Miller ROUGHNECK 1F Owner’s Manual

— September 1973
MODEL
ROUGHNECK 1 (60 Hz)
ROUGHNECK 1E (60 Hz)
ROUGHNECK 1E (50 Hz)
ROUGHNECK 1F (60 Hz)
ROUGHNECK 1F (50 Hz)
MODEL/STOCK NO.
SERIAL/STYLE NO.
DATE PURCHASED
OWNER'S MANUAL
MILLER ELECTRIC
MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO, 4579
FORM: OM-419
Effective with serial No. 70-553003
STOCK NO.
900 044
900 236
901 820
200 611
901 818
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.
item Part No. Listed Replaced with
No. In Parts List Part No. Description: | Quantity
6 603 945 010 681 KEY, woodruff 1/4 x 1
When ordering this key be sure to measure the length of the key as they are not interchangable. Order the
same length key as is in your unit. |
OM-419 Page А
Paragraph No,
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE
- 1. General .....
-2. Welding Cables
- 7. Polarity Switch
- 8. Range Switch
- 9. Exhaust Gases
EOS EEE SERE 4%
“ t = FE + NR N няни ни к я на ни в. вн ни ян кана кв % # 1 * a7 414 = = =m w=
- 3. Electrode Holder . ............... ea ee
- 5. Parallel Connections ............... ee ean er eee aaa naa
- 6. Power Disconnect Switch .......e.eereeeeroarenen e. PA
# LA OF FF RE RE 2
я + ка нии вм кии вн Ан & F 4 ®% EH #& #% wm & ¥# ¥ 4 a Fk * mE E E ENE mH ENE BB FF NE ENE ®wW в
-10. Power Circuit Ground ........ anadanaronradanmenavaaoanusooon
1-12. Hollow Castings (Welding of) ......... aire
1-13. Explosion Hazards . .......... eee eee eee eee
1-14. Ventilation ..
1-15. Solvents.....
1-16. Fire Hazards ..............m0mneniroarasearerara deaoverrorede,
"= = = = EEK EEE KK ото м ов о от око mw ov =m 4 F¥ = 2 = ®
= # 4 =% F =m 4 + = #* =m 1 = & % EFD = =m a & ®= = ENE mE =m
-17. Electrical Shock-Voltage ................. eer ere eae
-18. Electrical Shock-Dampness .............. e. eee eee
1
1
1-19. Starting Under
1
Load .................... eee ee a aa 18006
-20. Face Protection ......120220002 000121111110 PS
1-21. Eve Protection
1-22. Clothing ....
mm Fm ok % wor om oh wok mo mo ok mod ow ok NH EEE Mara aan EEE TR ON REE & wom op
+ вы ня + EB = & 4 w BE ¥ & ¥ 4 & FOV ON OF ве нк ви ии & & #& mom ow om ww ouw mom mE =m &
1-23. Hot Metal Burns ............ eaaaadonnoandoararanarerarereraaro
1-24. Grinding and Chipping .........e.eeee.evracareraenneao0nanra e neo
1-25. Compressed Gas Cylinder ..........eeenearrenvone a. RS
SECTION 2 — INTRODUCTION
General .....
и и = к инки и нашей и ши т Ш а нА вы ин ня им ны ян ин ви ин ан в вн вн +
Receiving-Handling ................. ee RR RR ea
2-1.
2-2.
2-3. Description ..
2-4. Safety ......
OREA ET TL LL EA EA
- - - - - - - - = = a - a“ - a - + =" + - = a - || - = a + - - = a - =" a - + - - - = = = = = =
SECTION 3 — INSTALLATION
и. ин и наи ди да кин А a = EN EN BB BB NE mE SS NE ия ни вн в 4 NE mB & "=" FB & 4 +.
3-1.
3-2. Generator Chassis Ground .. 1.112202 4 24 0 4 44 4 4 4 4 4 4 4 4 4 0 4 4 4 4 4 a a 2e 14 à
3 - 3.
SECTION 4 — ENGINE PREPARATION
4-1. Engine Lubrication .................... eee eee
4-2. Fuel........
a J = пи тмин к 4 i % H 4 # ® WN § WN & WN EN Hy EN EN FB ® EN & = ® NF FN EN FON mR OE & & EN & HN ON # & 4
4 - 3. Readying New Battery For Service 122004000044 4044 ae a aa aa 20 à
SECTION 5 — FUNCTION OF GENERATOR CONTROLS
5-1, Current Control ....... anaddoarasreruoorarndannaneneoaarnaa nena
5.2 Weld/Power Switch ........e_rescreonverereoredrarereororener.
5-3, 115 Volts AC Receptacies ......._ o .e.eecorcarrrenodeorormoronereoa
5-4. VoltAmpere Curves ....... .eeneovoaarvaran0nearanorarmaco armo
SECTION 6 — FUNCTION
- 3. Stop Switch ..
- 4, Start Button .
с) M GO CO)
OF ENGINE CONTROLS
и вы к § wm # = zx x 4 ке ня = & = = m » ww =m = & 4d #& + & #& 8 Ad FF F #& тан ки ти 3 я в кн
и ри риа к mm mm x йе ини дин ый и на та в ан ти в ка та + =m om + & 4 =m = ан ¥ = +
и и & ® 4 § ри в ви к ин ни т 4 4 & & #& ни тв Мм F F EH ® F ad в ен в 4 F + MN ¥
Page No.
Bb BAR (0 (0 0 0 0) 00 ©) № №3 № № = = = aed + 00 —
QT O1 du сл
nf =
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© © © ©
SECTION 7 — SEQUENCE GF OPERATION
- 1. Starting The Engine ........... aa naaa naaa naaa
-2. Stopping The Engine .......... a aredondecoreraoa nadan
- 3. Shielded Metal-Arc Welding........... oe ee ei
E wd
SECTION 8 — GENERATOR MAINTENANCE
8-1. General .................. ee aaa
8-2. Collector Ring Brushes ............... adadereraraae aaron
8-3. Welding Cables ............. Daanearererovenca are rene a ora ee.
SECTION 9 — ENGINE MAINTENANCE
. Lubricatión ©. ee ee LL LL LL ALL ALL an
Cleaning The Engine ........ RR RR LL 1100
. Spark Plugs ........ 2.2... .0erese een. ee eae
(О © © © ©
SECTION 10 — GENERATOR TROUBLESHOOTING
SECTION 17 — ENGINE TROUBLESHOOTING
PARTS LIST
-4. 115 Volts AC Power Operation . ......... iii iin.
- 1
-2
3
-4. Fuel Filter .......... RK KR 4 a a eee a 4 ae ea ea ae |
5 | | |
6
10
10
10
10
10
10
10
11
11
11
11
11
11
-
=== SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE seme
1-1.
GENERAL
These rules apply to ac and dc welding generators, sc trans-
former and ac/dc welding machines, and dc transformer recti-
fier welding machines.
In arc-welding operations, where electrically energized parts
are exposed, obsarve the following safety rules to insure max-
imum personal safety and protect nearby persons.
Failure to observe these safety precautions may expose not
only you, but fellow workers as well, to serious injuries. Once
these rules are learned and kept in mind, proceed with maxi-
mum assurance,
1-2. WELDING CABLES
DON'T overload cables, (Figure 1-1)
Figure 1-1. Don't overload cables
NEVER use welding cables at currents in excess of their rated
capacity. it will cause overheating and rapid deterioration of
the insutation. 1t is also uneconomical.
DON'T use worn or poorly connected cables. (Figure 1-2)
Figure 1-2. Don’t use worn or poorly connected cables
Inspect the cables frequently. Immediately repair all breaks
in the insulation with rubber and friction tapes. Tighten all
cable connections and adequately insulate any joints where a
connector may have an exposed conductive part. In addition
to the potential hazard to life, a hazard occurs when exposed
sections of cable come in contact with grounded metallic
objects, causing an arc. Unprotected eyes may be injured and
fire may result if combustible materials such as oil or grease
are in the vicinity. The efficiency and quality of welding will
be improved by elimination of these dangerous grounds, and
by keeping connections tight,
. ELECTRODE HOLDER
DON'T use electrode holders with defective jaws. (Figure
1-3)
Keep the jaws of the electrode holder tight and the gripping
surfaces in good condition to provide close contact with the
electrodes, Defective jaws will permit the electrode to wob-
ble, making control of the welding operations difficult.
Figure 1-3. Don’t use Electrode Holder with defective jaws
' DON'T use electrode holder with loose cable connections.
Keep the connections of the electrode lead to the holder
tight at all times.
Use only fully insulated electrode holders {and without pro-
truding screwheads.)
Never touch two electrode holders from two separate welding
machines at the same time.
CODE CONFORMANCE
The machine and its equipment must be installed and main-
tained in accordance with the National Electrical Code and
local requirements.
. PARALLEL CONNECTIONS
See diagrams in the instruction manual applying to the weld-
ing machine used.
1-6.
POWER DISCONNECT SWITCH
If the welding machine does not include a power disconnect
switch, install one at or near the machine,
1-7.POLARITY SWITCH
1-8.
DON'T operate the polarity switch under load.
The polarity switch {when supplied} is provided for changing
the electrode lead from positive (reverse polarity} to negative
{straight polarity). Never move it while under the load of a
welding current. Operate this switch only while the machine
is idling and the welding circuit is open. The potential dan-
gers of opening the circuit while carrying high current are:
1. An arc will form between the contact surfaces of the
switch and severely burn them.
2. The person throwing the switch may receive a severe burn
from this arcing.
RANGE SWITCH
DON "T operate the range switch under load, |
The range switch {when supplied} is provided for obtaining
required current settings, 1t must never be operated while the
machine is under the load of welding current, Operate the
range switch only while the machine is idling and the welding
circuit is open. The potential danger of switching the circuit
while carrying high current is the formation of an arc be-
tween the contact surface which will severely burn them,
Repeated occurrences of this arcing will eventually prevent
operation of the contacts.
. EXHAUST GASES
DON'T use gas engine units in confined spaces without vent-
ing the exhaust gases, (Figure 1-4}
if gasoline or other fuel driven welding machines are operated
indoors, provide means to pipe the exhaust gases to the out-
side air to avoid carbon monoxide poisoning.
OM-419 Page 1
Figure 1-4. Vent exhaust gases
1-10. POWER CIRCUIT GROUND
DONT use welding machine without grounding frame or
case. (Figure 1-5)
Figure 1-5. Ground frame or case
Ground the ground cable of every power circuit to prevent
accidental shock by stray current. The potential danger is
that development of a stray current may give a fatal shock
should a person, for example, place one hand on the welding
machine and the other on the switch box, or other grounded
equipment. Do not ground to pipelines carrying gases or
flammable liquids and conduits carrying electrical condue-
tors. Be sure conductors can safely carry the ground current.
When connecting the welding machine, properly ground the
machine frame or case.
1-11. CONTAINERS WHICH HELD COMBUSTIBLES
Page 2
DON'T weld on containers which have held combustible or
flammable materials or materials. which, when heated, give
off flammable or toxic vapors without proper cleaning, p purg-
ing, or inerting.
Welding containers which have held flammable or combust-
ible materials may be extremely dangerous. To prevent a fire
or explosion of the container, follow the recommendations
of the American Welding Society Pamphiet A6.0 “Welding or
Cutting Containers Which Have Held Combustibles”.
DON'T depend on your eyes or nose to decide if it is safe to
weld on a closed container. .
Find out what was in the container or use an explosimeter. A
very small amount of residusl flammable gas or liquid can
cause a serious explosion,
NEVER use oxygen to ventilate a container.
When you know the container held a gas or liquid which will
readily dissolve in water:
1. Flush out with water several times and then fill with
water as far as work permits, positioning container to
permit introduction of as much water as possible,
2. Before welding be sure there is a vent or opening to pro-
vide for release of air pressure.
1-12.
— When you know the container held a gas or liquid which wil!
not readily dissolve in water;
1. Clean out thouroughly with steam or a cleansing agent
and purge all air or inert with a gas such as carbon dioxide
or nitrogen before repairing. Carbon dioxide is heavier
than air and wil! tend to remain in the container if the
opening is at the top.
2. Use steam to clean out light material,
3. Use a strong caustic soda solution to clean out heavy oils
or grease,
4. Be sure to purge all air or inert with a gas, such as nitro-
gen or carbon dioxide, no matter how well you have
cleaned. There may still be traces of oil, grease, or other
readily oxidizable material under the seams.
Be careful when cleaning with steam or caustic soda wear
goggles and gloves.
DON'T clean where there is poor ventilation.
Ventilation is necessary to carry away harmful or explosive
. Vapors.
DONT clean where there are open flames.
When scraping or hammering to remove heavy sludge or scale,
use a spark resistive tool and keep it wet to avoid sparks. |
Keep your head and arms as far away from your work as
possible.
HOLLOW CASTINGS
DON'T weld on hollow {cored} castings that have not been
properly vented. The casting may explode. (Figure 1-6)
Ш —
ча
-
Figure 1-6. Don't weld on hollow (cored) castings
1-13. EXPLOSION HAZARDS
NEVER weld in or near explosive atmospheres. Such atmos-
pheres can be created by flammable gas leaks or by vapors
from flammable liquids (gasoline, alcohol, etc.) or by com-
bustibie dusts.
1-14. VENTILATION
. DON'T weld in confined spaces without adequate ventilation.
When welding in confined spaces, provide ventilation in
accordance with United States of American Standard Z49.1,
1967. Always provide adequate ventilation by blowers, air
lines, Or other acceptable means. Never use compressed ox-
ygen. The depletion of the oxygen supply, the heat of weld-
ing, and the fumes given off may cause severe discomfort or a
serious iliness.
When toxic fumes from lead or cadmium bearing materials or
any other substances are present in harmful concentrations,
always use an air supplied respirator.
1-15. SOLVENTS
1-16.
1-17.
Do not weld where chlorinated hydrocarbon vapors from de-
greasing, cleaning, or spraying may reach or be drawn into air
surrounding the welding operation, The heat of the arc can
decompose solvent vapors to form phosgene, a highly toxic
gas and other irritating decomposition products,
Do not weld where ultraviolet light from the electric arc can
penetrate air containing even minute amounts of vapors from
solvents such as trichtoroethylene or perchloroethylene, Ul-
traviolet light can decompose the vapors to form phosgene, a
highly toxic gas and other irritating products.
FIRE HAZARDS
DON'T weld near flammable or combustible materials.
Fires can be caused by the arc, by contact with the heated
metal, by slag, or sparks, Keep combustibles at least 35 feet
from the arc or suitably protected. If welding must be done
in a particular area, move the combustibles away, If they
cannot be moved, cover them completely with fire resistive
screens, Cover cracks or openings in floors or walls: sweep
floor free of combustibles and wet down, if wood, being sure
welder wears insulation shoe coverings. Avoid welding on par-
tion walls in contact with combustibles. Heated metal on
the other side of partition wall being welded upon can ignite
combustibles in contact with the partition. Where other than
a minor fire might develop, have a fire watcher stand-by with
suitable fire extinguishing equipment for at least one-half
hour after the welding is completed,
ELECTRICAL SHOCK-VOLTAGE
. OPEN power circuits before checking machines. -
Before working on the wiring, switches, controls, etc., open
the power line disconnect switch. In most welding shops the
power supply used for arc welding machines is 230 or 460
volts, Open circuit voltages are usually less than 100 volts and
welding or arc voltage drops are still lower. However, all of
these voltages are capable of developing a harmful or fatal
current to the body.
DON'T touch electrically “hot” parts,
NEVER touch any exposed or non-insulated part of the
cables, cable connectors, clamps, electrode holders, elec-
trodes, or the power supply equipment to prevent harmful or
fatal electric shock or burns.
. ELECTRICAL SHOCK-DAMPNESS
NEVER work in a damp area without suitable insulation a-
gainst shock. Keep hands, feet, and clothing dry at all times.
To prevent harmful body shocks, keep hands, feet and cloth-
ing dry. Never stand or lie in puddles of water, damp ground,
or against grounded metal when welding without suitable in-
sulation against shock. Always find a dry board or rubber
mat to stand on when water, moisture, or perspiration cannot
be avoided. Dampness between the body and an energized or
grounded metallic part iowers the resistance to the passage of
current to the body which may produce a harmful or fatal
shock. Salt in perspiration or sea water dangerously lowers
contact resistances.
Figure 1-7. Don’t leave electrode in contact with grounded
metallic surface.
1-19. STARTING UNDER LOAD
DON'T leave an uninsulated electrode holder, or a “live”
1-20.
1-21.
Se
electrode on the table top or in contact with a grounded
metallic surface. {Figure 1-7}
When it is not in use, never place an electrode hotder in
contact with the tabletop or other metailic surface in contact
with welding ground. Provide an insulated hook or holder for
the electrode holder. A potential danger is that a holder in
contact with the ground circuit provides a dead short circuit
on the welding machine, If the machine should be started up,
this short ctreuit would cause an excessive load on the ma-
chine and may darnage the insulation.
FACE PROTECTION
DON'T use cracked or defective helmets or shields.
Keep the helmet, hand shields, or face shield in good condi-
tion. If cracks occur in the fibre material, replace the shield,
since the leakage of arc rays may cause serious burns.
EYE PROTECTION
NEVER under any circumstances, look at an electric arc
without eye protection. ,
Me — к Do =
Figure 1-8. Use eye protection at all times
Make sure that flash goggles are used under the weld-
ing heimet at ali times, particularly while gas shielded-
arc weiding.
In some type of arc welding, such as gas shielded-arc welding,
ultra-violet and infra-red radiation from the arc is particularly
intense and requires constant attention to avoid arc flashes to
the weider when striking an arc and to avoid exposure to
other welders.
NEVER strike an arc without ascertaining that nearby per-
sons either have the necessary protective equipment or are
looking in the opposite direction.
For weiding operations in open areas, provide portable, non-
reflecting screens to shieid persons nearby from the rays of
the arc. Eye burns from the arc, through not generally per-
manent injuries, are exceedingly painful. Such burns fre-
quently referred to as “flashes”, feel like hot sand in the eye.
If the eye is focused on the arc without filterglass protec-
tion, infra-red radiation can cause retinal scarring and im-
paired vision. For eye burns consult your first aid station or
doctor.
NEVER use cracked, ill-fitting, or defective plates.
The filter glass plate provided in the helmets and shields must
be of reputable manufacture conforming to the latest Ameri-
can National Standards Institute, Standard Z2.1. Replace
cracked or ili-fitting fiiter plates promptly.
NEVER use filter plates without a protecting cover glass.
OM-419 Page 3
Keep a clean cover giass in front of the fiiter plate for the
protection thereof. Frequent renewal of these cover glasses is
necessary, since they become covered with spatter, reducing
vision,
1-22, CLOTHING
NEVER use poor, inadequate, or worn-out clothing. Wear
heavy shoes, tightly laced. Keep clothing dry.
| Proper and dry, oil-free clothing is essential for the weider's
1-23,
protection, Clothing must not only keep off the spatter and
molten particles, but must also obstruct the rays of the arc
and, when nacessary, insuiate the body from harmful electri-
cal currents,
Wear leather or asbestos gloves at all times to protect the
hands and wrists. Dark colored shirts are preferred to light
cones because light ones reflect arc rays to exposed parts of
the body. in the case of gas shielded-arc welding, light colors
are more reflective and may cause eye burns due to the in-
tense ultra-violet rays given off by the process. Avoid cotton
fabrics when gas shielded-arc welding.
An arc burn on the skin resembles a sunburn, except that it is
usually more severe. Clothing can be made flame resistant by
treatment with a solution of 3/4 pound of sodium stannate in
1 gallon of water, then wrung out and dipped in a solution of
1/4 pound ammonium sulphate per galion of water. Don't
wash clothing so prepared in water, but dry clean,
When welding operations are to be performed in vertical and
overhead positions, leather sleevelets, aprons, and in some
. cases leggings and ear plugs should be used to prevent severe
burns from spatter and molten metal,
HOT METAL BURNS
NEVER pick up hot objects. (Figure 1-9)
Figure 1-9. Never pick up hot objects
NEVER pick up pieces of metal which have just been welded
or heated, or the stub ends of electrodes which have been
discarded.
1-24. GRINDING AND CHIPPING
Figure 1-10. Never do any chipping or grinding without
NEVER do any chipping or grinding without protective
goggles. (Figure 1-10)
protective goggles.
Page 4
Whenever it is necessary to grind or chip metal, wear protec-
tive goggles specifically designed for this purpose. Serious eye
Injuries may result from failure to wear protective goggles,
1-25. COMPRESSED GAS CYLINDERS
NEVER strike an arc on a compressed gas cylinder. Always
observe the following precautions in regards to compressed
gas cylinders:
1. Avoid accidental contact of the electrodes, electrode
holder, or other electrically energized parts with a
compressed gas cylinder or any other pressure vessel.
Serious accidents or fires may result,
2. Use I.C.C.or D.O.T. cylinders. They are manufactured
and maintained in accordance with D.O.T. require-
ments and are safe so long as they are properly
handled. Don’t drop cylinders,
3. Identify gas content by the name marked on the cylin-
der, If the cylinder is unmarked, do not use it. Return
it to the supplier. Do not rely on a color code.
4. Never use a cylinder or its contents for other than
intended purposes.
5. Keep oil and grease away from oxygen cylinders and
cylinder valves.
6. Keep cylinders away from exposure to sparks, hot
slag, open flame and all possible sources of ignition or
excessive heat.
7. Be careful that cylinders are not placed so as to be-
come a part of an electrical circuit. Avoid third rails,
wires and electric welding circuits.
8. When transporting cylinders by crane, use cradle plat-
form or other suitable support.
9. Never hift the cylinders by slings, by the caps or by
electric magnets.
10. Never use cylinders as supports or rollers.
11, Never try to mix any gases in a cylinder,
12. Never try to refill a cylinder.
13. Mark or tag empty cylinders “Empty” or “MT”.
14. Send “Emptys” back to the supplier prompthy. 15.
15. Keep “Emptys” and“ Fulis” separate.
16. Never tamper with or alter cylinder numbers or other
markings, This is not only foolish but may be illegal.
17. Do not tamper with or change fittings on cylinders,
18. tf valves cannot be opened by hand, do not use ham-
mer or wrench. Notify supplier.
19. Protect cylinder valves from bumps, falls, falling ob-
jects, and from weather. Keep them covered with
cylinder caps when moving cylinders.
20. Keep valves closed on empty cylinders.
21. See that your cylinders are clear of passageways and
active work areas and that they are secured against
falling.
22. If adapter is required between cylinder and regulator,
always use a standard adapter. These may be obtained
from your supplier. Where right and left hand threads
are used on“ adapter, use two wrenches to insure leak
proof connections, -
23. Do not store cylinders in unventilated areas.
— SECTION 2 - INTRODUCTION
DOMESTIC MODELS EXPORT MODELS
Rope Start Electric Start Electric Start Rope Start Rope Start
60 Hz. 60 Hz. 50 Hz. 50 Hz. 60 Hz,
WELDING CURRENT RANGE 45-190 45-190 45-190 45-190 45-190
RATED QUTPUT AMPERES 180 180 180 180 180
DUTY CYCLE 100% 100% 100% 100% 100%
OPEN CIRCUIT VOLTAGE 80 80 80 80 80
115 VOLTS AC POWER 3.5kva 3.5kva 1.5kva 1.5kva 3.5kva
WELD RPM NO LOAD 3600 3600 3600 3600 3600
POWER RPM NO LOAD 1950 1950 1600 1600 1950
24 in. 24 in. 24 in. 24 in. 24 in.
HEIGHT 61cm. 61cm. 61cm. 61cm. 61cm.
22-3/4 in. | 22-3/4 in. 22.3/4 in. 16 in. 16 in.
WIDTH 57 cm. 57 cm. 57 em. 41em, 41cm.
37 in. 37 in, 37 in. 24 in. 24 in.
LENGTH 94 em. 94 cm. 94 cm. 79cm. 73cm.
350 Ibs. 385 165. 385 165. 353 Ibs. 353'Ibs.
APPROX. NET WEIGHT 158.8 kgs. | 174.7 kas. 174.7 kgs. 160 kgs. 160 kgs.
375 Ibs. 410 Ibs. 410 tbs. 465 Ibs. 465 Ibs.
APPROX. SHIPPING WEIGHT 170 kgs. 186 Kgs. 186 kgs. 217 kas. 211 kgs.
2-1. GENERAL
`
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
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 occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. À ccpy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Designation and/or Stock Number and
Serial lor Style) Number of the equipment be supplied.
2-3. DESCRIPTION
ENGINE
Figure 2-1. Specifications
STATIC
EXCITER
RHEOSTAT
REVOLVING
FIELD
WE LD/POWER
SWITCH
115VOLTSAC
RECEPTACLE
AC
REACTOR
WELD
STATOR
OUTPUT
TA-300 044-1A
Figure 2-2. Block Diagram
four cycle engine which is manufactured to specifications
which are required for use with this generator, The engine
features an automatic compression release camshaft for easy
starting.
This engine driven welding generator is designed to be used as
the power source for the ac Shielded Metal-Arc Welding pro-
cess. From 45 to 190 amperes of ac weld current may be
obtained by means of the five coarse range receptacles and
the Fine Current Control. .
115 volts ac power is available at the 3 prong duplex recep-
tacle on the front panel when the generator is being operated
at 1950 rpm on 60 Hz models or 1600 rpm on 50 Hz modeis
{throttle in power position}.
The engine used to drive this generator is a single cylinder
SAFETY
Before the equipment is put into operation, the safety sec-
tion 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, IMPORTANT,
and NOTE blocks found throughout this manual:
E
Installation, operating, and maintenance procedures,
practices, etc., which will result in personnel injury ог
L loss of life if not carefully fotfowed. B
IMPORTANT
Installation, operating, and maintenance procedures,
practices, etc., which will result in damage to equip-
| ment, i
Installation, operating, and maintenance procedures,
i practices, etc., which it is essential 1c emphasize. i
OM-419 Page 5
3-1.
| | о 3-3.
¡ TA-013 597 TA-013 596 TIONS
Figure 3-1, Allowable Tiit Angles Use Table 3-1 as a guide for selecting correct cable size for
~ the anticipated maximum weld current which will be used.
Mounting holes are provided in the welding generator base Table 3-1 takes into account total cable length, which means
for installations which require fixed mountings. Figure 3-2 the length given in the table includes the electrode and work
gives base mounting hole and overall unit dimensions, cable. Exampie: If the electrode holder cable is 75 feet (23
meters) long and work cable 25 feet (8 meters! long, you
A lifting eye is provided on top of the unit for moving pur- would select the size cable that is recommended for 100 feet
poses, (31 meters) at the maximum weid current you wil be using.
y Table 3-1. Welding Cable Sizes
If this unit is to be operated indoors, it should be Welding *Total Length of Cable {copper} in Weld Circuit) 206
located in a place where the engine exhaust fumes can Ampere 2 0 д = = > A == = 1/0
be vented out of the building. Failure to comply with 150 | 2 2 > "e 1/0 2/0 3/0 3/0
this recommendation may result in serious bodily in- 200 [1 14 q 140 2/0 2/0 4/01 . 4/0
I jury or loss of life. | 250 1/0 1/0 1/0 2/0 3/0 4/0 ‘4/6| 2-2/0)
| . ТА-901 181-10
3-2. GENERATOR CHASSIS GROUND (Figure 3-3) | 8
NOTE: “A. SO FEET OR LESS
, - . -8. CABLE SIZE IS BASED ON DIRECT CURRENT (DC), 100% DUTY
Normally engine driven welding generators are not required CYCLE AND El THER A 4 VOLTS OR LESS DROP OR A CURRENT
{о be grounded. However, this machine has auxiliary power .. DENSITY OF NOT OVER 300 CIRCULAR MILS PER AMP. SA
plant capability, therefore, grounding of the frame and case is STAND TES rea AU CL TAR eo OR me
recommended, For this reason a convenient grounding ter- WELDING POWER GENERATOR MUST BE USED. WHILE MOST
minal is provided on ali weider/power plant units. For de- O NE GENERATORS HAVE AN. OPEN Cle T
tailed grounding instructions consult your local or state codes ENE Ras ome OF SPECIAL Ces TSS Nave NIZA OPEN
or the latest issue of the National Electric Code. CIRCUIT VOLTAGE. : | :
— |
|
| 12-1/2" ai
* (20cm) (31.8cm) 24
: | | (61cm)
rr -
*(230m) (22.9em) |
To. 10-1/8" +
*(22.5em] (26.0cm) |
| 23/8" р”
+ | 4” (8.0cm) co or
*{14.9cm) le ; a - a >
-.. i Ú 22-3/4 SEE {94cm}
| 5 (57cm) | *(79em)
GENERATOR END *{41em) . .
EE (5.1em) |
*Export Model
Page 6
LOCATION
A good installation is essential if the generator and engine are
to provide satisfactory and dependable service. To ensure
proper carburetor and engine lubrication, the engine manu-
facturer recommends that the unit be set on a fairly level
plain when operating. Tilting not to exceed 23° on the car-
buretor side and 309 on the other three sides is recom-
mended by the engine manufacturers. Figure 3-1 shows the
maximum allowable tilt of the unit during operation.
IMPORTANT
MAX. FORE AND AFT TILT
IMPORTANT
MAXIMUM SIDE TILT
Equipment
Grounding
Terminal
TB-906G 044-3
Figure 3-3. Generator Chassis Grounding
WELDING CABLES AND JACK PLUG INSTALLA-
Figure 3-2. Dimensional Drawing -
—TB-900 044-1
Two jack plugs are furnished with this unit. Follow instruc-
tions carefully for proper installation of the jack plugs to the
welding cables. See Table 3-1 for proper welding cable size.
Standard jack plugs furnished with the unit will accommo-
date cable ranging from Size 6 to Size 1.
1. Clamp the welding cable in a vise with the uninsulated
end protruding upward out of the vise approximately
1-3/4 inches (45mm).
2. Place the steel tie wire (See A Figure 34) approxi-
matety 1/4 inch (6.4mm) from the end of the insula-
tion,
UN
TA-901 024-4
Figure 3-4. Jack Plug installation
3. Make a half turn around the cable bringing the {coped
ends of the tie wire together.
4. insert a rod of approximately 3/8 inch {10mm) dia-
meter through the two looped ends of the tie wire.
5, Twist the tie wire (B) until the entire tie wire is
twisted and is tight around the insulation of the weld-
ing cable. :
6. Clip off the looped ends of the tie wire.
7. Bend the untwisted tie wire over along the side (C) of
the uninsulated portion of the welding cable.
8. Wrap the strip of copper foil tightly around the unin-
sulated end of the welding cable and the twisted tie
wire (D).
9. Place the jack plug on the end of the welding cable
and push it onto the welding cable over the copper
coil (E).
10. — Insert the 1/4-20 set screws into the center and upper
. holes in the jack plug and tighten.
11. Remove the welding cable from the vise and insert the
jack plug into the fiber sleeve. Slide the fiber sleeve
over the jack plug and welding cable until the hole in
the fiber sleeve lines up with the 1/4 inch (6.4mm)
hole in the jack plug. '
12. Insert the 1/4 inch (6.4mm) self tapping screw
through the hole in the fiber sleeve into the jack plug.
Tighten the screw with a screw driver.
mme SECTION 4 - ENGINE PREPARATION rm res
See the Engine Manufacturer's manual for complete
De Core, o I
ENGINE LUBRICATION
All engines are shipped from the factory with their crankcase
filed with the required type and amount of break-in oil.
Before attempting to operate the engine, make sure the oil
level is checked.
The break-in oit should be drained after about 40 to 50 hours
of operation. If service or loading is at an extremely high
duty cycle during this period, or air and environmental condi-
tions are dusty and dirty, the oil should be drained after
about 2b hours of operation. Also, continued operation of
the unit in high temperature (above 909F or 32.29C.} wil!
necessitate an oil change after about 25 hours of running
time.
When changing the break-in oil, use a good detergent type cil
having an A.P.i. service designation of ms’. Refer to Figure
4-1, "Temperature-0il Viscosity Guide’, for proper weight
ol! to use in various operating temperatures, The oil capacity
of this engine crankcase is 5 U.S. (4.16 Brit) pints. Always
check the oil fevel after a change with the bayonet type
indicator in the oil filler tube.
CHECK OIL LEVEL
La]
F
{-1.11°C)
OE
(17.8%)
т
4
НЧ "pp
USE API
i SERVICE
MS OIE
e TA-900 044-2
Figure 4-1. Temperature - Oil Viscosity Guide
4-2.
4-3.
IMPORTANT |
Check oil level daily. During the break-in period,
check the oil level several times per operating day as
some new engines may use oil until the piston rings
etc. have seated. If oil must be added to the break-in
oil, use an oil type and weight as explained in the
I preceeding paragraph and Figure 4-1; I
FUEL
IMPORTANT &
= Do not mix oil with the gasoline. I
Use a good grade of “regular” gasoline, rated at least at 85
octane, for this engine. Fuels of lower octane ratings may
cause detonations {knocking} which could result in damage
to the engine bearings and head gasket. The fue! capacity of
the fuel tank is 1.5 gallons {U.S. Measure}.
CAUTION |
"A.
Never allow the fuel to drain on the engine, the
generator, or other components. Arrange provisions
for catching the fuel when being drained and if the
tank must be drained frequently, install a valve and
drain line in the tank. When filling the fuel tank, do
not fili completely full. The reason being that the cold
fuel will expand due to engine heat and the outside air
when operating in a warm climate. If the tank is too
full, it will overflow causing a potential fire hazard.
Also, do not attempt to fill the fuel tank with the
| engine running, always shut the engine down first. I
READYING NEW BATTERY FOR SERVICE (Elec-
tric Start Models Only}
This battery is shipped from the factory in a dry state, A
sufficient amount of electrolyte is shipped along in separate
OM-419 Page 7
— SECTION 5-FUNCTION OF GENERATOR CONTROLS
containers to activate the dry charge battery. To prepare the
new battery for operation, proceed : as follows:
Put on protective eye cover and clothing prior to pour-
ing the electrolyte solution,
1. Remove the battery from the unit and’ place | rf on a level
work table or other suitable area.
2. Filt the battery cells to the required level with electrolyte.
Do not dilute this electrolyte as it is pre-mixed to the
| required strength. I
3. Place a battery thermometer in one of the center cells and
check the specific gravity of each cell with a battery
hydrometer,
4. The battery temperature must be above 80°F and the
specific gravity reading above 1.240 prior to installation.
If both conditions are not met, charge the battery follow-
ing the beiow instructions:
a. Use an automotive type battery charger. This battery
should be charged at about a 3.5 ampere rate until
Weld-Power
| — Switch
— Fine Current
Coarse Current 45.60 100-140 Control
Range >
Receptacles `
ceptace 115 Volts ac
51.
. Electrode And Work Receptacles
Page 8
Work —
Receptacle
L— Receptacies
| = 3
т a
Figure 5-1. Control Panel View
CURRENT CONTROL (Figure 5-1)
. This welding generator is equipped with five Electrode
receptacies and one Work receptacie. The five Electrode
receptacles provide five ac welding coarse amperage ranges.
To select the amperage range desired, insert the electrode
cable jack plug into the desired Electrode receptacle. The
work cable jack plug must be inserted into the Work recep-
tacie and the opposite end connected to the workpiece.
Fine Current Control
The Fine Current Control permits selection of the eXact
amount of weld current desired within the range being used.
As the Fine Current Control is rotated in a clockwise direc-
tion, weld current will increase.
When utilizing the 115 volts ac receptacle, the Fine
Current Control must be set at the 100 (maximum)
1 position. : ;
The scale which surrounds the Fine Current Control is cali-
brated in increments of ten from Q to 100 percent. Due to
this percentage calibration, it should be noted that if the
operator is using this scale to select a fine amperage setting,
TA-900 044-6
5-2.
5-3.
correct electrolyte conditions are met. Lower charging
rates can be used, however, the time to obtain the
correct electrolyte conditions will ba longer.
b. When the battery is charged, remove it from the
charger and re-check the electrolyte level, Add if
necessary.
С. Rinse out the empty electrolyte containers with water
before discarding. Since battery acid is corrosive to
metals, do not pour into a metal sink or drain. Rinse
and mutilate the empty electrolyte container before
discarding. If acid has accidentally spilled on the bat
tery or work. area during filling or charging, flush and
mutilate the empty electrolyte container before dis-
carding. If acid has accidentally spilled on the battery
or work area during filling or charging, flush off with
clear water and neutralize with soda or ammonia solu-
tion. Use the same procedure if acid is spilled on cloth-
ing.
5. Re-install the battery in the unit making sure that the
negative (—) terminal of the battery is connected to the
ground cable.
IMPORTANT
Do not attempt to operate the engine without the
battery connected. Also, do not attempt to remove
the battery while the engine is running
|
the operator is selecting a percentage of the coarse range in
use and not an actual amperage value,
WELD/POWER SWITCH (Figure 5-1} |
A Weld/Power Selector Switch, located on the front panel! of
the generator, is provided to select either weld power or 115
volts ac power output from the generator.
When the generator is operated as a welding generator
the Weld/Power Switch must be in the WELD position
and the throttle lever in the WELD position. When
. operated as a power plant, the weld/power switch
-must be placed in the POWER position and the
throttle lever placed in the POWER position,
115 VOLTS AC RECEPTACLES (Figure 5-1)
115 volts ac is considered standard power. However, if
special output voltages and frequency were ordered in
the unit, refer to the nameplate on the unit for fre-
quency and output voltage and required engine rpm
for the given output, In some cases, the duplex recep-
tacle may be replaced with a receptacie designated by
the purchaser or customer. The basic instructions for
connection and operation as a power plant remain the
1 same. i
This generator is capable of furnishing up to 3.5kva of 115
— volts ac power on 60 Hertz models and 1.5kva of 115 volts ac
power on 50 Hertz models for operating various motors and
other 115 volts ac equipment. This is single phase power. -
AC voltage will decrease in accordance with the {oad applied
to the 115 volts ac Receptacles. This generator is designed to
deliver 30.5 amperes at 115 volts ac on 60 Hertz models and
13 amperes at 115 voits ac on 50 Hertz models provided the
engine rpm is up to specifications.
5-4.
(ELECTRIC START MODELS ONLY)
6-1.
6-2.
VOLT-AMPERE CURVES (Figure 5-2)
These volt-ampere curves show the ac output voltage avail-
able at any given output current within the limits of the
minimum and maximum Fine Current Control setting. Load
voltage Is predetermined to a large degree by arc character-
istics. Wi th the use of the volt-ampere curves, itis possible to
determine the amperage required for a particular load volt
age.
START BUTTON
- STOP SWITCH
(ELECTRIC START MODELS ONLY)
STOP SWITCH
(MANUAL START MODELS ONLY)
80
70 MW
©
o
AC YOLTS
in =
o oo
SECTION 6- FUNCTION OF ENGINE CONTROLS
NAMEPLATE RANGE MARKINGS
A 45-60
в 60-7 5
с 75-100
D 100-140
E 135-MAX.
a
“
“
.
`
D x
\ \
A pe
LA Г
| 1, E $d 1 1
100 125 150 175 200 225 250
А С AMPERES B-002 312
Figure 5-2. Volt-Ampere Curves
CHOKE
CONTROL.
THROTTLE
CONTROL
T8-900 044-7
Figure 6-1. Engine Controls
CHOKE CONTROL {Figure 6-1)
A CHOKE Control is provided for varying the fuel-air mix-
ture to the engine. When the CHOKE Control is rotated fully
counterclockwise, very little air will be admitted to the en-
gine 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 rotate
the CHOKE Control clockwise siowly untit it is rotated
clockwise as far as it will go. When the CHOKE Control is
fully rotated clockwise the engine should be ready for opera-
von. -
THROTTLE CONTROL (Figure 6-1)
The Throttle Control provides the operator with the capa-
bility of selecting either WELD or POWER engine speed,
6-3.
6-4.
To place the engine at WELD rpm, push the Throttle Control
in a downward direction as Tar as it will rotate. To obtain
POWER rpm, push the Throttle Control in an upward direc-
tion as far as it will rotate,
STOP SWITCH (Figure 6-1)
A Stop Button is provided on the engine for shutting the
engine down. To stop the engine, depress the Stop Button
until the engine ceases to rotate,
START BUTTON (Figure 6-1){Electric Start Models
Only
- Depressing the Start Button wiil engage the engine starter and
thereby start the engine. The Start Button must be released
as soon as the engine starts or resulting damage to the starter
will occur,
OM-419 Page 9
— SECTION 7 - SEQUENCE OF OPERATION
7-1.
7-2.
7-3.
Never operate the unit with the wrapper removed. If
the wrapper is removed, a safety hazard exists to per-
sonnel from moving and electrical components. Also,
weather protection to the internal components of the
y unit will be greatly reduced. '
STARTING THE ENGINE
IMPORTANT $
Make sure all electrical equipment connected to the
115 volts receptacle is turned off before starting the
engine. The engine when starting has low speed which
causes low voltage at the output receptacle of the
generator. This could result in damage to electrical
E equipment.
1, Fill the fuel tank and check to ensure that the oil leve! is
adequate.
2. Rotate the Choke Control fully counterciockwise. Lesser
degrees of choking may be required if the engine is warm.
3. Place the Throttle Control in the POWER position.
~ 4. On models without electric start, give a quick steady pull
on the starter rope. For models with electric start, depress
the Starter Button,
B. Once the engine has started, siowly rotate the Choke Con-
trol clockwise,
6. Allow the engine to run for a few minutes before applying
a load. This is necessary to enable the engine to properly
warm up and ensure proper lubrication,
7. Place the Throttle Control in the desired position.
STOPPING THE ENGINE
1. Remove the load from the welding generator.
2. Place the Throttle Control in the POWER position.
Operate the engine at this speed for 2 minutes; this will
allow internal engine temperature to equalize.
3. To stop the engine, depress the Stop Button.
SHIELDED METAL-ARC WELDING
1. Prepare the engine for operation as instructed in the en-
gine preparation section.
2, Make weld connections from the electrode holder jack
plug to the desired range receptacle and from the work
clamp jack plug to the work receptacle.
3. Rotate the Fine Current Control to the desired setting.
4. Place the Weld/Power Switch in the WELD position.
5. Start the engine as instructed in paragraph 7-1.
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious and even permanent
bodily damage.
6. Connect the work clamp to the object to be welded, place
the desired electrode into the electrode holder, and com-
mence welding.
TB-800 044-5
Figure 5-1. Shielded Metal-Arc Welding Connection Diagram
7-4.
115 VOLTS AC POWER OPERATION
1. Prepare the engine for operation as instructed in the En-
gine Preparation Section,
2. Rotate the Fine Current Control fully clockwise to the
100% setting.
3. Place the Throttle Control on the Engine in the POWER
postition,
4. Start the engine as instructed in paragraph 7-1.
5. Connect the auxiliary equipment or desired load to the
receptacle and commence operation.
8-1.
Page 10
- CAUTION
If any work is to be done on the rotor of the genera-
tor, remove the spark plugs from the engine. This witl
prevent engine compression from turning the rotor
and catching the repairman's hand between the rotor
. fan casting and the stationary adapter casting. I
GENERAL
Economical operation and trouble-free service of this welding
generator are based upon regular inspections and reasonable
attention.
Occasional blowing out of the unit with clean dry com-
pressed air is recommended, This should be performed peri-
odically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere.
8-2.
8-3.
COLLECTOR RING BRUSHES
The brushes should be inspected periodically to ensure their
proper function. The brush life 1s very good under nomnal
conditions. If the generator has been operating in an ex-
tremely dusty or dirty location, a close check of the brushes
for freedom of movement and cleanliness should be made
weekly. Under normal use the slip rings will discolor to a
dark brown. If it should become necessary to clean the slip
rings, use a 3/0 or finer sandpaper followed by a crocus cloth.
Never use emery cloth as part of the emery will embed itself
into the exciter or collector rings and in turn destroy the
carbon brushes.
WELDING CABLES
Check connections periodically for tightness. The cables
should be inspectéd frequently. and all breaks in the insula-
tion should be repaired with electrical insulating tape or the
cables replaced.
9-1.
9-2.
9-3.
LUBRICATION
This engine will require at least 10 hours of running time to
become fully broken in. During this period, the load on the
engine should be kept as light as possible. The oil level should
be checked a number of times during an operating day, as
some engines will use oil during the break-in period. After
about 40 to 50 hours of running time on the break-in oil,
drain the oil. Premium heavy duty oil, manufactured by any
one of the major oil companies, should be used as a replace-
ment ail. Tabie 4-1 gives a list of recommended grades and
types of oi! to use to keep oil level up during break-in and to
use after the break-in oil is drained. The oil capacity of the
engine is 5 pints, Check the dip stick to make sure oil level is
up to the required operating level.
In normal operation, oil should be changed after about 25
hours of operation. The oil should be drained after the engine
has been warmed up to normal operating temperature, thus
promoting foreign particle suspension in the oil and thereby
removal when the oil is drained. Foreign particles tend to
settle at the bottom of the crankcase when the oil is allowed
to cool, thereby avoiding removal and thus contaminating the
new oil added, |
CLEANING THE ENGINE
This air cooled engine operates most efficiently when kept
clean. Maintain cleanliness at all times. Wipe oil spills from
engine immediately to avoid accumulation of dust.
SPARK PLUGS
IMPORTANT
Do not attempt to clean the spark plug electrode by
sandblasting. Particles of abrasive may stick to the
spark plug and thereby enter the engine and cause
damage to the internai engine components. Also, the
I spark plug gap shouid be kept at .025”. | ]
The area around the base of the spark plug should be cleaned
95.
9-4.
9-6.
prior to removal of the spark plug to help avoid dirt getting
into the engine,
Remove the plug periodically and clean the electrode with a
wire brush or knife blade. Take care so as not to crack the
porcelain insulator-on the spark ptug.
FUEL FILTER
The fuel fiiter is located below the fuel tank. Check the
sediment bowl periodically for water and dirt deposits. How
often the filter has to be checked will depend on the grade of
gascline used and how dusty and dirty the location in which
the engine is being used.
AIR CLEANER
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. If dirty air gets
into the engine, it can wear out a set of piston rings within a
few operating hours.
. This engine is equipped with a dry paper type filter element.
Dry paper element type cleaners can be cleaned by removing
the element and tapping lightly, causing loose dirt to fall off.
The element should be replaced if dirt does not drop off
easily.
The paper element should be handled with care to avoid
perforations. Removing the dirt with compressed air can rup-
ture the paper element. Check to ensure that gasket surfaces
of element are not bent or damaged in any way. Gasket
surfaces must seal tightly at top and bottom of cleaner shell
to prevent foreign matter from entering the carburetor.
Whenever air cleaner is removed, cover air intake hole to
prevent dirt from falling into carburetor.
PERIODIC SERVICE
The efficiency of the engine depends a great deal on the care
and attention given it. By following a definite schedule of
- inspection and service, engine failure caused by neglect can
be avoided. Service periods are based on hours of running
time and are for normal operating conditions, For extreme
conditions of load, dust, dirt, etc., service more often.
Table 9-1. Periodic Engine Maintenance Chart
Each Every Every Every Every
PERFORM SERVICE AT INTERVALS INDICATED (X) Day 25 Hours 50 Hours 100 Hours 500 Hours
CHECK OIL LEVEL (maintain in safe operating range) ..... к) X
CLEAN AIR INTAKE SCREEN (plus other external surfaces). ..|.. X
REPLENISH FUEL SUPPLY (Use clean, fresh fuel) ..........}.. X
CHANGE OIL (Use API Service MS of proper weight) ........L.........}.. > €
SERVICE FUEL FILTER (remove and clean sediment bowl) ...|........[.... X
CHECK AIR CLEANER ELEMENT ..... vinnie anche oe. X
SERVICE SPARKPLUG {gap for.025”) .... o.oo oi, X
SERVICE BREAKER POINTS (gap .020”) .......... 2.222 rene ros, X
NOTE: Intervals stated are for good, clean operating conditions — perform services more frequentiy if dusty or dirty conditions prevail.
——— SECTION 10. GENERATOR TROUBLESHOOTING mes
INTRODUCTION
This data collected here, discusses some of the common problems
which may occur in this welding generator. A little thought will
probably solve the problem involved through the information pro
vided.
The assumption of this data 1s that a proper welding condition has
been achieved and has been used until trouble developed. In atl cases
of equipment malfunction, the manufacturer's recommendations
should be strictly adhered to and followed.
If after performing the following procedures the trouble is still not
remedied, it is recommended that a serviceman be called.
It is recommended that the circuitdiagram be used for reference
during the troubleshooting.
OM-419 Page 11
TROUBLE
PROBABLE CAUSE
REMEDY
No weld output.
Weld/Power Switch in POWER position.
Place Weld/Power Switch in WELD Position.
Poor connections on WELD/P OWER Switch.
Fuse F1 biown.
Replace fuse and check for defective associated
circuitry,
Low weld output.
Throttie control is in POWER position.
Place Throttle ono in WELD position.
Low engine speed with Throttle Control in
WELD position,
load speed).
Check engine speed which should be 3600 mm (no
Engine may require servicing or
overhaul- Ä
Poor coilector ring connections or defective
brushes,
Check collector ring for good brush contact. Use
3/0 sandpaper if it is necessary to clean sip rings.
install new brushes if necessary.
Fine Current Control defective.
Check for defective or loose connections on
rheostat R1. Replace rheostat If defective.
Low or no power output.
WELD/POWER Switch is in WELD position,
Place WELD/POWER Switch in POWER position.
Engine speed below normal power engine
throttle setting.
Check engine speed. If it is incorrect (1900 fom on
60 Hz models and 1600 rpm on 50 Hz models) see
engine manual for adjustment procedure,
Erratic weld current.
Damp, defective or wrong type welding
electrodes.
Try different electrodes.
Improper connection to workpiece.
Check and tighten any loose connections,
Jack plugs connected to WORK and
COURSE CURRENT RANGE Receptacle
are loose.
Twist jack plug in a clockwise direction to insure
tight fit.
Page 12
SECTION e
CARBURETION
Сре)
| FAILURE TO START |
ENGINE TROUBLESHOOT! NG
Mechanical
1
|. IGNITION
[compression]
Cylinders dry.
Sticking valve,
Loose or broken spark plugs.
Cylinder head gasket leaking,
Piston rings stuck,
Warped or broken valves,
Poor grade] [Restricted air cleaner, Plugs wet Breaker points pitted
of fuel Fue! pump diaphragm or dirty. or fused.
Water Choke Condensation | ISpark plug insulation bad,
in fuel Flooded on electrodes, | [Breaker arm sticking.
Gum Birt or gum holding Weak battery [ lImproper timing,
in fuel float needle valve Broken ignition cables.
Dirt Damaged HS needle valve. Ignition cables
in fuel Fuel line clogged. disconnected.
Improper Air vent, filler cap plugged. Wires to wrong plugs.
volatility Manifold gasket leak.
No fuel Muffler clogged.
| KNOCKING |
L
CARBURETION
MECHANICAL |
| IGNITION |
Poor grade of fue!
Octane rating to low | --
Heavy load at slow speed.
“1 Carbon or lead deposits in
-) Breaker points
too far advanced
cylinder head,
Loose connecting rod,
Loose main bearings. :
Burned out connecting rod,
Worn or loose piston pin,
Worn or loose timing gears,
Improper piston fit.
Valve fash too great.
Vaives sticking.
| | MISSING |
CARBURETION
Water in fuel
Gum in fuel
Dirty fuel system.
Vapor lock.
improper needle valve.
Improper carburetor
Improper fuel mixture.
Inoperative fual pump
(Dirt or mechanical).
Air leaks in system.
Defective float mechanism
Inoperative choke control
COMPRESSION
| Scored cylinders,
Improper valve lash,
Sticking valves,
Loose or broken spark plugs.
Cylinder head gasket leaking,
- | Piston rings stuck.
Warped or broken valves.
Sand hole in casting,
Valve springs weak or broken.
| OVERHEATING |
"=
CARBURETION|
—
[LUBRICATION]
|
Low grade of fuel.
Engine operated white
detonating, due to
low octane fuel or
heavy load.
Improper carburetor
setting.
Plugged air filter.
Leak in intake system.
ENGINE
FLYWHEEL
ALTERNATOR
On supply low,
Dirty or incorrect
grade of oil,
Engine overicaded,
Carbon deposits in
engine,
Restricted exhaust,
Choke control partially
pulled out,
Valves leaking.
Restricted air cleaner,
Recirculation of hot air.
Improper break-in,
| SURGING ___|
Improper heat range in plug.
Loose plug.
Poor insulation om plug.
Spark plug gap incorrect.
Worn and leaking ignition cables,
Wealk spark,
Loose electrical connections.
Breaker points pitted or worn,
Breaker paints sticking.
Improper tension of breaker point
spring. ‚
Improper breaker point gap.
Bad condenser.
Weak cout,
Worn out plug .
Defective ignition switch,
Grounding of ignition adcessories,
Moisture
Carburetor flooding.
Improper adjustment.
intake leaks.
Sticky controls
Improper lubrication,
WELD
52
78
OPERATED BY ENGINE THROTTLE
POWER
No E GROUND
— FE
- POWER
79
POWER
WINDING
WINDING
STATIC EXCITER PANEL
ELECTRODE
16
e
WORK
Circuit Diagram No. CB-900 044-1P
Figure 7-1. Circuit Diagram For Manual Start Model
OM-419 Page 13
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Page 14
September 1973 FORM: OM-419
Effective with serial No. 71-593696
MODEL STOCK NO.
ROUGHNECK 1 900 044
ROUGHNECK 1E 900 286
ROUGHNECK 1F 900 611
MODEL/STOCK NO, SERIAL/STYLE NO. DATE PURCHASED
PARTS LIST
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
RIN TE,
1
NWSA CODE NO. 4579
TD-200 286A
Main Assembly
Figure A —
ОМ-419 Раде 1
Quantity
Model
Manual “| Electric
Item Dia. Factory Start Start
No. Mkgs. PartNo. Description Export | Domestic | Domestic
Figure A Main Assembly
1 014313 WRAPPER............eorroveroroccereoomeracoeoo 1 1 1
2 Figure B GENERATOR & REACTOR (SeePage 3) .............. 1 1 1
3 602 018 SCREW, cap-sockethd 7/16-14x 1-1/2. ,.............. 1 1 1
4 602 215 WASHER, lock-split 7/16 .........—r—resresorencaras 1 1 1
5 602 226 WASHER, flat-7/16 ID x 2-1/4 OD x 3/16 ............. 1 1 1
6 603 945 KEY, 1/4x 7/8 ..L1120 40040 0 4 0 40 a aa a кк кк какие о . 1 1 1
7 017742 ADAPTER, fan ........eeoererverororeseorerrenea. 1 1 1
8 FigureC PANEL, rear with components (See Page 4) ............ i 1 1
9 038107 ENGINE (consisting Of). ........rre=errareorreerec.. 1 1
10 020251 , SWITCH, with leads {consistingof) .................. 1 1
11 015503 ..BRACKET mountingswitch ...................... 1 1
12 52 *027 878 ..SWITCH, limit-leaf actuator SPDT ................. 1 1
13 010298 .NIPPLE, 1x3 ........iremeresvsarereroarecncero, 1 1
14 *015 621 .MUFFLER .......ce.e.eemerereccioraareamavonor i 1
9 026 526 ENGINE (consisting of) ...........ece.esomrerevcameea i
10 022 496° . SWITCH, with leads (consisting of) .................. 1
11 015503 .,.BRACKET, mountingswiteh ...................... 1
12 S2 *012 879 ..SWITCH, limit-dual actuator DPDT . . ............... 1
13 010 298 .NIPPLE,1x3....... _—ererereserarecarercereree.. 1
14 *015 621 MUFFLER .....i..recrarareanoom0necndrovmacaroeno 1
15 024117 ADAPTER, engine.........esronmeacanesne, FU eee = 1 1 1
16 025576 PAN, base ......o_ecececdcracrorereve norvrreocareco. 1 i 1
17 010955 WASHER, flat 13/32IDx20Dx 1/8 244100000000 0 3 3 3
18 015754 MOUNT, engine......eoeracreararoro0serareseamarne. 2 2 2
19 021993 BASE... 101224 20 1e a a 4 a 4 0 4 a a a ee ea a ae a a en eue» 1
19 021990 BASE.......reareserecvoeserecrserarocnarmedvorere, 1 1
20 017175 PANEL, side ..........errrececarerareeroce cea. 2 2 2
21 022017 MOUNT, generator ......r_eereesrorvoresvvreonerec. 1 1 1
22 010 954 WASHER, flat 13/32 ID x 1-1/4 0D x 1/8 .........e..e. 3 3 3
23 604 435 BOLT, carriage 5/16-18x 7 ............ coun... ... 2
24 Batt *604 207 BATTERY, 12 volt 95 amp-hour........e s_ereeresneoo. 1
023652 CABLE, battery-positive .....1044400 0000000 an en ua 0 + 1
023 653 CABLE, battery-negative ......_e.ecoreroroenesonoorane. 1
25 017222 FHOLDDOWN, battery ........—._eceremorvororereara, 1
26 Figure D PANEL, front with components (See Page 5) ........... 1 1 1
022152 SWITCH ASSEMBLY, stop .......oeaarooroerorvera. 1
039608 PLUG ASSEMBLY, jack (consistingof) ............... 2 2 2
019833 STRIP, copper ..........o.eresasrarerecdereoreo. 1 1 1
101 219 PLUG, J2CK ........er—eedonvoreroreoresereerean. 1 1 1
602 814 INSULATOR, molded-red ........... PARA 1 1 1
602 160 .SCREW, self-tapping filister hd 8-32 x 1/4 ............ 1 1 1
602 178 SCREW, set-sockethd 1/4-20x 3/8 ......... 0... 2 2 2
025 918 KIT, label (includes alllabels) ....................... 1 1 1
*Recommended Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-419 Page 2
Quantity
Model
Manual Start Electric Start
Item Dia. Factory 50 Hz 60 Hz 50 Hz 60 Hz
No. Mkgs. Part No. Description 115V !230V |115V| 230V | 115V | 230V | 115V1 230V
Figure B Generator 8: Reactor (See Fig. A Page 2 Item 2)
36 018614 BRUSH SET, electrical (consisting
of) Lea 2 2 2 2 2 2 2 2
37 *020 034 . BRUSH, withspring .......... 1 1 1-1 1 1 1 1
38 600270 HOLDER, brush ............. 1 1 1 1 1 1 1 1
.39 018665 .CAP, holder ................ 1 1 1 1 1 1 1 1
40 018 641 BRACKET, mountingbrush holder 1 1 1 1 1 Л 1 1
41 Z 036 182 REACTOR .................. 1 1 1 а 1 1 1 1
42 017756 ROTOR (consistingof)......... 1 1 1 1 1 1 1 1
43 OL7 624 .FAN ... ..emerrorarerean ea 1 1 1. 1 1 1 1 1
44 024616 BEARING ................. 1 1 1 1 1 1 1 1
45 024 617 . RING, retaining-bearing ....... 1 1 1 1 1 1 1 1
46 022 040 STATOR ................... 1
46 **022 041 STATOR ................... 1
46 **022 038 STATOR. ................... 1
46 **022 039 STATOR ............. ea 1
46 **022 036 STATOR ................... 1
46 **022 037 STATOR ................... 1
46 **022 034 STATOR ......... eee 1
46 **022 035 STATOR ................... 1
47 017763 ENDBELL .................. 1 1 1 1 1 1 1 1
*Recommended Spare Parts.
**R otor and Stator Replacements are available on exchange basis. Contact Factory Service Department for details.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
Figure B — Generator & Reactor
TE-018 223
Quantity
- Model
Item Dia. Factory | Manual | Electric
No. Mkgs. Part No. Description Start Start
Figure C Panel, Rear With Components (See Fig. A Page 2 Item 8)
51 038 432 CIRCUIT CARD ASSEMBLY (consisting of) ...... PARA 1 1
52 Cl 604 005 .,CAPACITOR, metalized-paper 4 uf 150 volt de ..........e.ece o. 1 1
53 C2 031643 CAPACITOR, ceramic 0.01 uf 500voltde .................... 1 1
54 Fl 023014 FUSE ............... enano. eee eae era eee 1 1
556 01-10 027 369 . DIODE, 3 amp 600 volt straight polarity ................... a 10 10
56 022112 PANEL, rear ......eecoeeoenorerorerercóreneoo eee eee 1 1
57 015 712 GROMMET, rubber 5/8 ID x 7/8 hole x 1/16 groove ............. 1 1
58 CB +*012 612 CIRCUIT BREAKER, 10 amp (Spencer) or | |
58 CB +*027 889 CIRCUIT BREAKER, 10 amp (ETA) ...........eemenmanarac 2. 1
59 DH 027 856 DIODE, withlead &terminal ......... viverra. 1
60 C4 031722 CAPACITOR, mylar 1uf200volt. ........ coins. 1 1
61 010 311 CLAMP, steel nylon coated 3/4 dia .........e.eesrersmoró reo. 1 1
62 014159 BRACKET, mounting-capacitor...........o._ec-e—r.. enreda. 1 1
63 C38 031601 CAPACITOR, paper-oill 10 uf600voltde ...................... 1 1
64 Ll 036 011 CHOKE, 30 milli-henry .........e_eeeenaadonaoanvaranoaarorna 1 1
Figure C — Panel, Rear With Components тс-022 115
*Recommended Spare Parts.
+Be sure to order correct circuit breaker, as the mounting holes are different.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS,
OM-419 Page 4
*Recommended Spare Parts |
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
/
Figure D — Panel, Front With Components
Item Dia. Factory
No, Mkgs. PartNo. Description Quantity
Figure D Panel, Front With Components (See Fig. A Page 2 Item 26)
91 Work 039 800 RECEPTACLE ASSEMBLY, jack-red (consistingof) ............... 1
92 039 768 NUT, terminal-red ,.......oe_eseauenaraaaaaoononad—anararira 1
93 010 291 | WASHER, flatmylafil 5/81 Dx 1-1/40Dx 1/8 .................. 1
94 604 668 -.NUT, steel-self locking hex hd 1/2-20 .............. 2... a. .... 1
95 020 015 .RECEPTACLE ..........esrecsrorerrenvoreroovedroneono ne 1
96 601 881 NUT, steel-hex jam 1/2-20 . ci eee, 1
97 Elect 039 801 RECEPTACLE ASSEMBLY, jack-black (consisting of} ............. 5
98 032 796 NUT, terminal-black .............. eee eee 1
99 010 291 .WASHER, flat mylafil 5/8 ID x 1-1/4 OD x 1/8 .................. 1
100 604 668 1 NUT, steel-self locking hex hd 1/2-20......... .... eee eee 1
101 038198 .RECEPTACLE ......ee..0resonvacaeervanedrerernaonarerene a 1
102 601 881 .NUT, steel-hex jam 1/2-20 .............000000edo0orie.o aaa 1
108 Si *011 622 SWITCH, togele 3PDT 15 amp 125 volt ........._e-r.erorerereoo. 1
104 Ri *030 987 RHEOSTAT, WW 50 watt 25 ohm ......oeeeeonrerdaresvananerdoo ‚1
105 RC1 604176 RECEPTACLE, duplex-ground straight 2P3W 115 volt or
105 RC1 604103 RECEPTACLE, duplex-ground straight 2P3W 230 volt ............. 1
106 010 014 CLAMP, steel-cushioned 11/16 dia ........e.eecreoresrerveeraroo 1
107 017180 PANEL, front........................ eae 1
108 NAMEPLATE (order by stock, model & serial numbers) ............ 1
109 024 366 KNOB, pointer line indicator 1-1/8 OD x 1/4 bore.............e... 1
TC-018 247