reee en. 1
101 010 561 TEE, brass 1/8x 1/8 .......om—.emddieraanercarenvwrerrrevrrererecocon. 1
102 020 964 TUBING, copper 1 B ОБ х 1” Ig. ii i ii i eit 41 00000 1
103 : SR4 031 252 RECTIFIER, selenium ........... 200000000 0er oran encerrona rcora.. 1
104 GS1 035639 VALVE, 2 way 12 volt de ........._—rre=-—evreverrrre de rerarrverercercer. 1
105 023030 BREATHER, brass - vent 1/4 MPT.....,.....eesaeerverorveroerace rea. 1
1906 603 802 RIVET. round head 1/4 x 27 iit ieee etait nines 5 1
107 017544 BRACKET, mtg- vacuum chamber........r_20eíeeerceroriererrerrmeneane. 1
108 015713 CGROMMET, rubber 5/167 ID 1.222440 400440 4 0 68 6 4e 14 1 45 0 0 3 ea 1 0 0 0100 1
109 | 018 160 LINKAGE ASSEMBLY (consisting of) ............eerevererereri ee 1
110 024 799 .BALL JOINT, 1/4-28 thread ........e ceo resarevoresarardanza new rrt. 1
111 018 098 BOLT, hook .. tiie ite eee 6 0 0 0 004 48 40 0 0 2 84 0 0 001 00 6 1
112 010 334 . CLIP, CLOVIS © + ov vv eevee eee ee ee ee eee ee eee aaa 1
TA-018 757-6
Figure B - Control, Weld & idle Vacuum
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
Item Dia. Factory
No, Mkgs. Part No. Description Quantity
Figure C Generator Assembly (See Fig. A Page 4 Item 52)
116 025 271 ENDBELL ,.......eoeeorvecrreanoraatacarervoeerorarecoreaneA. 1
117 SR3 025 517 DIODE ASSEMBLY, reverse polarity (consistingof) ................... 1
118 025 305 INSULATOR .... iit teeta titanate 2
119 037957 . DIODE, 275 ampere 250volt . ..... ee ee hae aa eae ea 3
120 025 306 INSULATOR ........ereacararearonyyteraacarervenmorevecrcerao. 5
121 026 203 CHANNEL, neopreme 1/4 x 11-1727 ci iii iene 1
122 **031 963 STATOR ... iii i iinet saan 11421 4200 6 1
123 026 393 BAFFLE, air.......reeerxecorerrvrrescasraneavoresrerarornerme rv. 1
124 **031 964 ROTOR (consisting of) . ooo i iii ii ere ie ee ieee ius 1
125 024 617 RING, retaining ......eee_—esroerasarocverervoere retracto eve ne. 1
126 024616 BEARING .... iii i eis eae a ea eae aa 1
027 182 . KEY, 3/8x 1/2%X T°...1112 221140040400 ee 0 a a ee a a a eee sa a a see = 1
602 340 . KEY, 5/16 x 1-3/8° .....122 114406 aa ea 1 4 a 1 ea 040 0 es as aa ae 11 eee 0 1
127 017725 .FAN ...... Nenrodoconvoranearernrenvzoroaroaarnnvorvane ra e т. 1
128 025 525 ROD, threaded end 3/816 x 29-7167 . viii 1 000 6 6
129 018614 BRUSHSET (consisting of) ...........e_eseseorersroeaaanereen 3
130 018665 .CAP ieee eta aa i ee eee 1
131 600270 .BRUSHHOLDER ..........—erecvroeanorervorerarorerernarmervecne. 1
132 $020 084 BRUSH iii titi tetera е ко 1
133 025 321 BRACKET, mtg-brushholder .......... coin, 1
134 SR3 025 516 DIODE ASSEMBLY, straight polarity (consisting of) ................... 1
135 025 305 .INSULATOR 1.122200 04024000 4 a 04 a a a 0 ee a a 0 ee a a ee a 1 a ee aa eu 005 2
136 037956 .DIODE, 275 ampere 250 volt ..........ereaeacaaerenmvoerererecerm. 3
TD-027 1889
Figure C — Generator Assembly
*Recommended Spare Parts.
**Rotor and Stator are available on an Exchange Basis. Contact Service Department for Details.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 6
*Recommended Spare Parts.
BE SURE TQ PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 7
Item Dia. Factory :
No. Mkes. PartNo. Description Quantity
Figure D Panel, Front With Components (See Fig. A Page 4 [tem 69)
151 038 878 TERMINAL, power output - black (CONSISTING OF) ........e...eeecreerereno. 1
152 601839 .NUT,brass-hex 1/2-13 full .......... 0. urns 1
153 038913 .NUT, brass - hex 1/2-13 special ..........eom.emearoeer e... 1
154 038129 . BAR, bus ........... Cada a adormrrarerorarvereCreoreaa rea, 1
155 038865 .TERMINAL BOARD ..... teats 1
156 038 912 .BOLT, shoulder 1/2-13 x 1-11/16” eisernen 1
157 85 011 273 SWITCH, range (See Fig. DI Page 8) 1.120202 0 00000 sa see 0e 1
158 RI *030 990 RHEOSTAT WW300watt25 ohm ............sexeaxcereere.. 1
159 SI *011 801 SWITCH, toggle SPST 10 ampere 125volt ........... cil. 1
150 RCI 604 176 RECEPTACLE duplex-ground 2P3W ......... curio... 1
161. CRI 034 876 RELAY, switch (consisting of) ....... iin 1
022 230 .SWITCH, relay ........ ci iii iin 1
162 51 027823 SWITCH, key type - ignition ...........—..erenesnoerecaaonem.. 1
163 038 886 TERMINAL, power output - red (consistingof) ................. 1
164 028912 . BOLT, shoulder 1/2-13 x 1-11/16%” seien 1
165 038 885 . TERMINAL BOARD.......20400 00000020 a a a 3 a ee ee en ee 000 0 1
166 038129 .BAR, bus ......eeereovrrrrorerereaaoenorerreravererece, 1
167 038 913 . NUT, brass - hex 1/2-13 special ....0.0.0.0.00000000 00a Kern RG 1
168 601839 .NUT, brass - hex 1/2-18 full ..... iii 1
169 031858 PANEL, front- Upper ...... _.—r_ereeresverereserererreornene. 1
170 . NAMEPLATE (order by stock, model and serial number} ......... 1
171 019790 CONTROL, push-pull ....... iii i ieee nen 1
172 025 451 GAUGE, 01 pressure ........eoeervrereorvroevererrveavor—aro, 1
173 030530 METER, amperage 60-0-60................. ee teeta ea 1
174 025 452 GAUGE, temperature .. 122224044444 4e 4 4 a 44 6 ea 0 420 14 2 000 6 1
175 019 755 HANDLE, rheostat......1020204100 000044424242 i einen 1
602 178 SCREW, set 1/4-20 x 3/87 111210110044 242 4 4 tienes 1
176 019 754 HANDLE, range switch 122204204044 04004 a 0e sa 2 4 sa a en 6 1
177 010836 PIN, spring 3/16 x 1-1/4" (i i i ee 0 0 1
Figure D — Panel, Front With Components
TC-020 883-B
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure D1 011273 Switch, Range (See Fig. D Page 7 Item 157}
181 011 322 BRACKET, mtg - switch (consisting of). ................. ..exnererereorecrceo 1
182 010671 ‚SPRING .......eresxrermarmecoverorevarerooredranerovrarnaroraoreva, 1
183 010428 LOCATOR, quardant ........ece.eeceeecorirraraveriaecrareoadenrvrvorer. 1
184 011100 PLATE ASSEMBLY (consisting of) ...........ecemrearvreosareanvtrv orvecoo 1
185 011 013 .GUIDE, rotor .........e.eeec0eadodarersooxóeorvac eaoererorareranrero 3
186 011012 .SHIM, guide .......eeeeeonvororoverasecionerenaorerascarecorrorene. 6
187 011 019 .ROTOR ,.......e.eeserorererecrarecoamorerodrarernacorbavroneona 2
188 011 095 PLATE Lt a Aa 4 a 4 4 ea a 4 4 48 A A 4 ea a a 4 a sa 40 8 81 4 21 a 00 0 2
189 011 496 . CONTACT ASSEMBLY, movable (consisting of) ............ co. ii... 3
190 011 025 ..SPRING, pressure .......—._..eerenoreraranono0eoea_renoamoermordrerernv 1
191 011010 ..CONTACT, copper w/dimple .........oceeenaaronedarverenrareoverroas 2
192 011 007 ..SPRING, pressure ......._...—e-enerveaorarecoarnrzrrnrarerecaceerererna 1
193 011018 .CONTACT, stationary .........e.ereromvacororverarervoerdacarvoneree, 15
TB-011 273 | _ TB-011 100
Figure D? — Switch, Range
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUBMERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 8