Miller BIG 40 Owner's Manual

OWNER'S MANUAL November 1979 FORM: OM-450H Effective With Serial No, HK341102 MODEL BIG 40 MILLER ELECTRIC MFG. CO. 718 5. BOUNDS ST. P.O. Box 1079 APPLETON, WI 54912 USA NWSA CODE NO. 4579 PRINTED IN U.S.A. LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY -Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its 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 . Al engines are warranted by their manufacturer for one year from date of original purchase. Except as specified below, Miller's warranty does not apply to components having normal useful life of less than one 11) 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 warranted Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equip- ment to the original user: Quo =. E & Lo .. 1 уеаг 3 years — . Arc welders, power sources and components 2. Original main power rectifiers {labor - 1 year only) . All welding guns and feeder/guns . .......... . 90 days . All other Millermatic Feeders. ................. + year . Replacement or repair parts, exclusive of labor . 60 days . Batieries........122110 44124 aa 406 .. 6 MONths A EA AECA oa wow provided that Miller is notified in writing within thirty (30) days of the date of such failure. — a я EN = es A 7 DE ES Âs a matter of general policy only, Miller may honor claims submitted by the original user within the foregoing periods. in the case of Miller's breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at Miller's option (1) repair or {2} replacement or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station or (4) payment of or credit for the purchase price (less reasonable depreciatton based upon actual use) upon return of the goods at Customer's risk and expense. Upon receipt of notice of apparent defect or failure, Miller shall instruct the clai- mant on the warranty claim procedures to be followed. ANY EXPRESS WARRANTY ‘NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- TION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX- CLUDED AND DISCLAIMED BY MILLER. EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MILLER” WARRANTIES DO NOT EXTEND TO, AND NO RESELLER 15 AUTHORIZED TO EXTEND MILLER'S WARRANTIES TO, ANY CONSUMER. 12 YOLT | ERRATA SHEET After this manual was prihted, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. AMENDMENT TO SECTION 2 - INTRODUCTION Amend Figure 2-1. Specifications The Coarse Welding Current Range In Amperes should read as follows: MIN. - 65 55 - 100 85 - 190 120 - 250 220 - MAX. AMENDMENT TO SECTION 10 - TROUBLESHOOTING Amend Figure 10-1. Circuit Diagram For Welding Generator AC POWER WHT D STD. GA NE > > Ss fur, x w | 8... REMOTE CONTROL ACT {OPTIONALLY REMOTE CONTROL rois (OPTIQHAL) TO INSTALL, REMOVE LEAD 107 FROM Ay AND CONNECT TO 55 MOTE! GROUND STRAP MUST BE INSTALLER BETWEEN ENGINE FRAME AMD WELDER FRAME "71 [+ EQUIPMENT GROUND 1 OIL PRESSURE LÜPTIOHALY NEUTRAL GROUND AS AEQUIRED BY HATIONAL ELOCAL ELECTALS CODES ACECA TO OWNERS MANLIAL BEFORE MAKING ANY CONMECTICAS FA 12 53 2 т 7 m m | В = = m | m < o & 27 | oF 37 | | 1 Je I ce 1 1 ol) | 7, D3 CAUTION Fey 3 RC o + = REFER TO OWNERS I N Ica leas — MANUAL BEFORE в | 1 an I | (04 Ds ATTEMPTING YOL TAGE I | ip a > . CHANGE -OVER с ] 240%. [< | с WATER TEMP LA | SR3 | 5514 Nt I a) +— == == = о— = — = — D D HOLD Id 6 7 TO START OPTIONAL KIT +3 = Ly 20 INCLUDING 240 VOLT „” SAFETY SHUTDOWN -—— RECEPTACLE 73 | WELD METE AStOPTIONAL) TO INSTALL REMOVE LEAD AUTOMATIC IDLE CONTROL LO 0 Ра 5ТАНТ 7} UN 12 VOLT STARTER НА RUNNING HOLA METER (OPTIONAL) | | | | | | | la 2 + 76 | a 00 20 FROM 2 A CONNECT 5 Da Gif __ J TO SHUNT NEGATIVE* A POSITIVE* E TT POLARITY SW REY {OPTIONALLY * NEGATIVE A POSITIVE STUDS HOT USED WITH FOLARITY SWITCH ELECTRODE WORK Circuit Diagram No. B-072 428 Figure 10-1. Circuit Diagram For Welding Generator Effective With Serial No. JA440200 And Following Hem No. 46 47 48 65 79 134 136 Pg 10 Pg 10 Pg 10 Pg 10 Dia. Mkgs. 59 58 SR3 R4 VR1 Rb A2 HM S2 Part No. 025 474 025 473 025 182 000 553 005 631 “020 034 046 456 025 663 032 936 027 841 027 851 Pg 10 Shunt 030 080 Pg 10 V 025 638 Replaced With 025 474 025 473 005 765 010 679 048 083 *044 755 072 182 046 189 030 726 046 685 072 635 072 634 007 080 072 633 602 887 046 559 Deleted 047 090 011 948 024 694 103 634 103 633 048 498 010 082 . 019 603 010 805 038 769 103 632 011 645 011 074 011 075 011 953 047 208 Deleted 030 081 1017 364 046 654 1080 497 1079 496 1030 170 1601 158 1601 165 1010 014 *Recommended Spare Parts. TParts For Optional Equipment. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-450H Page B Description SWITCH, shut - down - high temp SWITCH, shut - down low oil............ . i inns BRACKET, mounting - alternator MOUNT, dual - stud я нивы нии чеке вв + чмо ни ни ни гв ян ых их нии ни нь я ии вв и яч ан ая няни ни нива та знании BRUSH, contact DIODE ASSEMBLY, straightpotlarity .......................... SUPPRESSOR (Eff W/JA440199) (consistingof) ............... . RESISTOR, WW fixed 5 watt 1000 ohm . VARISTOR, 0.6 watt 175 volts dc RESISTOR, w/bracket (Eff W/JA440199) (consisting of) . RESISTOR, w/leads.....11 11210000 4 44 4 4 RR .. RESISTOR, WW fixed 25 wattb50ohm ...................... . BRACKET, mounting - resistor ............eeo.ecessrare a AA FITTING, pipe - plug hex hd 1/4 NPT (part of engine assembly) .... = : x = = 05 5588 PE 4 TE FE KENN WR RN т вк вы + && 4 ® 4 4 4 BE BE BE BE KE * KE * # 4 Ew вы w= 4 & & METER, amp dc 50MV 0-600scale................... ..... .... SWITCH, polarity {consistingof). ............... ci iit. . GUIDE, contact movable . BEARING MOUNTING BOARD «Lo semen . BUS BAR, shorting ..............—eeee0aravedan iaa a aa aa ae . BUS BAR : = 5 4 = # = FE #+ kb 4 + 4 U U OU PP 5 PU PE EH F 4 F 4 ¥ 4 #% ® 4 2 ®B ® HB BE 4 EB & f+ * F & ®% 1 а 4 = & = = = mR ая ии чи ии нем вт ни ни чи ни чин ии тян ня NL HE NH HE EH NH EH EH BF . KNOB, ball HANDLE eee CONTACT BOARD (consisting of) .. PLATE, switch - toggle .........._..eereecxvrere:ere enn e. .. CONTACT ASSEMBLY, movabie switch (consisting of)........ ... SPRING, break - away governor ........._._e———eececcorarr reo ... SPRING, pressure ........... o eeeeceooroeseaaeeo,e reno, ... CONTACT GUARD, switch -polarity ........... iii iene. HE kb & & EE ут # Fr # + хи ни нивы тк FE & & & & & wm ss ss ss нь SHUNT, meter BO MV B00 amp... o.oo ieee irri een MUFFLER, exhaust ........eee ee ee eee eee METER, volt dc 0-100 scale FUSE BOX COVER, Junction box... i i i i a 4 ae ee a aa a aa a + BUSHING, snap - in 3/4 ID x 1 inch hole BLANK, snap - in 7/8 inch BLANK, button - plug 1 inch dia CLAMP, cushion 3/4 dia x 13/64 hole ...............0.7000. и и #4 # = # = #5 z- #5 x: = #F # и #5 U FU 6 4 няни на = = # + + H 4 % HU + F F тени на в 4 & NB & & 4&4 w & & ss ss нина ни наи кн ан няня d & =m & RK N N ss ss ss ss ss = § WN FF OF ® F 4 = = = EX = = 5 8 F ®E = ®E § §F ии тие ив ян чи NR EH HB OH EN OF EN % KN % ¥ nm + HE 4 ® & вв ина ни нивы ини нии ния ян KK 4 ®E ON 4 4 © HE 4 © & kb EB KE KE AEB Quantity a N aa — № —> — № aa aN Aa — — — — — сей o — — EC TABLE OF CONTENTS mmm as nn Section No. Page No. SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1, Introduction. ............. iii iin, ea, 1 1-2. General Precautions ...........c. iii iii aaa 1 1-3. Arc Welding..............e_eeeeñc_ecrnororevameroevereecceroo 3 1-4. Standards Bookletindex ...........c.c iii ii ie 4 SECTION 2 - INTRODUCTION 2-1. General... ee eee eee ere. 5 2-2. Receiving-Handling. ......... iii e. 5 2-3. Description...........o ce. ..es0e.e re .aaaa arena Rena b 2-4. Safety.....................e.easnaerierereccerervreonoo;e cora 5 SECTION 3 - INSTALLATION 3-1. LOCatION «ot eee eee 6 3-2. Weld Output Connections ......... _o.ereveaoarrereresr0o0. nm " 6 3-3. EquipmentGrounding Terminal... ................. aria... 7 3-4. 120/240 Volts AC Terminals. ...... cover ieee es 7 SECTION 4 - ENGINE PREPARATION 4-1, Lubrication............._...e eee se0reoaconrerversaarererer0ó.. 8 4-2. CoolantSystem............_oocooo0eaeae:::e::errrerverero. 8 4 - 3. Preparing New Battery ForService.............. iii 8 4 - 4. AirCieaner ............00000s000 00 0 2 A aran 9 4-5. Fuel ee eee ee 9 4 - 6. Carburetor Air Temperature Selector .............. iii, 9 SECTION 5 - FUNCTION OF GENERATOR CONTROLS 5-1, 120Volts ACReceptacle ........ cctv. 10 5 - 2. Range Switch And Fine AdjustmentControl . .................... 10 5-3. VOolt-Ampere CUIVES . oo i ite à aa a 8 ae ae a 4 aa a 110 0 10 b-4. DutyCycle .....LLL 11111112 14 4 44 a a a a 4e ae ee ee ee 4 000 11 b-5. Meters...11111 100010 Aa da 4e ea 0 8 4 à ee ea aa 4444 a a a eee 11 5-6. Polarity Switch ............ 0 a a 4 a aa aa a a a a a a a a ea ea a a aan» 11 5-7. 240Volts ACDuplex Receptacle . ........... cc iii... 11 5-8. Remote Amperage Control ............._ i iii, 12 SECTION 6 - FUNCTION OF ENGINE CONTROLS 6-1. ChokeControl............... .recvrererecaararererrenaaemen 12 6 - 2. Start Push Button And Ignition Switch ......................... 12 6 - 3. AutomaticldleControlSwitch ............. iit, 13 6-4. SafetyShutdown Switch ........... ci iin. 13 6 - 5. Battery ChargelndicatorLamp ................. cin... 13 6-6. Engine Temperature And Qil PressureLamp ..................... 13 6-7. Total Hour Meter. iii ieee 13 SECTION 7 - SEQUENCE OF OPERATION 7 - 1. Shielding Metal-Arc Welding (SMAW)} .............. .......... 13 7-2. Optional Power Plant Operation ............ cc iin. 13 7-3. Starting The Engine ............ iii 14 7-4. Engine Shut Down i i i i ie teen. 14 SECTION 8 - GENERATOR MAINTENANCE 8 - 1. 8 - 2. 8 - 3. General ee naa Brushes And Slip RINGS ..... oii i i ee aa ae» Welding Cables ........... cc ee ee ina SECTION 9 - ENGINE MAINTENANCE | 9 - O) O CO (D LS O LD I HD Сл оф © № — Lubrication... oe... aaa aneneeeevaroronaaaona Cooiant System .........._oeee_ececdarroreorere ca, eoarereae ne Governor Service. ...........oe ere .i.rescarredeorereeranernos Carburetor Float Setting ............. o eeeeec..reedarved 0d Air Cleaner Service RR RR 110 Automatic Idle Control/ Governor Linkage Adjustment ............ High Altitude Carburetor Modification .......................... Spark ATES Or «i ee eee a aa nee 0 SECTION 10 - TROUBLESHOOTING meen SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE === 1-1. INTRODUCTION We learn by experience. Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you. Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, devel- opment, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Acci- dents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given, Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules. Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others, Failure to observe these safe practices may cause serious 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 cutting; and 2 - Arc Welding {and Cutting){only). Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in this manual. ANSI 249.1 is the most complete. The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local tn- spection requirements also provide a basis for equipment installation, use, and service. GENERAL PRECAUTIONS Burn Prevention Wear protective ciothing - leather (or asbestos) gauntlet gloves, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. Avoid oily or greasy clothing. A spark may ignite them, Hot metal such as electrode stubs and workpieces should never be handled without gloves, 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 persons intending to weld or cut. Toxic Fume Prevention Adequate ventilation. Severe discom fort, illness or death can result from fumes, vapors, heat, ar oxygen enrichment or depletion that welding {or cutting} may produce. Prevent them with adequate ventilation as described in ANSI Stan- dard 249.1 listed 1 in Standards index. NEVER ventilate with oxygen. Lead -, cadmium -, zinc -, mercury -, and beryllium - bearing and similar materials, when welded {or cut} may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied 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, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration danger- ously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidently 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 tor flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radíant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene, DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethyiene. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated material; 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) of metallic particles that can cause short circuits. If combustibles are 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, ventilators, 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 {or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinguishing equipment during and for some time after welding or cutting if: a. appreciable combustibles (including building construc- tion) are within 35 feet b, appreciable combustibles are further than 35 feet but can be ignited by sparks c. openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to ensure supervisor's 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 A6.0, listed 3 in Standards index. OM-450 Page 1 Page 2 This includes: a thorough steam or caustic cleaning {or a solvent or water washing, depending on the combustible's solubility} followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AG.0. Waterfilling just below working level may substitute for inerting. A container with unknown contents should be cleaned (see paragraph above). 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). Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, PRECAU- THONS FOR SAFE HANDLING OF COMPRESSED GASES iN CYLINDERS, listed 6 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 equipment. Provide such protection with one or more relief devices. Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed. Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symptoms indicate a faulty regulator: leaks - if gas leaks externally. Excessive 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 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 accident. [See :1-3C,1 ICC or DOT marking must be on each cylinder, lt is an assurance of safety when the cylinder is properly handled. 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. tt 1s 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 support or roller. Locate or secure cylinders so they cannot be knocked over, Passageways and work areas. Keep cylinders clear of areas where they may be struck. Transporting cylinders. With a crane, use a secure support such as a platform or cradle, Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or mag- nets. Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allaw contents to exceed 130°F. Cool with water spray where such exposure exists. Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders. Stuck valve. Do NOT use a hammer or wrench to 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 far fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose {not ordinary wire or other substitute) as a binding to connect hoses to fittings. No copper tubing splices, Use only standard brass fittings 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 tangtes. Protect hose from damage by sharp edges, and by sparks, slag, and open flame, Examine hose regularly for leaks, wear, and loose connac- tions. Immerse pressured hose in water; bubbles indicate leaks. Repair leaky or worn hose by cutting area out and splicing (1-203). Do NOT use 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 people and sources of ignition. Wipe with a clean lint- less cloth, Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match. NEVER CON- NECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. Tighten connections. When assembling threaded connections, clean and smooth seats where necessary, Tighten, 1f connection leaks, disassemble, clean, and retighten using properly fitting wrench, Adapters. Use a CGA adapter (available from your supplier} 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 before opening cylinder {or manifold valvel by turning adjusting screw in {clockwise}. Draining prevents excessive 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 increases slowly. When gauge is pressurized {gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible feak, For fuel gas, open to less than one turn to permit quick emergency shutoff. 1-3. Use pressure charts {available from your supplier) for safe and efficient, recommended pressure settings on regulators. Check for teaks on first pressurization and regutarly there- after. Brush with soap solution (capful of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible. User Responsibilities Remove leaky or defective equipment from service immed- lately for repair. See User Responsibility statement in equipment manual. Leaving Equipment Unattended Close gas supply at source and drain gas. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn, ARC WELDING Comply with precautions tn 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 infrared energy radiates, weld- ments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described here and in standards referenced in index. Burn Protection Comply with precautions in 1.2, The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. DON'T 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 necessary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire-resistant leggings. Avoid outergarments of untreated cotton. Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks. 2. Eve and Head Protection Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding heimet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking are. 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 |M- MEDIATELY. 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 separate room or enciosed bay is best. In open areas, surround the *Trademark of Proctor & Gamble. operation with tow-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor level. Viewing the weld. Provide face shields for alt persons who will he 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. Toxic Fume Prevention Comply with precautions in 1-28. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. Fire and Explosion Prevention Comply with precautions in 1-2C. Equipments rated capacity. Do not overload arc welding equipment, lt 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 vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling. Compressed Gas Equipment Comply with precautions in 1-20, Shock Prevention Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection, To protect against shock: 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 between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body. 1. Grounding the Equipment When installing, connect the frames of each unit such as welding power source, control, work table, and water circula- tor to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel, Three-phase connection. Check phase requirement of equipment before instatling. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition 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 receptacle, the ground lead must be connected to the ground prong only. If the fine cord comes with a three-prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong. OM-450 Page 3 Page 4 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 ot! 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 covess secured before operation. 6. Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts. 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 fine fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Discon- nect all cables from welding power source, and pull all 115 volts line-cord plugs. 1-4. Do not open power circuit or change polarity white welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Leaving equipment unattended. Always shut OFF and dis: connect all power to equipment. Power disconnect switch must be available near the welding power source, STANDARDS BOOKLET INDEX For more infermatien, refer to the following standards or their tatest revisions and comply as applicable: 1. ANS! Standard 249.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 2501 NW 7th St., Miami, Fla. 33125, 2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA - TION AND EDUCATIONAL EYE AND FACE PROTEC- TION, obtainable from American National Standards Institute, 1430 Broachway, New York, N.Y. 10018. 3. American Welding Society Standard AG.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable same as item 1. 4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, Mass. 02210. 5. NFPA Standard 518, CUTTING AND WELDING PRO- CESSES, obtainable same as item 4, 6. CGA Pamphiet P-1. SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 500 Fifth Avenue, New York, N.Y. 10036. 7. OSHA Standard 29 CFR, Part 1910, Subpart , WELD- ING, CUTTING AND BRAZING, —_———— SECTION 2 - INTRODUCTION TZ E Welding | Welding Current Ranges | Open-Circuit Power Overall Weight Rated Current In Amperes Voltage While Dimensions | Pounds) Output Range |Coarse Ranges | Fine Range Range Welding (Inches) Net | Ship | 300 Amps MIN.-65 . 3KVA From Min. 55 ” 40 Volts DC To 100-175 To Max. Of To 50/60 Hertz, At Wich - 24.3/4" 1440 | 1480 100% |400 Amps | 125-250 |Each Coarse 90 Weld Height - 41-1/2" Range Volts DC Duty Cycle 225-MAX. Speed Figure 2-1. Specifications This welding generator has reconnectable capability to provide 240 volts ac auxiliary power at the front panel if the optional receptacle kit is ordered. Should preparation and installation (or information if factory installed) be desired, see Section 5-7 for complete instructions, and delete all reference to 120 volts ac duplex receptacle and replace with 240 volts ac duplex receptacle. 2-4, SAFETY - Before the eguipment is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The following definitions apply to CAUTION, IMPOR- and NOTE blocks found throughout this 2-1. GENERAL - This manual has been prepared especially for use in familiarizing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment. 2-2. RECEIVING —- HANDLING - Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occured during shipment. Any claims for loss or damge that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if occasion to file claims arises. When requesting information concerning this equipment, it is essential that Model Description and/or Stock Number and Serial (or Style} Numbers of the equipment be supplied. 2-3. DESCRIPTION - This welding generator is driven by a gasoline engine. The unit is designed to produce a DC output for Shielded Metai-Arc Welding (SMAW). A duplex receptacie, located on the front panel, provides up to 3 kva of 120 volts, 50/60 Hertz AC power, to operate lights, power tools, etc., while welding. —— — tags — —— 24-3/4"- — gm TANT, manual: EYL Under this heading, operating, and maintenance procedures or practices will be found that if not carefully followed may create a hazard to personnel. `ПМРОВТАМТ Under this heading, operating, and maintenance procedures or practices will be found that if not carefully followed may result in damage to equipment, Vier Under this heading, explanatory statements will be found that need special emphasis to obtain the most efficient operation of the equipment, SECTION 3 - INSTALLATION A *41-1/2" 1 2-7/8 + г da - 21/ 32” Diameter All Holes 26-15/16° Каир -— —24-1/8" Figure 3-1. Dimensions And Base Mounting Hole Layout EF installation, installation, ТВ-004 200-О OM-450 Page 5 3-1. LOCATION (Figure 3-1) - A proper installation site should be selected for the welding generator if the unit is to provide dependable service, and remain relatively maintenance free. AMPORTANT This unit must be located on an approximately level surface to ensure proper engine lubrication and gasoline carburetor operation. Figure 3-2 shows the maximum allowable tit for safe operation. Exceeding these limits can cause severe engine damage. Oil level in the crankcase must be checked when the unit is on a level surface. Side View TA-046 152 mounted on a trailer (optional), ensure that the engine end is mounted toward the front (hitch end) of the trailer to maintain proper weight distribution. Also ensure that the tongue weight of the trailer is approximately 10% of the gross vehicle weight. It is recommended that a properly fitting canvas cover (optional) be placed over the welding generator when not in operation to protect the unit from the environment. | ¡LLOINES /f 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 badily injury or loss of life. A proper installation site permits freedom of air movement into and out of the welding generator, and also least subjects the unit to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches of unrestricted space must be maintained between the welding generator front and rear panels and the nearest obstruc- tion. Also, the underside of the welding generator must be kept completely free of obstructions. The installation site should also permit easy removal of the outer enclosure for maintenance functions. Page 6 ZEN 7he engine exhaust system on this welding generator has not been equipped with spark arrestor unless it was specifically ordered as an optional accessory. A spark arrestor, maintained in effective working order, is mandatory if this welding generator is to be operated in a National Forest, or on California grasslands, brush, or forest covered land (see Section 4442 of California Public Resources Code). For other areas, check your state and local laws. [10:17:68 Do not place any filtering device over the intake air passages of the welding generator as this would restrict the volume of intake air and thereby subject the internal components to an overheating condition and subsequent failure. Warranty is void if any type of filtering device 1s used. Holes are provided in the base for mounting purposes. Figure 3-1 gives overall dimensions and the base mounting hole layout. On most welding generators a lifting device is provided for moving the unit. However, if a fork lift vehicle is used for lifting the unit, be sure that the lift forks are long enough to extend completely under base. LOLI ENEE 7he use of lift forks too short to extend out of the opposite side of the base will expose internal components to damage should the tips of the lift forks penetrate the bottom of the unit. 3-2. WELD OUTPUT CONNECTIONS (Figure 3-3) - To obtain the full rated output from this unit, it is necessary to select, install, and maintain proper welding cables. Failure to comply in any of these areas may result in less than satisfactory welding performance. EF AVIV Ensure that the unit 1s completely shut down before making any weld output connections. A. Location The POSITIVE and NEGATIVE terminals are located behind the left side access panel. Once the weld cables have been connected to the terminals, the cables exit the welding generator through the bracket on the lower left side of the front upright. The connection shown is for de reverso 3 . 5 < polarity Equipment Grounding Terminal Positive Weld ® RE || Qutput Terminal TR-046 341 Figure 3-3. Weld Output Connections Negative Weld Output Terminal B. Welding Cables If welding cables were not ordered with this unit, the steps listed should be followed to ensure the best welding performance: 1. It is recommended that the welding cables be kept as short as possible, be placed close together, and be of adequate current carrying capacity. The resistance of the welding cables and connections causes a voltage drop which is added to the voltage of the arc. Excessive cable resistance may result in overloading as well as reducing the maximum current output capability of this unit. Proper operation is to a great extent dependent on the use of welding cables and connections that are in good condition and of adequate size. An insulated electrode holder must be used to ensure the operator's safety. 2. 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 the work cable is 25 feet long, select the size cable that is recommended for 100 feet at the maximum weld current that is to be used. Table 3-1. Weld Cable Size "TOTAL LENGTH OF CABLE (COPPER) IN WELE CIRCUIT WELDING AMPERES| *50 | 100 150 200 250 300 350 | 400 100 4 4 2 2 2 1 1/0 1/0 150 2 2 2 1 1/0 2/0 3/0 3/0 200 1 1 1 1/0 2/0 3/0 4/0 4/0 250 1/0 1/0 1/0 2/0 3/0 4/0 4/0 2-2/0 300 2/0 2/0 2/0 3/0 4/0 4/0 2-2/0 | 2-3/0 350 3/0 3/0 3/0 4/0 4/0 2-2/0 | 2-3/0 | 2-3/0 400 3/0 3/0 3/0 4/0 2-2/0 | 2-3/0 | 3-27/0 | 2-4/0 A-002 702-A NOTE: "A. 50 FEET OR LESS. "B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC), 109% 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 OPENCIRCUIT YOLT- AGE (OCV] OF THE WELDING GENERATOR MUST BE USED. WHILE MOST WELDING GENERATORS HAVE AN OPEN-CIRCUIT VOLTAGE GF LESS THAN 100 VOLTS, SOME WELDING GENERATORS OF SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUET VOLTAGE. 3, Do not use damaged or frayed cables. 4, Follow the electrode holder manufacturer's instructions for installing the electrode holder onto the electrode cable. 5, Use correct lugs on the weld cable to connect the work clamp and to connect the cables to the weld output terminals. Install the cables to the output terminals according to Section 3-2A. 6. Ensure that all connections are clean and tight. 3-3. EQUIPMENT GROUNDING TERMINAL (Figure 3-3) - Normally engine-driven welding generators do not require grounding. However, this machine has auxiliary power plant capability; therefore, grounding of the frame and case is recommended. Also, unusual circumstances may require machine grounding. For these reasons a convenient grounding terminal is provided on all weld/power units. For detailed grounding instructions consult your local or state codes and the latest issue of the National Electrical Code, If additional information regarding your particular operating circumstances and/or grounding requirements is needed; consult a qualified electrician or vour dealer. After determining the extent to which any grounding requirements apply to your particular situa- tion, follow them explicitly. 3-4. 120/240 VOLTS AC TERMINALS (Optional) - The 120/240 volts ac terminals act as a junction point for connecting accessory equipment. The 120/240 volts ac, 7.5 kva, 31 ampere power that can be obtained at these terminals may be used to run power tools or provide standby service to rural, residential, or other buildings requiring 120/240 volts 3 wire connection. | [XN IR Due to the high potential that is present at the 120/240 volts ac terminals while the welding generator is operating, it is recommended that connections to the 120/240 volts ac terminals be made only by a licensed electrician in order to avert any chance of personal injury due to faulty installation. Never attempt to make connections to the 120/240 volts ac terminals while the engine is running. TC-000 680-8 Circuit Grounding Jumper Lead (Shipped Ungrounded) [TANNER Do not change fuses or connect any lead wires while engine is running. [nstall circuit grounding jumper lead if NEC or local electrical code requires grounded neutral conductor. Insert load lead wires through proper cord grip box connector. Strip 1/2 inch insulation and connect to proper load terminals and tighten connectors securely. 3 7he FINE ADJUSTMENT control must be rotated to the 100 (full counterclockwise) position whenever the 120/240 volts power plant is being uti- lized. The voltage will vary in accordance with the load applied to the 120/240 volts terminals. OM-450 Page 7 AA SECTION 4 - ENGINE PREPARATION MOLES See the Engine Manufacturer's manual (F-163 Engine) for complete engine care. 4-1. 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 dipstick. Add a quality brand of oil if the oil level is low. See the oil selection chart, Table 9-1, in Section 9. New engines have very close clearance between their moving parts. Therefore, itis recommended that loading of the engine be kept to 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 9-1, in Section 9 for correct oil type and grade to use after the break-in cil is drained. Keap Crankcase Oil At This Level Never Operate Engine « | With Oil Below This Level Figure 4-1, Oil Level 4 - 2. COOLANT SYSTEM - The liquid capacity of the coolant system in this welding generator is 9 quarts {U.S. Measure). This unit is shipped from the factory with the proper amount of water and antifreeze to permit operation of the unit at temperatures down to 0°F. 1 MINIMAX If this welding generator is to be operated in temperatures which are below 0°F, additional antifreeze will have to be added to the coolant system or the liquid in the system will freeze and cause the engine to overheat. The coolant system is equipped with a 180°F thermostat. If the thermostat should fail, ensure that the replacement has an equal temperature rating. If the thermostat should fail, replace it immediately. Do not run the engine without a thermostat. If the thermostat remains closed, the engine will overheat. If the thermostat remains open, or the engine is run without a thermostat, the engine will run cold. As a result, excess carbon will accumulate, and the oil will become contaminated with sludge. 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. Page 8 AA-900 718-5 Caution should be exercised at all times when removing the radiator pressure cap. The cap will turn to an almost full open position, at which point a provision has been made to permit venting built up pressure within the radiator. Allow the pressure to escape before completely removing the cap from the radiator neck. When removing the cap, it is recommended that a glove or rag be used to protect the operator's hand from possible exposure to extremely hot coolant. 4-3. PREPARING NEW BATTERY FOR SERVICE Ne] 7:88 Never attempt to operate the engine without the battery connected. Do not attempt to remove the battery while the engine is running. A. Wet Charged Battery Connect the negative battery cable to the negative (-) terminal on the battery. This is all that is required to put the battery into service providing it has not discharged during transportation and warehousing. If the battery has enough power to start the engine, it will charge up while the engine is running. The wet charged battery is shipped with the electrolyte solution added and normally in an operational status. However, due to long periods of idleness, the battery may become weak and thus require charging. The battery should have a specific gravity reading of 1.260 (at 80°F) when fully charged. If the battery requires charging, see Section 4-3B, Step 4. B. Dry Charged Battery This battery is shipped in a dry state. To prepare the new battery for operation, it will be necessary to obtain electrolyte and proceed as follows: [XVI Put on protective eye cover and and clothing prior to pouring the electrolyte solution. 1. Remove the battery from the unit and place it on a level worktable or other suitable area. 2. Fill the battery cells to the required level with electrolyte, 3. Place a battery thermometer in one of the center cells and check the specific gravity of each cell with a battery hydrometer. 4. The battery should have a specific gravity of 1.260 (at 80°F) prior to installation. If this condition is not met, charge the battery as follows: Tee Ensure that the battery caps are removed before charging. Failure to do so may cause the battery to explode should overcharging occur. 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, disconnect it from the charger and recheck the electrolyte level. Add if necessary. Install the battery caps. 5. Rinse 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, neutralize with soda or ammonia solution and flush off with clear water. Use the same procedure if acid is spilled on clothing. 6. Reinstall the battery in the unit ensuring that the negative (-) cable is connected to the negative (-) battery terminal. 4-4, AIR CLEANER - This engine is equipped with a dry element type air cleaner. The air cleaner requires no initial service. 4-5. FUEL [FX Do not attempt to fill the fuel tank with the engine running. Do not fill the fuel tank completely as cold fuel will expand when exposed to outside temperature in a warm climate or to engine heat. If the tank is too full, it will overflow causing a potential fire hazard. Never allow fuel to drain on the engine or other components, Ze] EF UNES Use a good grade of “regular”, “low- lead”, or “no-lead” gasoline of at least 85 octane for this engine. Fuels with a lower octane rating may cause detonation (knocking) which could damage the engine. The “low-lead’’ or “no-lead” fuels lower the pollution factor and reduce combustion chamber deposits if used exclusively. E | E Ny 11.35 25 30 10.4. 229 275 9.46 2.08 25 8.52 187 2.25 787 17 20 6.62 146 175 567 1,25 15 473 104 125 3.78 083 10 294 062 0,75 198 0.4 05 95 0.21 0.25 © 50 100 150 200 250 300 350 1400 D.C. WELD AMPERES AT 100 DUTY CYCLE WELD В-005 606 Figure 4-2. Fuel Consumption Chart The capacity of the fuel tank is 17.5 gallons (U.S. Measure). The fuel tank is equipped with a standpipe in the bottom of the tank. As a result, the tank will not go completely dry. The standpipe holds 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. TVE The fuel tank cap may be equipped with a valve on the inside. Before operation, examine inside of cap. If the cap is equipped with a valve, the valve must be in the OPEN position at all times or proper venting will not take place. Figure 4-2 illustrates typical fuel consumption under specific load conditions. Fuel consumption will vary from one engine to another. Different brands of fuel, operating conditions, condition of the engine, etc., will affect the fuel consumption of this engine. 4-6, CARBURETOR AIR TEMPERATURE SELEC- TOR (Figure 4-3) - The air intake to the air cleaner is equipped with a selector tube which allows the air to be drawn either from the surrounding engine compartment air or heated air, drawn from around the exhaust manifold of the engine. Heated air will prevent carburetor icing in cold weather. Air Cleaner Air Inlet — Air Selactor (Shown In Cold Manifold Stove T7 = = ce Weather Position) TA-900 955-4 Figure 4-3. Carburetor Air Temperature Selector Figure 4-3 shows the selector tube in the cold weather operating position. When the tube is in this position, it must remain about 1/2" 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 retighten. OM-450 Page 9 _ DNS Range Pr Control Switch => г 120 Volts AC JE Receptacle CO es - | @ > Y > 7 7 и - 7 . 16-900 955-2С Figure 5-1. Generator Controls 5-1. 120 VOLTS AC RECEPTACLE (Figure 5-1) (For Optional 240 Voits AC Receptacle, See Section 5-7) LION The auxiliary power capability of this welding generator is primarily intended for use with por- table cord-connected accessory equipment (lights, drills, grinders, etc.). Do not connect this unit to any service box, switchboard, panelboard, or other equipment normally supplied by other electrical power unless a proper transfer switch and grounding procedure 15 employed (see Section 3-3 for unit grounding information). ALWAYS consult the local electric utility, local and state codes, and the latest issue of the National Electrical Code for proper installation procedures. Since hazardous voltages are present, it is recommended that the installation be made by a licensed electrician to avoid injury or damage caused by improper or faulty installation, Up to 3 kva of 120 volts ac, 50/60 Hertz power is available at this duplex receptacle for operating 120 volts ac or 120 volts universal power tools, lights, etc., when the welding generator is being operated at weld rpm. The voltage will vary in accordance with the load applied to the 120 VOLTS AC receptacle. The voltage at various loads may be determined from Figure 5-2. 280 140 130 4 o = © È — O > 240 120 uu“ Eu 3 220 по En u «< 200 100 0 10 20 30 40 AC POWER AMPERES AT 120V. 0 5 10 15 20 AC POWER AMPERES AT 240V. Figure 5-2. AC Power Curve For 120 {And Optional 240) Volts AC Receptacle В-005 192-А Раде 10 SECTION 5 - FUNCTION OF GENERATOR CONTROLS „Fine Adjustment 5-2. RANGE SWITCH AND FINE ADJUSTMENT CONTROL. (Figure 5-1) LEER Do not change the position of the Range switch while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts to become pitted and eventually inoperative. AUB The FINE ADJUSTMENT control may be adjusted while welding. The Range switch provides five coarse amperage ranges. The range of each switch position is displayed on the nameplate. The FINE ADJUSTMENT control permits the operator to select a welding amperage and open-circuit voltage between the minimum and maximum values of the coarse range selected by the Range switch. The scale surrounding the FINE ADJUSTMENT control is calibrated from 0-100 percent in increments of 10. When using this control, the operator is selecting a percentage of the coarse range in use, and not an actual amperage or open-circuit voltage value, 5-3. VOLT--AMPERE CURVES {Figure 5-3) - The volt-ampere curves show the output voltage and amperage of the welding generator available at any point from the minimum to maximum of each coarse range. The FINE ADJUSTMENT control controls the output between the minimum and maximum curves of each coarse range shown. Load voltage is predetermined to a large extent by the arc characteristics. With the use of the volt-ampere curves it is possible to determine what the weld current will be at a particular arc voltage. The volt-ampere curves show the minimum and maximum curves of each coarse range. When the FINE ADJUSTMENT control is adjusted, the volt-ampere curve will fail between the minimum and maximum curves of the particular coarse range in use. о 100 200 300 400 500 600 700 800 D € AMPERES Figure 5-3, Valt-Ampere Curves 5-4. DUTY CYCLE (Figure 5-4) - The duty cycle of the welding generator is the percentage of a ten minute period that a welding generator can safely be operated at a given output current setting. This welding generator is rated at 100 percent duty cycle. This means that this unit can be safely operated at rated load con- tinuously. If the welding current is increased, beyond rated output the duty cycle will decrease. Figure 5-4 enables the operator to determine the safe output of the welding generator at various duty cycles. LUSSIER Exceeding the indicated duty cycle will cause damage to the internal components of the welding generator. RATED OUTPUT = 500 wv LL oc o 400 a о > e ay, “€ a = 300 = 250 30 40 50 60 70 BO 90 100 % DUTY CYCLE Figure 5-4. Duty Cycie Chart 5-5. METERS (Optional) - The meters are provided to monitor the welding operation. They are not intended for exact current or voltage measurements. These meters are internally connected to the output terminals. The voltmeter will indicate the voltage at the output terminals, but not necessarily the actual voltage at the welding arc {due to cable resistance, poor connections, etc.). The ammeter will indicate the current output of the unit. 5-6. POLARITY SWITCH (Optional) - The POLARI- TY SWITCH provides a means of selecting either DC STRAIGHT or DC REVERSE polarity without changing cable connections. B-053 133 Do not change the position of the POLARITY SWITCH while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts to become pitted and eventually inoperative. MALIN /F the welding generator is equipped with a POLARITY SWITCH (optional), the weld output terminals are labeled ELECTRODE and WORK. To ensure that the weld current output will be in accordance with the labeling of the position on the POLARI- TY SWITCH, connect the electrode holder cable to the ELECTRODE terminal and the work cable to the WORK terminal. 5-7. 240 VOLTS AC DUPLEX RECEPTACLE (Ор- tional} {Figure 5-1) The auxiliary power capability of this welding generator is primarily intended for use with por- table cord-connected accessory equipment (lights, drills, grinders, etc.). Do not connect this unit to any service box, switchboard, panelboard, or other equipment normally supplied by other electrical power unless a proper transfer switch and grounding procedure is employed (see Section 3-3 for unit grounding information). ALWAYS consult the local electric utility, local and state codes, and the latest issue of the National Electrical Code for proper installation procedures. Since hazardous voltages are present, it is recommended that the installation be made by a licensed electrician to avoid injury or damage caused by improper or faulty installation, This welding generator is equipped with a voltage changeover terminal strip TET and proper stator to provide reconnection capability for 240 volts ac. Although the capability for either 120 or 240 volts ac is present, an optional kit must be purchased if 240 volts is desired at the front panel. A. Power Curve For Optional 240 VOLTS AC Duplex Receptacle {See Figure 5-2) Up to 3 kva of 240 volts ac 50/60 Hertz power is available at the duplex receptacle for operating power tools, lights, etc., when the welding generator is being operated at weld rpm. NC he FINE ADJUSTMENT control may be in any position when using the 240 VOLTS AC duplex receptacle on the front panel. The voltage will vary in accordance with the load applied to the 240 VOLTS AC receptacle. The voltage at various loads may be determined from Figure 5-2. B. Installation Of 240 VOLTS AC Duplex Recep- tacle TELE Ensure that the engine is completely shut down before attempting any connections or examina- tion of components on or near terminal strip TET. da E NIE Before proceeding with this installation, familiarize yourself with the circuit diagram provided in the Troubleshooting Section of this manual. LiL АЛ directions, such as left or right, are with respect to the operator facing the welding generator front panel. MALE Retain all hardware removed during this procedure for reinstallation. 1. Shut down the welding generator and raise the right side panel. OM-450 Page 11 2. Remove center bolt from insulation board (see Figure 5-5), remove and retain insulation board. 3. Remove 120 VOLTS AC duplex receptacle RC1 located on front pane! (see Figure 5-5). Remove leads and allow to hang free. 4. Connect leads removed from RC1 to the 240 volts ac duplex receptacle RC2 (one on each side of receptacle). 5. Install RC2 in front panel. 6. Affix supplied 240 VOLTS AC label over existing 120 VOLTS AC designation for duplex receptacle on nameplate. Terminal Strip TE1 Duplex Receptacie ZA Canter Bolt DB 742 [ng ulation Board 0 TA-059 485 Figure 5-5. Location Of Reconnectable Com- ponents 7. Remove and retain jumper links from terminal strip TE1 (see Figure 5-6}. 8. Move lead No. 3 (only lead on jumper link side) from terminal B to terminal A {same side of TE1). See Figure 5-6. 9. Position jumper links on TE1 for 240 volts (see Figure 5-6). 10. Install insulation board over TE1 and secure with ° bolt. 11. Lower right side panel of welding generator and resume operation. 240 VOLTS AC (OPTIONAL) TA-059 243 Figure 5-6. Jumper Link Arrangement For 120 And 240 Volts AC 5-8. REMOTE AMPERAGE CONTROL (Optional) - The REMOTE AMPERAGE CONTROL receptacle provides a junction point for connecting a Remote Amperage Control to the amperage control circuitry in the welding generator. To connect the Remote Amperage Control to the REMOTE AMPERAGE CONTROL receptacle, insert the three-pole twistlock plug from the Remote Amperage Control into the receptacle and rotate clockwise as far as possible to secure the plug in the receptacle. When remote control of the amperage is desired, the AMPERAGE CONTROL switch must be placed in the REMOTE position. If a Remote Amperage Control is not used, the switch must be in the STANDARD position. When in the STANDARD position, only the FINE AD- JUSTMENT control on the front panel will control the amperage. When a Remote Amperage Control is used, the control is a fine adjustment of the setting of the FINE ADJUST- MENT control on the welding generator. For example: If the FINE ADJUSTMENT control on the welding generator is set at the 50% position, the Remote Amperage Control will provide (from its minimum to maximum positions) fine adjustment of one half (50%) of the welding generator output for the range selected by means of the Range switch. If full adjustment of the range selected is desired the FINE ADJUSTMENT control on the welding generator must be set at 100% (maximum position}. mors SECTION 6 - FUNCTION OF ENGINE CONTROLS «= = Battery Charge Indicator Lamp —_ | ee PSS ‚ Safety Engine Temperature A > Shutdown And Oil Pressure — lgnítion Switch Switch Lamp Start Push Button TB-900 955-2C Figure 6-1. Engine Controls Page 12 ,Choke Control . Automatic Idle Control Switch 6-1. CHOKE CONTROL (Figure 6-1} - À 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 pulled fully out, very little air will be admitted to the engine thru the carburetor thereby supplying a richer mixture of fuel. This position is required if the engine is cold when started. As the engine warms up, it will be necessary to push the CHOKE control inward slowly until it is pushed in as far as it will go. When the CHOKE control is fully in, the engine should be ready for operation. 6-2. START PUSH BUTTON AND IGNITION SWITCH (Figure 6-1) - Placing the Ignition switch in the RUN position will energize the welding generator ignition circuitry. When the Ignition switch is in the RUN position, depressing the START push button will engage the starter motor and start the engine. Once the engine has started, release the START push button. Placing the Ignition switch in the OFF position will shut the welding generator down. The Ignition switch must be left in the OFF position when the engine is not running to prevent the battery from discharging. 6-3. AUTOMATIC IDLE CONTROL SWITCH {Figure 6-1) - The automatic idling device saves fuel by allowing the engine to idle when the welding generator is not loaded. The AUTOMATIC IDLE CONTROL switch regulates the operation of this device. A. ON Position When the AUTOMATIC IDLE CONTROL switch is in the ON position, the engine will remain at idle rpm until an arc is struck or load applied, after which the engine speed will increase to weld rpm. Approximately 10 seconds after the arc is broken or load removed, the engine will return to idle rpm. The AUTOMATIC IDLE CONTROL switch ON position would normally be used for Shielded Metal-Arc Welding {SMAW), as this process does not require a constant speed. The ON position may also be used when the 120 VOLTS AC duplex receptacle is being used. B. OFF Position When the AUTOMATIC IDLE CONTROL switch is in the OFF position, the engine will run at governed weld rpm (1850). — SECTION 7 - SEQUENCE OF OPERATION 197. VUELO NES Never, under any circumstances, operate the welding generator with any portion of the outer enclosure open or removed. In addition to being a hazard to personnel, weather protection to the internal components of the unit wilf be greatly reduced. Warran- ty is void if the welding generator is operated with any portion of the outer enclosure open or removed. LY ALONE 7he weld output terminals are electrically energized when the engine is running. Disconnect the welding cables when not welding and ао not touch the output terminals when the engine is running. 7-1. SHIELDED METAL-ARC WELDING (SMAW]) 1. Ensure that the engine has been prepared as instructed in Section 4, 2. Make connections to the weld output terminals as required. 3. Rotate the Range switch and FINE ADJUST- MENT control to the desired position. Do not change the position of the Range switch while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts to become pitted and eventually inoperative. DUE 7he FINE ADJUSTMENT control may be adjusted while welding. 4. Start the engine as instructed in Section 7-3. 6-4. SAFETY SHUTDOWN SWITCH (Figure 6-1) - If oil pressure drops to an unsafe ievel or water temperature becomes too high, the engine will automatically shut down. IIE When attempting to start the engine, the push button switch, located on the lower right portion of the front panel, must be depressed and held in until the engine starts and the OIL & TEMP light goes off. This switch is protected by a fuse located on the bottom of the switch assembly directly behind the front panel. Should this fuse open, the engine would not start. 6-6. BATTERY CHARGE INDICATOR LAMP (Figure 6-1) - The AMPS warning lamp is illuminated when the engine battery charge current is not flowing. It is normal for this lamp to be illuminated when the Igni- tion switch is in the RUN position and the engine is NOT operating 6-6. ENGINE TEMPERATURE AND OIL PRESSURE LAMP (Figure 6-1) - The OIL & TEMP warning lamp is illuminated if the oil pressure decreases below 8 psi or if the coolant temperature increases above 240°F. It is normal for this lamp to be illuminated when the Ignition switch is in the RUN position and the engine is NOT operating. 6-7. TOTAL HOUR METER (Optional) - This unit can be equipped with an hour meter. The meter, labeled TOTAL HOURS, registers the total hours of engine operation. This information is useful for routine maintenance on the engine. 4 Prior to welding, i it is imperative that proper protective clothing (welding coat and gloves) and eye protection (glasses and welding helmet) be put on. Failure to comply may result in serious or permanent bodily damage. 5. Place the AUTOMATIC IDLE CONTROL switch in the desired position and commence welding. 7-2. OPTIONAL POWER PLANT OPERATION RLU YN: VWI Ensure that all electrical equipment connected to the 120 VOLTS AC receptacie and 120/240 volts ac terminal strip is turned off before starting or stopping the engine. When starting or stopping, the engine has low rpm which causes low voltage at the output of the generator. This could result in damage to electrical equipment. 1. Ensure that the engine has been prepared for operation as instructed in Section 4. 2. Make connections to the 120/240 volts ac terminals as instructed in Section 3-4. 3. Rotate the FINE ADJUSTMENT control to 100 (full counterclockwise). 4. Start the engine as instructed in Section 7-3. 5. Once the engine is operating properly at weld/ power rpm, power may be obtained from the welding generator, OM-450 Page 13 7-3. STARTING THE ENGINE Check the engine oil level and radiator coolant level. Ensure that no loose parts, etc., are laying in or on the unit. Make the necessary connections to the generator before attempting to start the unit. Fill the fuel tank with fresh gasoline. 1. Make all welding and electrical connections to the welding generator. 2. Place the AUTOMATIC IDLE CONTROL switch in the ON position. This should be done to permit the engine to warm up at idle rpm. 3. Choke the engine as necessary. 4. Place the Ignition switch in the RUN position. 5, Press the START push button and SAFETY SHUTDOWN push button. DE SECTION 8 - GENERATOR MAINTENANCE If any work is to be done on the rotor of the generator, remove the spark plugs from the engine. This will prevent engine compression from turning the rotor and catching the repairperson’s hand between the rotor fan casting and the stationary adapter casting. Also, disconnect the negative (-) battery cable from the battery. 8-1. GENERAL - The efficiency of the welding generator depends a great deal on the care and atten- tion given it. By following a definite schedule of inspection and service, failure caused by neglect can be avoided, Occasional blowing out of the unit with clean, dry compressed 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. 8-2. BRUSHES AND SLIP RINGS - Brush life is very good under normal operating conditions. The brushes and slip rings should be inspected every six months. Check for cleantiness of the slip rings and freedom of motion of the brushes. If the welding generator has ———————"_ SECTION 9 - ENGINE MAINTENANCE ÿ Refer to the engine handbook for detailed information concerning maintenance on this engine, While the handbook is a general coverage type publica- tion, it does contain vital maintenance instructions for this engine. 9-1. LUBRICATION Table 9-1. Oil Selection Guide Recommended Qil-AP| Service Classification SD or SE Below 0°F.| 0° to 32°F. | 32° to 76°F. | Above 76°F. (-18°С.} | (-18° to 0°C.) | {0° to 24°C.) {24°C.} : SAE 10W-30 | SAE 10W-30 Page 14 NIGEL: VWI Always ensure that the starter pinion and flywheel have stopped rotating before reengaging the starter motor, otherwise the ring or pinion may be damaged. 6. When the engine starts, release the START push button. When the OIL & TEMP light goes off, release the SAFETY SHUTDOWN push button. 7-4. ENGINE SHUT DOWN 1. Remove all weld and power loads from the unit. 2. Allow the engine to idle for a few minutes to permit the internal engine temperature to equalize. Increase the idling time if the engine has been operating for an extended period or at full load. De Do not operate accessory power equipment from the 120 VOLTS AC receptacle during the engine shutdown-idling period. 3. Place the Ignition switch in the OFF position. been operating under extremely dusty « or - dirty conditions, increase the frequency of inspection. 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. This can usually be remedied by simply spraying the slip rings with an antioxidant type contact cleaner and running the engine. Under normal use the slip rings will discolor to a dark brown. If a build up of brush material is noted, it may be necessary to clean the slip rings. Use a 1/0 or finer sandpaper followed by a crocus cloth. Never use emery cloth as part of the emery will embed itself into the rings and in turn destroy the carbon brushes. Replace the brushes if they become chipped or broken or if less than 1/2 inch of brush material is left. 8-3. WELDING CABLES - Check connections periodically for tightness. The cables should be inspected frequently and all breaks in the insulation should be repaired with electrical insulation tape or the cables should be replaced. ito]: 25 INE 7his engine may use oil during the break-in period (first 50 hours of operation). Check the oil level several times a day during this period. If the ой level is low, add a quality brand of engine oil (see Table 8-1). The load on the engine should be kept as light as possible during the break-in period. LUE AGI Do not mix different brands of oils. Generally, motor oils fall into two categories: phosphate base, and sulphonate base. The phosphate base oils are acidic; the sulphonates are alkaline. Although both bases produce good oils, mixing the two bases pro- duces a checmical reaction which greatly reduces the lubricating properties of either oil. The mixing of oils could cause extensive damage to the engine. After about 50 hours of running time on the break-in oil, drain the oil and change the oil filter. Premium heavy. duty oil, manufactured by any one of the major oil com- panies, should be used as a replacement oil. Table 9-1 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 dipstick to make sure oil level is up to the required operating level. Under normal conditions the oil and filter should be changed every 150 hours. Under extremely dirty conditions the interval should be shortened to 50 hours or "less. The oil should be drained after the engine has been warmed up to normal operating temperature, thus pro- moting foreign particle suspension in the oit and removal when the oil is drained. Foreign particles tend to settie at the bottom of the crankcase when the oil is allowed to cool, avoiding removal and contaminating the new oil 9-2. COOLANT SYSTEM Caution should be exercised at all times when removing the radiator pressure cap. The cap will turn to an almost full open position, at which point a provision has been made to permit venting built up pressure within the radiator. Allow the pressure to escape before completely removing the cap from the radiator neck. When removing the cap, it Is recommended that a glove or rag be used to protect the operator's hand from possible exposure to extremely hot coolant. This unit is shipped from the factory with the proper amount of water and antifreeze to permit operation of the unit at temperatures down to 0°F. If the engine is to be operated in a temperature below 0°F, ensure that a good grade of ethylene glyco! antifreeze is added to the coolant system. Change the coolant solution as often as necessary. The coolant system capacity is 9 quarts (U.S. Measure). During the break-in period of a new engine, one of the greatest dangers is overheating. There are several possi- bie causes of overheating, but the basic causes are a lack of engine lubrication and coolant circulation. At the first sign of overheating, shut the engine down and make a thorough check to determine the cause. Temperature of the engine coolant is regulated by a thermostatic valve located in the outlet at the front of the cylinder head. This unit retards the flow of coolant until a predetermined temperature is reached, usually varying between 170°F and 180°F. When the desired temperature is achieved, the valve opens and the circulation of the coolant through the system begins. If the thermostat should fail, replace it immediately. Ensure that the replacement has an equal temperature rating. Do not run the engine without a thermostat. If the thermostat remains open, or the engine is run without a thermostat, the engine will run cold. As a result, excess carbon will accumulate and the oil will become contaminated with sludge. Ne: The engine fan and alternator belts are subject to normal wear and should be checked for proper tension periodically. Check and readjust tension after the first 50 hours of operation, and whenever belts are replaced. 9-3. GOVERNOR SERVICE - The governor speed setting and sensitivity setting are factory set to obtain correct weld rpm and engine response to changing load conditions. The governor speed control setting is factory locked with a lead seal. Do not remove this seal unless absolutely necessary. LIE 7he governor, as used in conjunction with this engine, does not have a “No Load Surge” adjustment as described in the Engine Manual. The engine is factory set to operate at 1200 rpm idle speed and 1850 rpm when it comes up to weld speed. For information concerning governor adjustment, refer to the Engine Manual, Fuel System Section. 9-4. CARBURETOR FLOAT SETTING Do not bend, twist, or apply pressure on the float body. The float body, when viewed from the free end, must be centered between and at right angles to the machined surface, and must move freely on the float axle. To ensure correct fuel level in the float chamber, check distance {dimensions A, Figure 9-1) from top of float to machined surface of throttle body (no gasket} with throttle body inverted. This dimension should be 1-1/16 inches plus or minus .020 inch. To increase or decrease distance from the top of the float body to the machined surface, use a long nose pliers and bend the float lever at a point close to the float body. т А | = AO Figure 9-1. Carburetor Float Setting 9-5. AIR CLEANER SERVICE (Figure 9-2) - The air cleaner is one of the most important parts of the engine from the standpoint of engine life. An engine consumes several thousand cubic feet of air per hour when operating. If dirty air gets into the engine, it can wear out a set of piston rings within a few operating hours. TA-080 504 A dirty air cleaner element is usually accompanied by a loss of power and black smoke in the engine exhaust. Servicing of the element is accomplished in the following manner: Remove the filter element lock assembly and seal. Inspect the gasket on the end of the element for damage. Clean the element as indicated in Figure 9-2. Wipe out the inside of the air cleaner housing OM-450 Page 15 before installing a new or cleaned element. Do not use the element if the seal is damaged or missing. LEE When it becomes necessary to service the air cleaner in the field, follow the Steps in Figure 9-2. It is recommended that a spare element always be kept on hand for replacement. New elements are available from your distributor. à E Do not operate engine without the air cleaner element in place. It is recommended that the element be replaced after six washings or 1 year, whichever comes first. Page 16 For a temporary expedient in the field, the element can be cleaned by tapping the side or the end carefully against the palm of the hand. CAUTION: Do not tap element against a hard surface. The element may be damaged by doing so. Compressed air, not to exceed 100 ibs. of pressure can clean the element, insert nozzle inside the element and blow out dust, Clean dust from the outside of the element by holding the nozzle at least 6 inches from the element. If compressed air is not available, or if soot, oily vapor, or any dirt is present which cannot be removed by compressed air, then the element is to be washed. Agitate element H warm water containing a non-sudsing detergent. CAUTION: Do not use water hotter than the hand can Stand; solvents or oil; fuel oil, or gasoline. Reverse flush with clean water to thoroughly rinse all loosened foreign material from the filter, 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 indicates that the element is damaged and, therefore, is unfit for further use. Replace the element, Figure 9-2. 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. TA-900.716-7 Governor Idle Control *Optional Solenoid TC-080 519 Figure 9-3. Automatic Idle Control/Governor Linkage Adjustment And High Altitude Carburetor Modification 9-6. AUTOMATIC IDLE CONTROL/GOVERNOR LINKAGE ADJUSTMENT (Figure 9-3) To obtain proper engine idle and/or weld speed perform the following procedures: 1. Loosen the linkage socket nuts {6 & 8) and remove the hardware (10) securing the linkage socket (9) to the governor. Rotate the linkage socket (9) until the throttle stop plate (2) is about 1/32 inch from the stop (1). A clockwise rotation of the linkage socket (3) will shorten the gover- nor linkage {7) and reduce the gap; a counterclockwise rotation of the linkage socket (9) will lengthen the governor linkage (7) and widen the gap. (In some cases it may be necessary to adjust the linkage (7} itself to obtain the 1/32 inch gap required.) Tighten the linkage socket nuts (6 & 8) to lock the position of the linkage sockets (5 & 9). ДО Check the linkage (7) for freedom of movement throughout its entire travel. If the linkage is binding due to the linkage sockets (5 & 9) being out of proper alignment, loosen the linkage socket nuts (6 & 8) and rotate the sockets (5 & 9) slightly until unrestricted movement of the linkage (7) is restored. Tighten the linkage socket nuts (6 & 8). RLV Ensure that body limbs are clear of the fan before starting or working on the engine. 2. Recheck all connections made thus far. Place the AUTOMATIC IDLE CONTROL 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. 3. Pull the arm (3) toward the front of the welding generator to the idle position. Maintain pressure on the arm (3) to butt against the idle screw (4) throughout the following adjustments: A. Rotate the idle speed screw (4) to obtain 550 rpm. Clockwise rotation of the screw (4) will increase engine rpm, whereas counterclockwise rotation of the screw (4) will decrease engine rpm. B. Rotate the idle mixture adjustment screw (18} counterclockwise until the engine begins to falter or roll; then rotate the screw {18) clockwise until the engine operates smoothly. Rotating the screw (18) clockwise restricts the fuel flow, making the air-fuel mixture leaner. Rotating the screw (18) counterclockwise admits more fuel, making the air-fuel mixture richer. Loosen the alignment screw (19) and position the idle alignment clamp (22) radially and lateraily until the following conditions are simuitaneously met: A. Position the clamp (22) laterally so that the outer edge of the clamp (22) is flush with the end of throttle shaft (23). B. Position the clamp (22) radially so that the idle arm (21) is positioned radially approximately as shown in Figure 9-3. Tighten the alignment screw (19). Loosen the two idle control screws (17). Place the AUTOMATIC IDLE CONTROL. switch in the OM-450 Page 17 ON position, Operation of the idling device is automatic when the AUTOMATIC IDLE CON- TROL switch is in the ON position. When the engine is running, engine speed will remain at idle until an arc is established, at which time the engine immediately comes up to weld rpm. When the arc is broken, a time delay of approximately 10 seconds will exist before the engine returns to idle rpm. The length of this time delay is not adjustable. Ensure that the idle contro! solenoid plunger (17) is at the end of its travel within the solenaid coil body. 6. Pull the arm (3) toward the front of the welding generator to the idle position, Maintain pressure on the arm (3) to butt against the idle screw (4) and adjust the length of the idle linkage arm (21) until 1200 rpm is obtained. Tighten the two idle control screws (17). VII Do not readjust the idle speed screw (4) when adjusting the idle control idle speed. Check the idle linkage (20) for freedom of movement throughout its entire travel, If the linkage (20) is binding due to the linkage (20) being out of proper alignment with the idle arm (21) adjust the idle alignment clamp (22) laterally until unrestricted movement of the linkage (20) is restored. Repeat Steps 4, 5 and 6. FXII Ensure that body limbs are clear of the fan before working on the engine. 7. Place the AUTOMATIC IDLE CONTROL switch in the OFF position. Loosen the governor speed adjusting screw securing nut (11). Adjust the governor speed adjustment screw (12) until a high speed of 1850 rpm is obtained. Tighten the securing nut (11) to maintain the governor speed setting. 8. Check the governor engine regulation by apply- ing and removing the engine load. if a governor sensitivity adjustment is deemed necessary. loosen one of the two locking nuts {13) and proceed with the following instructions. A. IF REGULATION RANGE IS TOO BROAD - Decrease the governor spring (15) tension by sliding the sensitivity adjustment screw (14) inward. B. IF REGULATION RANGE IS TOO NAR- ROW - Increase the governor spring (15) tension by sliding the sensitivity adjustment screw (14) outward. C. IF ENGINE SURGES (HUNTS) UNDER LOAD - Increase the governor spring (15) tension by sliding the sensitivity adjustment screw (14) outward. 9. Tighten the two locking nuts (13) to maintain the desired governor sensitivity. Readjust the gover- nor speed by repeating Step 7. Page 18 Whenever the governor sensitivity [Step 8) is adjusted, the governor speed (Step 7) MUST be read- justed. Whenever the governor speed (Step 7) is adjusted, the governor sensitivity (Step 8) MAY need readjustment. 9-7. HIGH ALTITUDE CARBURETOR MODIFICATION (Figure 9-3) - The Teledyne Walbro carburetor can be equipped with an adjustable main jet for high-altitude operation {above 4000 ft.). Minor adjustment will be necessary for proper operation at a particular altitude. Whenever a carburetor adjustment is deemed necessary, see Figure 9-3 and proceed as follows: Loosen the main adjustment screw locking nut (25), Ap- ply a maximum rated welding load to the welding generator. Rotate the main adjustment screw (24) clockwise until the engine begins to falter and lose rpm. Rotate the main adjustment screw (24) counterclockwise until the engine operates smoothly; then continue counterclockwise rotation for 1/4 turn. Rotating the screw (24) clockwise restricts the fuel flow, making the air-fuel mixture leaner. Rotating the screw (24) counterclockwise admits more fuel, making the air- fuel mixture richer. Remove the engine load. Tighten the locking nut (25). LLL AVR Restricting the fuel flow to the point where the mixture is too lean will cause valve burning. 9-8. SPARK ARRESTOR (Optional) The engine exhaust system on this welding generator has not been equipped with spark arrestor unless it was specifically ordered as an optional accessory. A spark arrestor, maintained in effective working order, is mandatory if this welding generator 15 to be operated in a National Forest, or on California grasslands, brush, or forest covered land (see Section 4442 of California Public Resources Code). For other areas, check your state and local laws. Internal combustion engines operating in a highly combustible environment are a common fire hazard. Glow- ing carbon particles blown out with the exhaust can retain sufficient heat to ignite materials. While no prac- tical spark arresting device will stop all sparks, this device will minimize fire hazards by removing and trap- ping most solid particles provided that it is properly maintained. The carbon trap should be serviced weekly or every 50 -— operating hours, whichever occurs first, The entire spark arrestor should be inspected every 1000 operating hours or three times per season. A. Inspection 1. Visually examine the outside of the device for holes, cracks, or metal corrosion. 2. With the engine stopped, look inside the spark arrestor outlet tube with a flashlight or other light source. Visually examine the vanes and the outlet tube for metal or weld failure. The vanes must be firmly attached to the inlet tube and the outlet tube must be completely intact (this is an important factor in maintaining spark arresting efficiency). 3. Check the mounting clamp to ensure that the spark arrestor is securely mounted, Replace the spark arrestor if inspection reveals any signs of failure. B. Servicing The Carbon Trap TAIN \' IR Service the device in an area where there is no danger from flying sparks or hot carbon particles. 1. Stop the engine and allow the exhaust system to cool. 2. Remove the cleanout plug from the bottom of the spark arrestor with a wrench. If a crust has formed over the hole, break it loose with a screwdriver or similar tool. . 3. Start the engine and run it at idle rpm to blow collected particles out the cleanout hole. If particles are slow to discharge, momentarily cover the end of the exhaust stack, 4. Stop the engine. Replace and secure the cleanout plug. E SECTIONT0- TROUBLESHOOTING mms: Summ EU VIE Hazardous voltages are present on the internal circuitry of the welding generator while the engine is running. Shut down the engine and disconnect the negative (-} battery cable before attempting any inspection or work on the inside of the unit. Troubleshooting of internal circuitry should be performed by qualified personnel only. The following chart is designed to diagnose and provide remedies for some of the troubles that may develop in this welding generator. It is assumed that proper installation has been made, according to Section 3 of this manual, and that the welding generator has been functioning properly until this trouble developed. Use this chart in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, the nearest Factory Authorized Service Sta- tion should be contacted. In all cases of equipment malfunction, the manufacturer's recommendations should be strictly followed. TROUBLE PROBABLE CAUSE REMEDY No weld output. rings and brushes. Poor contact between slip Clean slip rings (See Section 8-2). Replace the brushes. tween positions. Range switch S3 is be- Place Range switch $3 in proper position. Erratic weld current. Damp or trodes. defective elec- ‘Use new, dry electrodes, Loose or dirty connections. Check connections both inside and outside of welding generator. No output at 120 VOLTS AC receptacle RC1, no weld output. rings and brushes. Poor contact between slip Clean the slip rings (see Section 8-2). High or low voltage at 120 volts receptacle RC1 and weld output terminals. Improper engine speed. Check the engine speed. The engine must run at 1850 rpm when AUTOMATIC IDLE CONTROL switch is OFF and no load is applied (see Section 9-6). Battery discharges between uses. Ignition switch S1 left in RUN position. Ensure the Ignition switch S1 is left in the OFF position when the unit is shutdown. Build up of acid on top of battery (white-grayish substance). Clean battery with soda solution; rinse with clear water, Infrequent use. Periodically recharge battery. Defective battery. Replace battery. Engine ran fine but slowly stopped; unable to restart engine. If fuel tank cap is equipped with an inside valve, it may be in the CLOSED position {other probable causes can be found in the engine manual). | Examine the inside of the fuel tank cap. If the cap is equipped with an adjustable valve, rotate the valve to the OPEN position, OM-450 Page 19 NEUTRAL GROUNG AS REQUIREB AC POWER г, # BY NATIONALE LOCAL ELECTRIC CODES Г) WHT (OPTIONAL) 1 REFER TO OWNERS MANUAL BEFORE = H MAKING AMY CONNECTIONS STD = GRA Gh y ==> > 85/40. ! 2 ZA > dd 72 REMOTE CONTROL ACA 53 LOPTIONALS о = . » REMOTE CONTROL FACILITIES T 8 a ! OPTIONAL) n в 2} I TO INSTALL, REMOVE LEAD 103 m = | FROM A1 AND CONNECT TO $5 г m | A o , "505 a 27 | 26% E NOTE: GROUND STRAP MUST BE 2 as INSTALLED BETWEEN ENGINE 4 1250 Zi HIGH” y FRAME AMD WELDER FRAME t , ЧР REAR VIEW == | 1 Da FF Da EQUIPMENT CAUTION prey 3 2 Do! bi ren REFER TO OWNERS I ı yea ca + MANUAL BEFORE a Tes ‘| 42 GR 1 I р. Ds ATTEMPTING VOLTAGE I + + = CHANGE -OVER I kd I с WATER TEME | | | v5i 5 Hd - о al ad JIL PRESSURE o— em = I Pi + Pr + HOLD IN De 07 - MSN TO START OPTIONAL KIT | $= SRa ] E SHUNT / T SAFETY SHUTDOWN ACL EE 30 + LT WELD METERS(OPTIONAL) 75 | TO INSTALL REMOVE LEAD Te E a TT 20 FROM Z ACONNECT AUTOMATIC OFF IDLE CONTROL. - J TO SHUNT RUN Ne ——|-]-- — > POSITIVE* E POLAMITY sw. REY. — ¿OPTIOMALI 1 ! AUNNIHÉ L HOUR METER QP TIONAL) E NEGATIVE & POSITIVE STUDS NOT USED WITH POLARITY SWITCH ELECTRODE WORK 12 VOLT STARTER = о === === === === сны ЧЕ E a He 4 Circuit Diagram No. B-046 418 Figure 10-1. Circuit Diagram For Welding Generator DIODE 052 ISOLATED po < >! RESET POSITIVE В < + + 7 o С ° 9k R B В 6 £54 QUTPUT Q50 OUTPUT T (DELAY ON) PIN VIEW (DELAY OFF) C< $ > À A RESET a Е < + к BURDEN RESISTOR Я Q51 8 D53 AÍSCR al/G F 20 5 0 y KAG K CT Req D55 SCR508 54 L Za HE ——— 6 $ 5 NEGATIVE J< © 2 + + TERMINAL REFERENCE A B CD ПОЗЕ К | Circuit Diagram No. A-081 887 Figure 10-2. Circuit Diagram For Electronic ldle Device Page 20 E November 1979 FORM: OM-450: Effective With Serial No. HK341102 77 10 76 75 78 | Figure A - Main Assembly ОМ-450 Раде 1 rr TL Lr TT E Includes Items 46 thru 53 L TR-900 955-G OM-450 Page 2 Item Dia. Factory No. Mkgs. Part No, Description Quantity Figure A Main Assembiy 1 017 430 STRAP, mounting tank - fuel 1.111220 0 0004444 44 4 44 recacarreorvoa. 2 2 010 434 STRIP, rubber 1/2x2x2................ ..rrcrecciaorrecieanrence— 2 3 006 698 TANK, fuel (consisting of)....................e cen 4 ee aa ae a aa a a da na aa ne» 1 4 018 858 CAP «ee re 0 1 602 938 FITTING, pipe- galvanized plug 1/8NPT ......... iii eae 1 5 010 870 FITTING, pipe - brass nipple hex 1/8 NPT w/extension ....................... 1 6 015 602 VALVE, shut-off w/strainerfuel .............. cris: reos naan 1 7 006 014 FITTING, brass - flared inverted elbow M 1/4 x 1/8NPT.............. mee... 2 8 007 829 LINE, fuel.............. ee ce ee ee 1 9 CT 081 359 TRANSFORMER, control -idle............e e. 4 aa 44 aa se a 0 aa a des a sen 0 1 10 R2,3 030060 RESISTOR, WW adj375watt200hm ......c iii iii cece eee 2 11 017 479 SEAL, weather - lifteye .............e e. ._..ec00rrecorecareveraaoórenvena e 1 12 031 868 BRACKET, mounting - air cleaner ............o_.eeeereccdererere rece. e. 1 13 018 765 AIR CLEANER, intake (consisting of) .............0.0v0rm0secrdaror rea 1 14 018 859 . САР ee ee ar 1 15 008 698 . BAFFLE, dust - cap ......... 2... ee ee ee aaa 1 16 010 433 NUT, WING. coi ee er ce cre re eee een, 1 17 *017 309 ELEMENT oe ee 1 18 000 272 .CLAMP, air cleaner iii ec cr aa 00 1 19 010 861 CLAMP, hose 1-1/16 - 2 inch dia ............ 220 ena. 5 010 862 CLAMP, hose 1-13/16 -2-1/2 dia... ........... 2... ieee eee 0 1 20 018 365 HOSE, air cleaner - intake .................. 0... recioredderedeaa ca. 1 21 023 626 CABLE, battery - positive ......10100 0004404 444444 4e 4 ae 4 84 a A a a ee A ae an 0 1 22 022 893 DOOR, access - battery ................ RR a a a a a a eee 1 23 049 685 CATCH, door ..................0 0002222000020 0rddercaarerdeeararovrooaca 2 24 010 515 BOLT, J$5/16-18..................000 eee eee ee 4 25 005 612 DOOR, side .............. 0.000 002260000220 raréarednavderanerecarar aa 2 26 081 824 COVER, top.............—.eoeeeeecdoaorrereecerecreroarererodooorrecrecrcezao 1 27 03b 968 WASHER, neoprene 5-7/80Dx3-6/8IDx 1/16 ............................. 1 28 027 529 PIN, cotter 1/4 - 3-1/2 i ee en 6 29 053 966 GUARD, fan . i er KG 2 30 *О17 363 HOSE, radiator .....00000000000400000008 0000ER ir e eee er e OÙ 31 605 839 RADIATOR, w/shroud (consisting of). 101000000444 4e a sa aa a aa a a aa 0 1 32 605 982 .CAP, radiator ............. RER a a a a area a 1 33 081 500 ENCLOSURE, radiator.......... eee 1 34 006 015 FITTING, pipe - brass drain cock 1/4 NPT LL Le 140 4 4 4 4 44 ae a da 4 4 4 aa aan 1 35 006 037 HOSE, radiator - lower ............... 6.2... A A da a A de a A aa da a a aan 1 36 BLADE, fan (included with engine - see engine partstist) ...................... 1 37 BELT, V included with engine - see engine partslist) ......................... 1 38 031 980 ENGINE, gasoline (consisting of) ................. ii cnn. 1 39 005 772 . CONTROL, weld/idie - electronic (consisting of) ..................... 0 1 40 GS1 005 373 .. SOLENOID, 14 voits dc 0.84 amp pulltype........11111000 00 inners. 1 41 047 474 .. BRACKET, mounting -idledevice . .......... iii ieee. 1 42 015 713 .. GROMMET, rubberb/16 ID x 1/2 mounting hole .......................... 1 010 837 . . PIN, Spring - COMPIESSiON . ov vite tee eee eee er eee eee, 1 005 740 .. STRIP, mounting - throttle slotted holes. ............... iu... 1 005 739 .. STRIP, mounting - throttle round holes ................. 2.0... acera 1 43 049 640 . LEVER, control-idie .....112 01100144 4444 4e ea 4 4 4 ee ae A ee 4 KR 1 44 020 365 . STOVE, Manifold... ee ee 1 45 017 594 .CLAMP, stove ee a a a a A a aa a ane 1 46 59 025 474 . SWITCH, shut - down low oil ............ 1 LL id, 1 47 $8 025 473 . SWITCH, shut-down hightemperature... ........... cities 1 48 025 182 . BRACKET, mounting - alternator........... ee... eee eee eee 1 49 605 429 . ALTERNATOR, 35amp 12 volts............ AAA a 0 1 026 837 . INSULATOR, terminal nylon {use with alternatorleads) . ..................... 1 50 605 430 . PULLEY, single belt ........... ee aan 1 Page 3 Item Dia. Factory No. Mkgs. Part No. Description Quantity Figure À Main Assembly (Cont'd.) 51 025 181 . TUBING, steel 5/8 OD x 12 ga wall x 1/2............e0s0s00rrerereer ree 1 82 027 541 .PIPE, exhaust 1022000000 o: ie AD Das ee ee a rase 1 b3 017 389 . CAP, weather-exhausiNo. 4........................ ea 1 54 Figure C GENERATOR ASSEMBLY (See Page bb) ........ iii iio, 1 55 017 477 ROD, holddown - battery. ............e— —.eseesreeerrerrrrraeriereren eee 2 56 BATT *015709 BATTERY, 12 volts 53 amp hour ............eeeeeeenenvecerearererecar 1 57 023 641 CABLE, battery - negative .............._oeeesrecc.re0e:0aeoie. e AA 1 58 017 431 HOLDER, battery ............_oe.eeoeesecrrreava dao erre an nerecrooce.. 1 59 023 892 CABLE, ground - engine ............_e.esesvecacoren rent errereocrecier ene 1 60 004 444 UPRIGHT, base - center .............o..0e00eseaa0rreavecar e ereerea == 1 61 MOUNT, engine (included with engine - see engine parts list) ...............e.. 1 62 010 266 SPRING .............20v0írececicrereiaaracererCeecenraarrrnarearerecrer 2 63 017 420 LATCH, door. ............eeeeccereererevecaa ea ere eaerentereorca renace 2 64 72 027 982 STABILIZER ................000r0rxe0ra0decrer e a A a a ee ere eccarerrorenaDe 1 65 000 553 MOUNT, dual stud - generator ..........o_eoseresrvecsacoca e rnve ten DIA 2 66 010 144 CLAMP, nylon 7/16 dia .................0e€000s0000rrereeor tr entren. 1 67 603 107 HOSE, neoprene - slit 5/32 ID x 11/32 OD (order by ft.) .........e..e.ee......e.. 1 ft. 68 ТЕ! 038 621 BLOCK, terminal 30 amp 4 pole ........200020002 0004 44 4 aa a 4 a 4 eevee 1 69 038 620 LINK, jumper - terminal block .............e _eceererecrenor venecia ar eee0,. 2 70 053 967 INSULATION, rectifier... o.oo tit tite eee te cece ect cies 1 71 052 372 BRACKET, mounting -stripterminal ........... iii iii e 1 72 035 860 RECTIFIER ASSEMBLY (consisting of)... ..... coir aa sa aa ea a ee a aan 6 1 73 SR1,2 035 704 . RECTIFIER, integrated 30 amp 600 voits.........10004 0102 see a aa ea ea aan 0 2 74 031 926 . НЕАТ SINK Lotte it A4 da 4 A 4 da Re 4 a i etree ens 1 75 081 828 BASE 0000ER RR RK RER RK 1 76 049 082 UPRIGHT, base - front...........e..oe_.eeendrrroraereenrereecaaeer e ea 1 77 Zi 036 259 REACTOR (consisting of) ..................esr2res0e:dearer rear oa. 1 025 138 .COIL, reactor - lefthand ................... 000 e. .neco0ncervererneeco ra 1 025 139 . COIL, reactor - center ...........eee.eeraavereorrerieeear vera Teron recen 1 025 140 .COIL, reactor - right hand ...........ees.e.evreoariae aaa aer eececrAD 1 78 Figure D PAÑEL, front - with components (See Page 8). .............eoerecrerrenecea— 1 79 005 601 PAÑNEL, front - lower or.......... —.eeserereneaovrererere eve dredenmrecere 1 79 005 631 PANEL, front - tower (used with polarity switch} ................ ooo... 1 80 Figure B_ TERMINAL ASSEMBLY, power output (See Page 6) ......... 2.2020... 1, 1 81 028 218 FRAME, mounting - stabilizer & reactor ............ cri... 1 82 VS1 024017 SUPPRESSOR, 75 Uf BB VOSS AC o.oo ee teeta 1 83 081 983 STRIP, mounting - transformer .........._....e.enrxrrerxene ea area AA 1 84 027 105 STRIP, cotton 1/8x 1 x20............. ee ee ee ee ee eee 2 024 480 KIT, label (includes all labels) ...........c. coi iii iia 1 *Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-450 Page 4 Item Dia. Factory No. Mkgs. Part No. Description Quantity Figure B Terminal Assembly, Power Output (See Fig. À Page 4 Item 80) 101 081 491 BRACKET, mounting - terminal poweroutput. . .......... iii. 1 102 Neg 039046 TERMINAL, power output - black (consisting of) ........... PE 1 103 601 879 . NUT, steel - hex full 1/2-13................ m.5.:700cosrerr0rerresrresre ere. 1 104 039 044 . BUS BAR 10ER rte ee eae 1 105 601 880 . NUT, steel - hex jam 1/2-13 ...............e000r0rrie cer rare a aa a een 1 106 039 045 .TERMINAL BOARD, black. ...........eo eee a a een 0 1 107 053 032 .CLIP, spring - bus bar ............e0ee20s0drvreerariorarer errar ecev Ds 1 108 601 976 .SCREW, cap-steelhexhd 1/2-13 x 1-1/2... i iii ia ian 1 109 Pos 039 047 TERMINAL, power - output - red {consistingof) .................. ott 1 110 601 976 .SCREW, cap - steel hex hd 1/2-13 X 1-1/2 ...0.0000000000 0000ER 1 111 053032 .CLIP,spring-busbar ........ i a 0 05 1 112 039 049 TERMINAL BOARD, red ... citi ee eter teeter nae 1 113 601 880 . NUT, steel - hex jam 1/2-13 . ci ii KERN 1 114 039 044 BUS BAR oot ee ee aa 1 115 601 879 . NUT, steel -hex full 1/2-13. iii i ee ieee iain 1 > 102 a TB-048 150 Figure B - Terminal Assembly, Power Output BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. [tem Dia. Factory No. Mkas. Part No. Description Quantity Figure C Generator Assembly (See Fig. A Page 4 Item 54) 116 025 271 ENDBELL ......... ee 1 117 SR3 046 457 DIODE ASSEMBLY, reverse polarity {consistingof) ......................... 1 118 025 305 INSULATOR i KR 2 119 037 957 . DIODE, 276 amp 300 volts reverse polarity. .................. ..... ........ 3 000 901 .CAPACITOR, ceramic 0.01 uf 500 volts de ........... 2... ae 2 046 455 . CAPACITOR, ceramic 0.01 uf 500 volts de ...........e. 4 4 a 4 a a aa eee 1 120 025 306 INSULATOR o.oo ee ee ce 5 121 026 203 CHANNEL, neoprene 1/4x 11-1/2 1111112444 e. 1 122 059 023 STATOR or ..... ee ee a ea ea a a aa ae 1 Page 5 item Dia. Factory No. Mkgs. Part No. Description Quantity Figure C Generator Assembly (See Fig. A Page 4 Item 54) (Cont'd.) 122 059 017 STATOR (used when unit is equipped with ac power terminals). ........ eae 1 123 039 207 BAFFLE, Gir «oot iti re tee ee eee ee ee A ee eee eee 0 1 124 032 311 GUARD, generator ..............e20rerieierrraaenrelecerereaeararcen ee. 1 125 **003 632 ROTOR (consisting Of) o.oo vivir i eect 4e ee a ee ian 1 126 024 617 , RING, retaining ............_oeeeeerceeveriro rr rerrrrrea dan aoo ren erara 6 1 127 053 390 . BEARING ..............0e00smarirde cera re veracerercereedrec0cmorevere=— 1 035 775 . KEY, steel 3/8 x 3/8 x 1-1/2.............000000rerr ei recorrer eera a a a aa 0 1 128 035 917 .FAN..................... A4 4e de ee 4 ee ee ee 1 129 025 525 ROD, threaded end 3/8-16 x 29-7/16 ......120200 0144440 ii ieee 6 130 010 021 CLAMP, 9/16 dia. x 11/32 hole ......1202 201140114444 ie iii cies 1 131 018 614 BRUSH SET (consisting of) 122020040444 44 cet ieee ia 3 132 018 665 .CAP.......... iii, ee a A A ea ae eee a 0 a 0000 1 133 600 270 . ВВЫ5ЗН НОСОЕВ ............ 5... ууу 4 A a 4 este tite iat eee eae as 1 134 *020 034 BRUSH... co iii i et a a a 4 tr re aa 1 135 025 321 BRACKET, mig-brushholder............. cc iia 1 136 SR3 046 456 DIODE ASSEMBLY, straight polarity {consistingof) ......................... 1 137 025 305 .INSULATOR ..............0r.0e0s.resrrarrecorereorrarecrorrecrrerre 2 138 037 956 . DIODE, 275 ampere 300 volts straight polarity... ......... cc vino... 3 000 901 . CAPACITOR, ceramic0.01ufb00voitsde ........ ii. 2 046 455 , CAPACITOR, ceramic 0.0Tufb00voltsde ............ cc iii iin... 1 *Recommended Spare Parts. **Rotor is available on an Exchange Basis. Contact Distributor for Details. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Figure C - Generator Assembly TD-007 743 ОМ-450 Page 5 Item Dia. Factory No. Mkgs. Part No. Description Quantity Figure D Panel, Front - With Components (See Fig. A Page 4 Item 78) 151 047 778 LIGHT, indicator - red 12 volts {consisting of} ......... iii, 2 152 048 156 . LENS, light-end red ...... oc. iii an enana a 1 153 PL1,2 *048 155 .BULB, incandescant - flanged base 12 volts. .............. eee 1 154 047 478 PANEL, front - Upper. «o.oo iit i ee ee dd 4 A dde a da aa à 1 155 S83 005 015 SWITCH, range (See Fig. DT Page 9) ............ iii. 1 156 R1 *605 9650 RHEOSTAT, WW300watt3d ohm ..... oc. iti eee. 1 157 S45 *011 609 SWITCH, toggle SPDT 15 amp 125 volts ..............e.eoeceri re. k à aa ee ea a 40 2 1588 PB1 011 767 SWITCH, push button - start ............o e. .ee0srdxe die 0 aaa oa ea 1 159 RC1 604 176 RECEPTACLE, duplex - grounded 2P3W 15 amp 125 volts ............... 1 160 C1 063 286 CAPACITOR, ignition Buf i iia 1 161 MS1 011 072 SWITCH, magnetic w/adj plate & clamp (consistingof) ....................... 1 162 F 048 317 . FUSE, miniature glass 14 amp 32 volts ................. 020000 aaa 1 163 PCT 049 443 CIRCUIT CARD ASSEMBLY, weld/idle control {See Fig. D2 Page 10) ........... To 164 019 730 CONTROL, push-pull. oe eee eee eee a da aa aan 1 165 019 755 HANDLE, rhe0sStat. e... A 1 602 178 SCREW, set 1/4-20 x 3/8 1.111110 1444 4 444 4 4 4 4 4 de RR 0 1 166 019 754 HANDLE, range - switceh..................—000 2... 0d a 000a RR ean 1. 167 010 836 PIN, spring 3/16 x 1-1/4 ec, FE 1 168 NAMEPLATE (order by model & serial number) ere... 1 155 -- Fig D1 160 Fig D2 TC-048 389 Figure D - Panel, Front - With Components *Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 7 Item Factory No. Part No. Description - Quantity Figure D1 005015 Switch, Range (See Fig. D Page 8 Item 155) 181 - 005 001 BRACKET, mounting - switch {withoutspring) ........... coin... 1 182 010 671 SPRING, extension................ ae aa ae ae ee na ner 1 183 017428 LOCATOR, quadrant .......... ee ee ee ee eee a eden. 1 184 004 998 CONTACT BOARD ASSEMBLY, switch - range {consistingof) ................ 1 185 100 623 . GUIDE, contactboard-movable ............. cc iii 3 186 100 622 | SHIM, guide -contacthoard . . .......... iii ieee an, 3 187 011880 .CONTACT BOARD, movable switch ............oeoeerederieierrare cane. 2 188 004 999. CONTACT BOARD, stationary ...........ew_eoerrerdcsevoreceorerererecooo 2 189 011 645 . CONTACT ASSEMBLY, movable (consistingof) ............... ......: SA 3 190 011075 .. SPRING, pressure .........e_ eect eee eee eee Eee, 1 191 011 953 LL CONT A CT Lr i tree eee ee ee cece 2 192 011074 .. SPRING, pressure .............. ee ee ee 1 193 011 644 .CONTACT, stationary ...........ee..e.euadeoa aa 0 ade aaradeoreconan e 15 sl 189 193 at. ‘Includes 19 Item 190 18-011 273 TB-011 100 Figure D1 - Switch, Range BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-450 Page 8 Dia. Factory Mkgs. Part No. Description I Quantity Figure D2 049 443 Circuit Card Assembly, Weld/ldle Control {See Fig. D Page 8 {tem 163) C50;54 035 522 CAPACITOR, mylar 0.047 uf 100 volts .................. 2x0 aa ae 0 2 C51,52 031 651 CAPACITOR, tantalum 68 uf 20 volts de ............. ee 2 C53 080 507 CAPACITOR, tantaium 22 uf 1B volts... o.oo 4 4e ea ea 1 D50,54 027 369 DIODE, rectifier 3 amp 600 volts straight polarity .............«.......... 2 DS1,52,53,56,57 026 202 DIODE, rectifier 1 amp 400 volts straight polarity .............. ......... 5 D55 037 243 DIODE, zener 18 volts Twatt .........._—.w_eo_reacervrrrrrer00r reee но о 1 a50 000 088 TRANSISTOR, 800 MA 40 volts 111010010440 444 ae ee a se rase» 1 Q51 039 355 TRANSISTOR, unijunction 15 MA 40 volts ...........e_eeerercerrena 1 R50,53 000 039 RESISTOR, carbon 2 watt 680 Ohm ........... iii, -. 2 R51,56,64 605 919 RESISTOR, carbon 0.25 watt 47 ohm ..............—-—.mrreeereeree. e 3 R52 605 916 RESISTOR, carbon 0.25watt 1K ohm ........... iii. 1 R54,60 035 824 RESISTOR, carbon film 0.25 wat 270 Ohm .............. .... vv. 2 R57 052 146 RESISTOR, carbon film 0.25 watt620K ohm ............. oil 1 R58 053 572 RESISTOR, carbon film 0.25 watt 12K ohm ................. aa see S 1 R59 052 138 RESISTOR, carbon film 0.25 watt 20K ohm ...........e.... 00000. 1 R61,52 030 026 RESISTOR, carbon 0.5 watt 560 ohm ........ ...... ci iii... 2 R63 003 272 RESISTOR, carbon film0.2bwatt Tmegohm............... .. a a ee 406 1 R65 000 885 RESISTOR, carbon fiim 0.26 watt 10K ohm .................... ..... 1 SCR50,51 080 508 THYRISTOR, SCR 8.5 amp 200 volts ..............e.m..0ecrrerrrerea e. _2 SR50 035 841 RECTIFIER, integrated 1.6amp 200volts.................. iii... 1 080 506 HEAT SINK, dual i ed ec ea 1 C53 TA-048 15: COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY. Figure D2 - Circuit Card Assembly, Weld/idle Control BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 9 Dia. Factory Mkgs. Part No. Description Quantity Parts For Optional Equipment A2 025 663 METER, amp de 50MYV 0-400 scale ....... coi 026 943 INSULATOR, amp meter ............—e..eeeev0ra0davrare0niereerrereverererereA 0 F1,2 *012 625 FUSE, cartridge 45 amp 250 volts .........e...._.eeeserrerrmecrveareaterererr er 0 039 169 HOLDER, fuse - cartridge 60 amp 250 volts ........202 02002 sa a eee see ee ses a ae eee 039 269 BOX, fuse-holder ........... criti, PPE 010 493 BUSHING, snap b/8ID 7/8 mountinghole ............... ci iii. | HM 032936 METER, hour 4-40 volts .............eeeeeesovererrearrenerecerv error nns RC2 604 103 RECEPTACLE, straight - duplex grounded 2P3W 15 amp 2b0 volts ................... 025 234 CAP, straight - grounded 2P3W (used with RC2) ..............—eeexicereerreaerae RC3 032 897 RECEPTACLE, grounded - twistlock 3P3W {remote currentcontrol) .. ................ 52 027 841 SWITCH & TERMINAL ASSEMBLY (consistingof} ........... cco 027 847 . BRACKET, mtg - switch & terminalboard . ............. iii 0 6 038 311 . INSULATOR, polarity switch. . ...... ci cc ican 011 281 . CONTACT BOARD ASSEMBLY, polarity switch (consistingof) .................... 010 082 ..SPACER, between mounting pad €t switch. ..........e..ec_ecrerreorerercerenec. 010 805 .. HANDLE ..........eerxeooasda =adonoorceaaerecaarranenorvarareerervereca E e. 011 948 .. GUIDE, moelded ............ooeeecorrrrdenaeoracact e KEANE 019 603 ..KNOB, round. ..........o_eeeonrecrrresnenoaaearrerereri vere erererevereman. 024 694 ..BEARING............e0crxerexuedarvenrereamecereevaceonverecvocorrreerecraD 038 769 . . PLATE, movable - with contacts............0.000 200000 iia 103 633 ..BAR, contact. ...........e ee srexerecocesavroraeie a a ee ee a ea eee ea AA ea ee 0 ee 00 103 634 .. BOARD, mtg-components...........000000 02004 aa aa eee aa se ee ea aan a ne sa ea 604 318 ..NUT, steel -selflockinghex 1/4-20 ..... ea ee a aa a ea en ae a ne es a 039 046 . TERMINAL, power output - black {consistingof) ................. coi ee» 039 044 ..BUSBAR.........—..ocenerrazareaneaavenmenoorarerereraverorverarernerrree—— 039 045 .. TERMINAL BOARD, black 111212400211 04 4 ae ea a ee a a aa a a ee ee ee era 0 6 601 976 . . SCREW, cap - steel hex hd 1/2-13 x 1-1/2....22 020040 e aa ee eee ee ae eee den 0 06 601 880 . . NUT, steel - hex jam 1/2-13 .......22 000400 ie ei eee es en ee eee 601 879 . . NUT, steel - hex full 1/2-13 i ie i catenins 053 032 .. CLIP, spring-busbhar.........200000 00000 aa ae ee aa ea se eee ee see ee ne sa een 0 027 851 COVER, polarity switch ............_—e—eceserverereracarereanoar er rerere rete Shunt 030080 SHUNT, meter 50MY 400 amp ...........e-—e-—reseevecoreroaorerrerreecocaar ene S6 011 620 SWITCH, toggle SPST 16 ampere 125 volts (remote current control) ................. HM 032936 METER, hour 4-40 volts oir eee ita eatin aes 028 262 MUFFLER, exhaust... o.oo itera iit eect tirana ans 027 561 MUFFLER, exhaust - low noise ........ coi iii icine 027 540 PIPE, black 1-1/2 X 2 «oii iit aie ee tt te eee ite a a ae 061 387 GASKET, carburetor-highaltitude ............. iii iii eee 0 010 429 JET, carburetor-highaltitude . .............. coi iii eae 6 010 875 CLAMP, muffier 2 inch dia ..... unen recerca cari eorerrenec er rrrcacar ae. 015700 BRACKET ASSEMBLY, mtg - muffler ............-..—.———esecrsvrrereerrr recrea 027 564 SPACER, anti-noise - mtg muffler..............—.—.——_eeevrreccrrerarerrerverecenrAD \ 025 638 METER, volt de 0-100 scale .........eoee.eeeeeenorevrreerrenerrereceecr are. 015 732 FITTING, pipe - brass elbow street 45 1/8NPT ........... iio 602 946 FITTING, pipe - brass tee 1/8 NPT ..........._..esrrreocerervierere rr ececre re. 048 498 BUS BAR, polarity switch ............_—..esmeeresexvanecurrrrerern Er Terre 047 208 GUARD, switch - polarity ...............ee-e.esreervrvecerenrte ever error... SE) o o da NL Da a Sa LALA == AN — BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-450 Page 10

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