Miller AEA-200LE User manual

Miller AEA-200LE User manual
 January 1977 FORM: OM-410G
Effective with Serial No. HG061707
MODEL STOCK NO.
AEA-200 60 Hz 900 435
AEA-200E 60Hz 900 447
AEA-200L 60 Hz 900 441
AEA-200L 50 Hz 901 281
AEA-200LE 60 Hz 900 450
AEA-200LE 50 Hz 901 349
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MODEL/STOCK NO, SERIAL/STYLE NO. DATE PURCHASED
OWNER'S MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO, 4579
PLA
LIMITED WARRANTY
EFFECTIVE: NOVEMBER 1. 1976
This wartanty supersedes all previous MILLER warranties and is ex-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY —Miller Electric Mfp. Co., Apple-
ton, Wisconsin warrants to Customer that all new and unused
Equipment furnished by Miller is free from defect in workman-
ship 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 warran- |
ties of their respective manufacturers, if any. At the present time,
the manufacturer's warranty on the Mag-Diesel cogine on DEL-
200 is limited to six months and on all other engines to one year.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedics
therefor shall he, at Miller's option, (1) repair or (2) replace-
ment or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Milter service station or (4) payment of or credit for
the purchase price (less rcasopable depreciation based pon
actual used upon return of the poods at Customer's risk and ex-
pense. Upon receipt of notice of apparent defect or failure,
Miller shall instruct the claimant on the warranty claim proce-
dures to be followed.
As a matter of general policy only, Miller may honor an erigi-
nal user's Warranty claims on warranted Equipment in the event
of failure resulting from a defect within the following periods
from the date of delivery of Equipment to the original user:
|. Arc welders, power sources, and components ,.. | year
2. Original main power rectifiers ............ 3 years
E "nn x +
3. AN welding guns and feeder guns 0110000 90 days
4. All other Millermatic Feeders oo... IEEE | year
provided that the user so notifies Miller in writing within thirty
(30) days of the date of such failure.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY ОК КЕР-
RESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT WHICH, BUT
FOR THIS PROVISION, MIGHT ARISE BY IMPLICA-
TION, 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 ALI EQUIPMENT FURNISHED BY MILLER 15
EXCLUDED AND DISCLAIMEDR BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUS-
TRIAL 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 T0., AND NO RE-
SELLER 15 AUTHORIZED TO EXTEND MILLER'S WAR-
RANTIES TO, ANY CONSUMER.
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet fists exceptions to data appearing later in
this manual.
AMENDMENT TO SECTION 11 — ENGINE TROUBLESHOOTING
EIT Fp Aa
NOTE
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The circuit diagram(s} on this supplement replace any other circuit diagram(s) appearing later in this
manual, |
Amend Figure 11-3 and 11-4 as follows:
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WORK ELECTRODE
| - Circuit Diagram No. CB-900 441-2L
— Effective With Serial No. HHO39082 Thru HHO465621
BREARER |
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MAGHETS
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GROUND COMPENSATE FOR MATERIAL
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16 с EF
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WORK ELECTRODE
Circuit Diagram No, CB-900 441-2111
Effective With Serial No. HH046622 And On
Figure 17-3 Circuit Diagrams For Manual Start Welding Generators With Power Plant
| OM-410G Page À
EQUIPMENT
GROUND
THROTTLE
FOWFR
SAFETY. y
SWITCH | SWITCH
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Q1914 DNAAUTQAZS SIL 19% 7
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FA ADDED WHEN REQUIRED TO
ARAN FOR MATERIAL
FLECTRODE Circurit Diagram No. CB-900 450-1J
- | Effective With Serial No, HH039082 Thru HH046622
Boaco Sais |
TO IGN,
SWITCH
TOTAL TIRE METER
СОРТ ОМА)
x
I
t
lb; > | BREAKER
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сон. E | |
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TO AAT TERY" TERMINAL
als Rs laz i PO gu STARTER SOLENOID
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o 12 BAT
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7
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ena 50 + 00000
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= COLE FCTOR
STATOR ê RINGS
= ODO OOOO FOTO
= WELD
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AC-7 rs
EQUIPRENT X As ADDED WHEN REQUIRED TO 7 |
GROUND COMPENDATE FOR MATERIAL
VARIATION. < 37
16 eN 26
= 27
= =
17 25
ñ
L. L H я Г] =“
WORK ELECTRODE — Circuit Diagram No. CB-900 450-1K1
Effective With Serial No, HH046622 And On
Figure 11-4. Circuit Diagrams For Welding Generators With Etectric Start And 60 Hz Power Plant
Quantity _
; LL Morel
i Weld Welds Power
: ED Hr. 50 Hr.
Item Dia. Part No, Listed Replaced With Maat Cote Manual Еее an foo
No. 1Mkgs. In Parts List Part No. Description Start | Start | Start | Stan | Start | Start
74 si 011 622 052769 SWITCH, toggle 4PDT 15 amp 125 volts . . . AAA
77 Rb 008 951 052 782 RESISTOR, dual-adjustable 180 watt 12 ohm 1 1 1 1 1 1
107 0172 571 Deleted |
108 012 618 Deleted
118 SR4 039 123 052 785 RECTIFIER, silicon-diode . ............ 1 1 1 1
119 01,2 037 5772 037 672 DIODE (quantity changes) ............. 2 2 2 2.
120 VR1 039 122 Deleted
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-410G Page В
Ds TABLE OF CONTENTS —mernm__
Section No. Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
- 1. introduction ee aaderorecredodanona
- 2. General Precautions. 1.100101 11 LL LL LVL LL A NL AA A LA LA ALL LL
- 3. Arc Welding 1111100214 ee ea
1
1
1
1-4. Standards Booklet Index ........ 0 iii 4 4 4 eee ee
BL) = =
SECTION 2 — INTRODUCTION
- 1. General LL ee ee 0
- 2. Receiving-Handling ........ ii i RN mo,
- 3, Description 11.121204 044 44 44 4 4 4 4 RR Ra aa Le Pe.
- 4, Safety ea ena oa Rada aeroerecraiorenodraren
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Readying New Battery For Service ........._._. e... .0m0eeearaoa a
Air Cleaner ...........r00rerere cie 0merarerarereaiarerexemeen
BELL
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со ©
SECTION 5 — FUNCTION OF GENERATOR CONTROLS
- 1. Electrode & Work Receptacles ...... oii
- 2. Fine Amperage Control ....... 2.20. a LL LL LL LL a La LL 12
- 3. 115 Voits DC Receptacle 1.111110 010 4 004 LL AA LA LA LA 4 A da aa à
- 4, Weld/Power Switch 211111100001 LL A 4 NA A AR A A 4 ea a aa aa à
- 5. 120/240 Volts AC Terminal Strip 22211114 ee eee
- 6, 120 Volts AC Duplex Receptacle ............. 7... rie. acera
- 7. Voit-Ampere Curves 111412200100 ee a a a a RAA A
GT O1 O1 O1 GI O1 C1
© О WW © OD DO ©
—— al
SECTION 6 — FUNCTION OF ENGINE CONTROLS
G-2 Throttle Contra N 4 A A A AA A aa 10
6-3, Starter Switch ..... 44 4 4 A A LL NV LR A A A A A A A A AN A A A a A ANA AE 10
SECTION 7 — SEQUENCE OF OPERATION
1. Starting the Engine 1.104044 44 44 44 4 4 a LA VA La LL 10
2. Stopping the Engine 1.111000 04 44 4 4 4 14 4 4 A 4 4 44 4 4 4 4 4 a 4 A a aa à T1
- 3. Shielded Metal-Arc Welding... ... 101444 4 A La 44 RM 11 -
4, Power Plant Operation ......220220 00204 LL 4 4e 4 4 4 A ER A 4 4 0 4 4 a na 0 0 11
md ed a] wad
Section No, o | Page No.
SECTION 8— GENERATOR MAINTENANCE
8-1. General . .—. ...n0rreraraeno0r rara neranoec enero Cee 11
8-2. Collector Ring Brushes ............ i. 11
8-3. Welding Cables ............. iit ee eee 11
SECTION 9 — ENGINE MAINTENANCE
9- TF, Lubrication Lo... ee ee ee eee ec. 11
9-2. Cleaning the Engine .. 1.202000 44 4 44 4 4 4 6 4 4 4 4 4 4 4 4 4 4 0 4 8 4 0 A 0 40 0 12
9-3. Fuel Filter 112000100212 4 0 ea 111 a a ea ee PS 12
9-4, Periodic Service 1. 11120 2244 4 4 4 4 6 84 4 4 4 4 8 4 4 8 4 A4 4 4 8 8 a 4 a 804 6 12
9-5. Spark Plugs 1.110010 0 444 4 6 4 4 44 KR a eo 12
SECTION 10 — GENERATOR TROUBLESHOOTING
SECTION 11 — ENGINE TROUBLESHOOTING
PARTS LIST
wm SECTION 1-SAFETY. RULES FOR OPERATION
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 weld-
ing 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 main-
tained. 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 in-
jury or death. When safety becomes a habit, the equipment
can be used with confidence,
These safe practices are divided intd two Sections: 1
General Precautions, common to arc welding and cutting; and
2 - Arc Welding (and Cutting) tony).
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 Z49.1 is the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local in-
spection requirements also provide a basis for equipment in-
stallation, use, and service.
GENERAL PRECAUTIONS
Burn Prevention
Wear protective clothing - leather (or ashestos} gauntlet
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and stag.
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 gioves,
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 orina
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 discomfort, iliness or death can
result from fumes, vapors, heat, Or oxygen enrichment or
depletion that welding {or cutting] may produce, Prevent
them with adequate ventilation as described in ANSI 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
OF ARC WELDING POWER SOURCE mum
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 airsupplied 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 down-
stream 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 {or flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultra-
violet {radiant] energy of the arc can also decompose tri-
chloroethylene and perchloroethylene vapors to form phos-
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the welding or cutting atmosphere or where the
radiant energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or perchloroethylene,
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 stag 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 weld-
ing 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 =
с. 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 pro-
duce flammable or toxic vapors when heated, must never be
welded on or cut, unless container has first been cleaned as
described in AWS Standard AB.0, listed 3 in Standards index.
OM-410 Page 1
Page 2
This includes: a thorough steam or caustic cleaning lor 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 recom-
mended in AB.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 1f 1t 15 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 gaso-
line),
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, PRECAU-
TIONS 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 regula-
tor 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 tise 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 manufacturer's 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 preduce
short circuit arcs that may lead to a serious accident. {See
1-3C.)
ICC or DOT marking must be on each cylinder. It 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 con-
tent. Notify supplier if unmarked. NEVER DEFACE or alter
name, number, or other markings on a eylinder. It is illegal
and hazard ous.
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 allow 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
suppher.
Mixing gases. Never try to mex any gases in a cylinder,
Never refill any cylinder.
Cylinder fittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
Use ferrules or 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 other-
wise damaged.
Coil excess hose to prevent kinks and tangles,
Protect hose from damage by sharp edges, and by sparks,
slag, and open flame.
Examine hose regularly for leaks, wear, and loose connec-
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 reguiator 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 connec-
tion leaks, disassemble, clean, and retighten using properly
fitting wrench,
Adapters. Use a CGA adapter (available from your supplier}
between cylinder and reguiator, 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 an nut or shank) for fuel gas. | -
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder (or manifold маме} Бу turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at high pressure seat by allowing seat te open on pressur-
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Stand to side of regulator while opening cylinder valve,
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge reaches regu-
lator maximum) leave cylinder valve in following position:
For oxygen, :and inert gases, open fully to seal stem against
possible leak, For fuel gas, open to less than one turn to
permit quick emergency shutoff.
Use pressure charts {available from your supplier} for safe
and efficient, recommended pressure settings on regulators.
Check for leaks on first pressurization and regulary there-
after. Brush with soap solution icapful 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 equip-
ment manual.
Leaving Equipment Unattended
Close gas supply at source and drain gas.
Hope Staging-Support
Rope staging-support should not be used for welding or cut-
ting operation; rope may burn.
ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc
Welding, properly done, is a safe process, but a careless opera-
tor snvites 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, reftect 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 clathing {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
sleaves, flame-proof apron, and fire-resistant leggings. Avoid
autergarments of untreated cotton.
Bare skin protection, Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre-
vent entry of sparks.
2. Eve and Head Protection
Protect eyes from exposure to arc. NEVER look at an elec»
tric arc without protection,
Welding helmet or shield containing a filter plate shade no.
12 or denser must be used when welding. Place over face
before striking arc,
Protect filter plate with a clear cover plate.
Cracked or broken heimet or shield should NOT be worn:
radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IM-
MEDIATEL Y. 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 ayes should the halmet
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 enclosed bay is best, In open areas, surround the
*Trademark of Proctor & Gamble.
operation with low-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for all persons who
will be looking directly at the weld. :
Others working in area. See that all persons are wearing flash
goggles.
Before starting to weld, make sure that screen flaps or bay
door are closed,
Toxic Fume Prevention
Comply with precautions in 1-28.
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kilt.
Fire and Explosion Prevention
Comply with precautions in 1-2C,
Equipment's rated capacity. Do not overload arc welding
equipment, It may overheat cables and cause a fire,
Loose cable connections may overheat or flash and cause a
fire.
Never strike an arc on a cylinder or other pressure 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 1-2D.
Shock Prevention
Exposed hot conductors or other bare metal in the welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur-
face when welding, without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or moisture between body
and 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 equip-
ment before installing. If only 3-phase power is available,
connect single-phase equipment to only two wires of the
3-phase line, Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become electri-
cally HOT - a dangerous condition that can shock, possibly
fatally.
Before welding, check ground for continuity. Be sure conduc-
tors are touching bare metal of equipment frames at connec-
tions.
if a line cord with a ground lead is provided with the equip-
ment for connection to a switchbox, connect the ground lead
to the grounded switchbox, If a three-prong pfug is added for
connection to a grounded mating receptacie, 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-410 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 onginal cable,
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks.
6. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units should
have insulating covers 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 prassed, 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 line fuses (or lack 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 while welding,
If, in an emergency, it must be disconnected, guard against
shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and dis-
connect all power to equipment.
Power disconnect switch must be available near the welding
power source,
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANSI Standard 249.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 71h St., Miami, Fla. 33126,
2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA-
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y. 10018.
3. American Welding Society Standard A6,0, 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 51B, CUTTING AND WELDING PRO-
CESSES, obtainable same as item 4,
6. CGA Pamphlet 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 Q, WELD-
ING, CUTTING AND BRAZING,
SECTION 2 - INTRODUCTION
Amperes | Amperes | Open- Weight
Output 100% | Welding | Circuit Current Dimensions (Pounds)
Model Duty Cycle Range Voltage Adjustment Power inches) Net | Ship
Welding Generator Only 470 | 520
115 Volts
Welding Generator With Weld! hile. 515 | 565
. ing — 1 kv
Electric Start Five Selections Height- 27
: In Each Width - 20
Welding Generator With O 75-225 80 vals Of Three 115 Volts (25 On Electric
Power Plant Ranges With DC Power White Start Models} | 475 | 525
Infinite Control Welding — 1 kva Depth - 47
Welding Generator 120/240 Volts Single-
With Power Plant & Phase, 60 Hz, 530 | 570
Electric Start AC - 5 kva*
2-1.
2-3.
*115/230 Volts 50 Hz - 4 KYA on 50 Hz Models
Figure 2-1
. Specifications
IGNITION § IGNITION THAONTLE POYER-VELD
SWITCH E COIL* SWITCH "SWITCH
STARHTER*
SOLENOID
FINE AMPERAGE
CONTROL
VARISTOR
EXCITER
REVOLVING
a
EXCITER
STATOR
EXCITER
RECTIFIER
115 VOLTS DC
AECEPTACLE
*Elecwic Sarr Made Only
= Power Pham Made) Only
COLLECTOR
(RINGS
Figure 2-2.
GENERAL
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
DESCRIPTION
This unit is a gasoline engine-driven welding generator which
produces ac welding current. This welding generator is de-
signed to be used in conjunction with the Shielded Metal-Arc
(Stick Electrode} Welding process.
In addition to welding capability, all models are equipped
with a two-pole, three-wire receptacle through which 1 kva of
115 volts de electrical power can be obtained while welding,
Power plant models are equipped to provide up to 5 kva of
120/240 volts ac electrical power when operating at power
rpm.
REVOLVING |
FIELD
Fl
RECTIFIER 5A"
THI VOLTS AC
RECEPTACLE"
MOZO YOLTS
TEAMINAL
STRIP"
STATOR"
CHARGE RESISTOR" J
WIHDING R3
CIRCUIT
EREANER
DIODE*
a
STATOR
WELD
WINDENG
COARSE
AMPERAGE
RECEPTACLES
TAPPED
REACTOR
COARSE
AMPE RAGE
JACK PLUG
FUSE F1*"
STATOR**
POWER
WINDING
AC
WORK
AECEPTACLE
FINE
AMFERAGE
RELEPTACLES
FINE
AMPERAGE
JACK FLUG
AC
Block Diagram
24. SAFETY
ELECTRODE
RECEPTACLE
POWER
POSITION
SWITCH
WELD POWER
я
WELD
POSITION
TB-000 774
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:
Under this heading, installation, operating, and main-
“tenance procedures or practices will be found that if
not carefully followed may create a hazard to
y personnel,
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
ment.
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
OM-410 Page 5
3-1,
13-7/8°
*25" an models with elactric start
Page 6
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,
CAUTION |
If this unit is to be operated indoors, it should be
located in a place where the exhaust fumes from the
engine can be vented out of the building. Failure to
comply with proper venting may result in serious
| bodily injury or loss of life. J
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 mini-
mum of 18 inches of unrestricted space must be raintained
between the welding generator front and rear panels and the
nearest obstruction. Aliso, the underside of the welding
generator must be kept completely free of obstructions. The
installation site should also permit easy removal! of the weld-
ing generator outer enclosure for maintenance functions.
IMPORTANT
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 weld-
ing generator internal components to an overheating
condition and subsequent failure. Warranty is void if
I any type of filtering device is used. I
Holes are provided in the welding generator base for mount-
ing purposes. Figure 3-1 gives ovarall 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 the base.
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal compon-
ents to damage should the tips of the lift forks pene-
1 trate the bottom of the unit. I
|
— 157"
7/16” Dia.
Figure 3-7. Dimensional Drawings
EQUIPMENT GROUNDING TERMINAL {Figure 3-2)
Normally enginedriven welding generators are not required
to be grounded. However, this machine has auxiliary power
plant capability, therefore, grounding of the frame and case is
recommended. For this reason a convenient grounding ter-
minal is provided on all weld/power units. For detailed
TB-900 435-260) -
3-3.
grounding instructions consult your local or state codes or
the latest issue of the National Electrical Code.
Equipment
Grounding
Terminal TB-800 468-2C
Figure 3-2. Equipment Grounding Terminal
WELDING OUTPUT CONNECTIONS
Welding Cables
It is recommended that the welding cables be kept as short as
possible, placed close together, and be of adequate current
carrying capacity. The resistance of the welding cables and
connections cause a voltage drop which is added to the volt-
age of the arc. Excessive cable resistance may result in over-
loading as well as reducing the maximum current output of
which the welding generator is capable. The proper operation
of any arc welding generator 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.
Use Table 3-1 as a guide for selecting the correct welding
cable size for the anticipated maximum weld current that will
be used. Table 3-1 takes into account the total cable length
for the weld circuit, This means the length of the Electrode
cable that connects the Electrode Holder to the welding
generator and the Work or ground cable between the welding
generator and the work piece. For example: If the Electrode
cable is 75 feet long and the Work or ground cable is 25 feet
long, select the size cable from Table 3-1 that is recom-
mended for 100 feet. In a situation where a maximum weld
current of 150 amperes is anticipated, No. 3 weld cable is
recommended for both the Electrode and Work cables,
Table 3-1. Welding Cable Sizes
WELDINGL TOTAL LENGTH OF CABLE [ COPPER) IN WELD CIRCUIT
AMPERES] "50 | 100 | 150 | 200 | 250 | 300 | 350 | 400
100 | 4 4 4 3 | 2 1 | 1% | w0
150 | 3 3 2 + [1/0
200 | 2 2 1 | vo
250 | 1 1 | 10
A-002 702
NOTE: ‘A. 50 FEET OR LESS.
*B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE QPEN-CIRCUIT VOLT-
AGE (QCV) OF THE WELDING GENERATOR MUST BE
USED. WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAR 100
VOLTS, SOME WELDING GENERATORS OF SPECIAL
DESIGN MAY HAYE HIGHER OPEN-CIRCUIT
VOLTAGE.
B. Jack Plug Installation
The supplied red jack plugs are to be connected to the weld
cables in order to facilitate connection to the weld output
receptacles. Connect the red jack plugs to the Electrode
Holder cable and the Work clamp cable as follows:
1. Remove 3/4 inch of insulation from one end of each
welding cable.
2. Clamp the welding cable in a vice with the uninsulated
end protruding upward out of the vise approximately
1-3/4 inches.
4-1.
AT THIS LEVEL — — _ _ |
NEVER OPERATE
ENGINE WITH CIL
>»
jin
g
Е ПЕ)
В
Е
TA-901 024-4
Figure 3-3. Jack Plug Installation
3. Place the steel tie wire (See Item A Figure 3-3)
approximately 1/4 inch from the end of the insula-
tion, ;
4. Make a half turn around the cable bringing the looped
ends of the tie wire together.
5. insert a rod of approximately 3/8 inch diameter
through the two looped ends of the tie wire.
NOTE
See the Engine Manufacturer's manual for complete
engine care,
E.
LUBRICATION
This engine was shipped from the factory with the crankcase
filled with the correct amount and type of break-in ail unless
otherwise ordered. Check the oil level before attempting to
operate the engine. It should be up to the full mark on the
bayonet type indicator. Add a quality brand of detergent oil
if the oil level is low. See the oil selection chart {Table 9-1) in
Section 9).
IMPORTANT
New engines have very close clearance between the
moving parts. Thus, it is recommended that leading of
the engine be kept to a minimum during the first 10
hours of operation. Be sure to check the oil level
several times each day during the engine break-in
period. This engine requires about 10 haurs of running
| time before becoming fully broken in. |
KEEP OIL
BELOW THIS LEVEL ——-++- LOW
4-2,
TA-900 435-8
Figure 4-1. Oil Level Indicator
After about 10 hours of running time, drain the break-in oil.
See the oll selection chart {Table 9-1) in Section 9 for correct
oil type and grade to use after the break-in oil is drained.
FUEL
Use a good grade of ‘regular’ gasoline, rated at least at 90
octane, for this engine. {Do not mix oil with the gasoline).
Fueis of lower octane ratings may cause detonations (knock-
ing) which could result in damage to the engine bearings and
6. Twist the tie wire (B) until the entire tie wire is
twisted and is tight around the insulation of the
welding cable.
7. Clip off the looped ends of the tie wira.
8. Bend the twisted tie wire over and along the side {C)
of the uninsulated portion of the welding cable.
9. Wrap the strip of copper foil tightly around the unin-
sulated end of the welding cable and the twisted tie
wire (D).
10. Place the jack plug on the end of the welding cable
and vd in onto the welding cable over the copper
foil (DD),
11. Insert the 1/4-20 set screws into the center and
bottom hotes in the jack plug and tighten (E).
12, 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 remaining hole in the
jack plug.
13. © Insert the 8.32 self tapping screw (F) through the hole
in the fiber sleeve into the jack plug. Tighten the
screw with a screw driver,
SECTION 4 - ENGINE PREPARATION sm== Ñan
head gasket. The fuel capacity of the fuel tank is 3,8 gallons
(U.S. Measure),
CAUTION \
In order to reduce potential fire hazards inspect the
engine of this weld/power generator for fuel and/or
oil leaks prior to putting the unit into service, Con-
tinue to check for fuel and/or oil leaks during the
break-in period and periodically thereafter, Qil seepage
may exist at the main bearing seals beyond the normal
I break in period. I
IMPORTANT
Before starting the engine for the first time check the
carburetor main metering jet assembly nut and the
adjustment needie packing or lock nut for tightness
to prevent fuel leaks. Recheck these nuts for tightness
after the engine has been run approximately 50 hours,
and again after any required adjustments. See the
engine manufacturer's manual for location of these
1 nuts. |
CAUTION \
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 fill completely full. The reason being that the cold
fuel will expand due to engine heat and the outside air
when operating in a warm climate, If the tank is too
full, it will overflow causing a potential fire hazard,
Also, do not attempt to fill the fuel tank with the
engine running, always shut the engine down first,
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 consump-
tion of this engine.
OM-410 Page 7
rar
bé
#6
y Y y 75 30 75 10 125 10 US 90 125 2%
2 i i WELO AMPERES AT 100% DUTY CYCLE
5 T T T T T T Т T T 1
3 3 05 16 1% 926 23 20 235 40 as 50
POWER KVA AT 100% DUTY CYCLE B-006 345
Figure 4-2. Fuel Consumption Chart
4-3. READYING NEW BATTERY FOR SERVICE (Elec-
tric Start Models Only)
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,
A. Wet xt Charged Battery
The wet charged battery is shipped with the electrolyte solu-
tion 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 800F) before operation.
If this level is not present when it is to be used, charge the
battery as instructed in step 4 of item 4-3B.
1f the battery does not require any additional charg-
ing, the only step required to place the battery into
operation is to connect the negative {—) battery cable
to the > negative (—) terminal on the battery.
Page 8
Put on protective eye cover and clothing prior to
pouring the electrolyte solution.
This battery is shipped in a dry state. A sufficient amount of
Electrode Receptacl
all
r
4-4,
SECTION 5 - FUNCTION OF GENERATOR CONTROLS
es
electrolyte is shipped along in separate containers to activate
the dry charge battery. To prepare the new battery for opera-
tion, proceed as follows.
1. Remove the battery from the unit and place it on a level
work table or other suitable area.
2, Fill the battery cells to the required level with electrolyte,
Do not dilute this electrolyte as it is pre-mixed to the
I required strength. I
3. Place the 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 80CF and the specific
gravity reading 1.260 prior to installation. If both condi-
tions are not met charge the battery following the instruc-
tions below:
Prior to charging the battery the battery caps must be
removed, Failure to remove the caps could result in the
battery exploding should the battery be e overeharged,
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.
¢, Rinse the empty electrolyte containers with water be-
fore discarding. Since battery acid is corrosive to met-
als, do not pour into a metal sink or drain. Rinse and
mutitate the empty electrolyte container before discard-
ing. If acid has accidentally spilled on the battery or
work area during filling or charging, flush off with clear
water and neutralize with soda or ammonia solution.
Use the same procedure if acid is spilled on clothing.
5. Re-install the battery in the unit making sure that the
negative {—} termina! of the battery is connected to the
ground cable.
AIR CLEANER
This engine is equipped with a replaceable dry element type
air cleaner. The air cleaner requires no initial service.
Weld/Power*
Switch
À
@
Ko Po
120 Volts AC*
120 VOLTS AC — Duplex
Receptacle
=e 225 || zu [[ 20 JI ms
[=] , “ (0
ñ
work
Receptacle 4 (©) <= MID о || (25 | юо || 0
a] o -
TERMINAL 8
10
O | E
WELD prisa LL POS TOA
AC
wT 5
Les ir
Truly Evel Tor
nr 3000
Fenton
115 Volts DC
| r ———""_ Receptacle
FORD (HADT ILE MOTION
LC VOLTS TI
"a
a °
a мед
D— Fine Amperage Control
*Power Plant Models Only
Figure 5-1. Generator Controls
TA-900 435-4C
5-1.
5-3.
5-4,
ELECTRODE & WORK RECEPTACLES (Figure 5-1)
The five ELECTRODE and three WORK receptacles provide
fifteen amperage ranges ranging from 4b to 225 amperes.
Amperage range selection is made by placing the electrode
and work cable jack plugs into the desired ELECTRODE and
WOR K receptacle.
Exact amperage selections can be determined through use of
the amperage scales located to the right of the three WORK
receptacles. To obtain any one of the fifteen available amper-
ages, insert the work cable jack plug into the WORK recepta-
cle to the left of the scale on which the amperage range
appears,
Insert the electrode cable jack plug into the ELECTRODE
receptacle directly above the position on the scale at which
the amperage range appears.
Amperage range selections can be determined through use of
the amperage scale on the nameplate. The amperage desired
can be selected by reading the amperage scale immediately to
the right of the WORK amperage selector receptacle to be
used and down from the ELECTRODE amperage selector
receptacle to be used.
FINE AMPERAGE CONTROL (Figure 5-1)
The Fine Amperage Control permits selection of the exact
welding amperage desired within the range being used. As the
Fine Amperage Control is rotated in a clockwise direction,
weld current will increase, When the Fine Amperage Control
is set at the 100 {full clockwise} position, the amperage
which is indicated on the nameplate for the range in use will
be obtained.
The scale which surrounds the Fine Amperage Cantrol is
calibrated in increments of ten from 0 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,
the operator is selecting a percentage of the coarse range in
use and not an actual amperage value,
NOTE
The Fine Amperage Control must be set at the 100
position when utilizing the 120 VOLTS AC Recep-
1 tacle or 120/240 Volts AC terminal strip, i
115 VOLTS DC RECEPTACLE (Figure 5-1}
A two-pole, three-wire receptacle, labeled 115 VOLTS DC, is
provided on the front panel to serve as a junction point for
connecting accessory equipment which requires 115 volts de
electrical power. The rated output of the 115 VOLTS DC
Receptacle is 1 kva. The engine must be operating at weld
rpm whenever the 115 VOLTS DC Receptacle is used,
WELD/POWER SWITCH (Figure 5-1)(Power Plant
Models Only)
A two-position switch, labeled WELD/POWER, is provided
on the front panel for selecting weld current output or power
plant output. In order for the welding generator to operate,
the WELD/POWER Switch must be in the WELD position
when the engine is operating at weld rpm and in the POWER
position when the engine is operating at power rpm. Hf it is
desired to change from weld operation to power plant opera-
tion or vice versa while the engine is operating, observe the
following procedures:
Changing From Power Plant Operation to Weid
Operation
1. Turn off or disconnect ali equipment connected to the
welding generator.
2. Place the WELD/POWER Switch in the WELD position.
3. Place the Throttle Control in the WELD position.
4. Make connections to the weld output receptacles.
B. Changing From Weid Operation to Power Plant
5-5.
Operation
1. Break the arc and disconnect the welding cables from the
welding generator.
Place the Throttle Control in the POWER position.
Place the WELD/POWER Switch in the POWER position,
Set the Fine Amperage Control at the 100 position.
п ов ое ю
Make connections to the 120 VOLTS AC duplex recepta-
cle,
6. Do not turn on the equipment which is connected to the
power plant until the engine has come up to proper speed.
120/240 VOLTS AC TERMINAL STRIP (Figure
5-2) (Power Plant Models Only)
CAUTION |
Do not attempt to make connections to the 120/240
Volts AC terminal strip inside of the unit while the
engine is operating. Always shut the engine down be-
fore making connections to the 120/240 Volts AC
terminal strip. In order to obtain 120/240 Volts full
I capacity output follow the instructions in item 5-5. |
A four-pole terminal strip is provided behind the right side
panel to serve as a connection point when 120 or 240 volts
60 Hertz power is needed. 120 or 240 volts ac will be avail-
able at this terminal strip only when the Throttle Control and
WELD/POWER Switch are bath in the POWER position.
Figure 5-2 shows the terminals to which connections must be
made in order to obtain 120 or 240 volts ac.
The 120/240 volts 60 Hertz power that can be obtained at
this terminal strip May be used to provide standby service to
rural, residential, or other buildings requiring 120/240 volts,
3-wire connection.
An access hole with strain relief is provided on the rear
panel of the generator enclosure for routing leads to
the 120/240 Volts terminal strip.
NOTE
Each of the two 120 volts ac branch circuits is capable
of furnishing 2.5 kva of power yielding a total of 5 kva
of power.
a dl
120/240 Volts AC
Cable Input Hole
& Strain Relief
И
TB-900 468-18
Figure 5-2, 120 or 240 Volts AC Connections
OM-410 Page 9
120 VOLTS AC DUPLEX RECEPTACLE (Figure
5-1) {Power Plant Models Only) |
The dupiex 120 VOLTS AC receptacle, located on the front
control panel, will provide a total of 20 amperes of 120 volts
60 Hertz power. Whenever this receptacle is to be used, the
engine must be operating at power rpm and the WELD/
POWER Switch must be in the POWER position.
VOLT-AMPERE CURVES (Figure 5.3)
The Volt-Ampere curves show the output voltage and current
of the welding generator available at any point from the mini-
mum to maximum of each coarse current range.
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 current range.
—— SECTION 6- FUNCTION
6-1.
6-2.
6-3.
7-1.
Page 10
CHOKE CONTROL (Figure 6-1)
A Choke Control is provided for varying the fuel-air mixture
to the engine. When the Choke Control is pulled fully out,
very little air will be admitted to the engine thru the carbu-
retor 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 Con-
trol 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.
THROTTLE CONTROL (Figure 6-1)
The selection of weld, power (Power plant models oniy), or
idle rpm is made by adjustment of the THROTTLE Control.
To operate the engine at weld rpm, push the Throttle Control
fully over to the left. Placing the Throttle Control in the
notch in the center of the throttle bracket will provide power
rpm {Power plant models only). Idle rpm is obtained by mov-
ing the Throttle Control into the notch on the extreme right,
STARTER SWITCH (Figure 6-1)(Electric Start
Models Only)
The Starter Switch, located on the engine blower housing,
provides the following three functions:
Off Position
The OFF position removes voltage from the engine electrical
system. The Starter Switch is to be in this position when the
engine is not running or for stopping the engine,
EXT \
Never under any circumstances, operate the weld/pow-
er generator with any portion of the outer enclosure
open or removed. In addition to being a hazard to per-
sonnel, weather protection to the internal components
of the unit will be greatly reduced, Warranty is void if
the weld/power generator is operated with any portion
of the outer enclosure open or removed.
STARTING THE ENGINE
1. Fil the fuel tank and check to ensure that oil level is
adequate.
80
70
60H
о
> 40 IF
Ww
« 30 Fr
20
| | i |
0 50 100 150 200 250 300 350
A € AMPERES
B-002 895
Figure 5-3. Volt-Ampere Curves
OF ENGINE CONTROLS:
Throttle
Control
*Starter
Switch
Choke ——— y
Control
*Electric Start Models Only
TB-900 468-10
Figure 6-1. Engine Controls
B. Run Position
Whenever the engine has started and is operating, the Starter
Switch must be in the RUN position. The Starter Switch is
spring-loaded to return to the RUN position automatically
from the START position.
C. Start Position
The START position will actuate the engine starter and
thereby start the engine.
SECTION 7 - SEQUENCE OF OPERATION mmm
IMPORTANT BW
Make sure all electrical equipment connected to the
120 VOLTS AC receptacle and 120/240 Volts ac
terminal strip 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 equipment.
2. Pull the Choke Control fully out, Lesser degrees of chok-
ing may be required if the engine is warm,
3. Place the Throttle Control in the IDLE position.
4, The WELD/POWER switch may be in either the WELD or
POWER position (power plant models only}.
5. On models without electric start, give a quick steady pull
on the starter rope. For models with electric start, place
the Starter Switch in the START position.
6. Once the engine has started, release the Starter Switch to
the RUN position and slowly push the Choke Control
inward.
7. 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.
8. If the engine is to be operated at POWER rpm, place the
Throttle Control in the POWER position and the WELD/
POWER Switch in POWER position {power plant models
only). |
9. 1f the engine is to be operated at WELD rpm, place the
WELD/POWER Switch in the WELD position ang then
place the Throttle Control in the WELD position {power
plant models only).
7-2. STOPPING THE ENGINE
1. Remove all weld and power loads from the welding gener-
ator.
2. Place the Throttie Control in the IDLE position. Operate
the engine at this speed for 2 minutes; this will allow inter-
nal engine temperature to equalize.
3, To stop the rope-start models, depress the Stop Button on
the blower housing. On electric start models, place the
Starter Switch in the OFF position.
7-3. SHIELDED METAL-ARC WELDING (Figure 7-1)
8-1.
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.
1. Prepare the engine for operation as instructed in the
engine preparation section.
2. Make connections to the desired WORK and ELEC-
TRODE Receptacles,
3. Rotate the Fine Amperage Control to the desired setting.
If any work is to be done on the rotor of the gen-
erator, 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 cast-
ing. Also on electric start models disconnect the
1 negative (-) battery cable from the battery, 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 recommerided. This should be performed
periodically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere.
7-4,
8-3.
4. Place the WELD/POWER switch in the WELD position
{power plant models only). |
5, Start the engine as instructed in item 7-1.
TB-900 435-5C
Figure 7-1. AC Welding Connections
6. Place the Throttle Control in the WELD position.
7. Connect the work clamp to the object to be welded, place
the desired electrode into the electrode holder, and com-
mence welding.
POWER PLANT OPERATION (Power Plant Models
Only)
1. Prepare the engine for operation as instructed in the
Engine Preparation Section,
2. Make connections to the 120/240 Volts AC terminal strip
and/or 120 Volts duplex receptacle as instructed in items
5-5 and 5-6.
3. Rotate the Fine Amperage Control to the 100 setting.
4. Place the WELD/POWER Switch in the POWER position.
IMPORTANT
ad TT pe = 3 Te pe 3
E: E _ = — Я
Make sure all electrical equipment connected to the
120 VOLTS AC receptacte and 120/240 Volts ac
terminal strip 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 equipment.
5. Start the engine as instructed in item 7-1.
6. Place the Throttle Control in the POWER position.
7. Turn on the auxiliary equipment and commence opera-
tion.
SECTION 8 - GENERATOR MAINTENANCE ——————s
8-2.
COLLECTOR RING BRUSHES
The brushes should be inspected periodically to ensure their
proper function. The brush life is very good under normal
conditions. If the generator has been operating in an extreme-
ly dusty or dirty location, a close check of the brushes for
freedom of movement and cleanliness should be made
weekly. Under normal use the commutator and slip rings will
discolor to a dark brown, If it should become necessary to
clean the slip rings or commutator, use a 3/0 or finer sand-
paper followed by a crocus cloth, Never use emery cloth as
part of the emery will embed inself into the exciter or collec-
tor rings and in turn destroy the carbon brushes.
WELDING CABLES
Check connections periodically for tightness. The cables
should be inspected frequently and all breaks in the insula-
tion should be repaired with electrical insulating tape or the
cables replaced.
9-1.
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 cil 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 10 hours of running time on the break-in oil, drain the
OM-410 Page 11
oil, Premium heavy duty oil, manufactured by any one of the
major cil companies, should be used as a replacement oil.
Table 9-1 gives a list of recommended grades of oil 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 3-1/2 quarts.
Check the dip stick to make sure oil level is up to the re-
quired operating level,
In normal operation, oil should be changed after about 50
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,
Table 9-1. Recommended Engine Oil
LOWEST TEMPERATURE AT SAE NO.
THE ENGINE OIL
Above 909F (320C]) for Continuous Duty No. 50
300F (- 19C) 10 90°F (329C) No. 30
OOF {18°C} to 300F {- 10C) No. 10W
Below O9F (180C) No, 5W
—r—]—]——— SECTION 10- GENERATOR TROUBLESHOOTING
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.
FUEL FILTER
The fuel filter is located below the fuel tank. Check the
sedement bowl periodically for water and dirt deposits, How
often the filter has to be checked wiil depend on the grade of
gasoline used and how dusty and dirty the location in which
the engine is being used.
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 toad, dust, dirt, etc., service more often.
Table 9-2. Periodic Engine Maintenance Chart
OPERATIONAL HOURS
MAINTENANCE ITEMS a 50 100 200
Inspect Unit X :
Check Fuel х
Check Oi Level X
Check Air Cleaner x1
Clean Governor Linkage x1
Check Spark Plug X
Change Crankcase Oil x1
Clean Crankcase Breather X
Clean Fuel System
Check Battery
x1 - Perform more often in extremely dusty conditions,
9-5. SPARK PLUGS
The area around the base of the spark plugs should be clean-
ed prior to removal of the spark plugs to help avoid dirt
getting into the engine,
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 internal engine components, Also, the
spark plug gap should be kept at 025”.
Remove the plugs 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 plugs.
The following chart is designed to diagnose and provide remedies for some of the common 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 func-
tioning 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 Station should be contacted, In all cases of equipment malfunction, the
manufacturer's recommendations should be strictly followed.
TROUBLE
PROBABLE CAUSE
REMEDY
No 115 volts de output.
Loose lead in 115 vde circuitry.
Ensure all leads are secure,
Low weld output,
Engine speed is low.
Adjust engine speed to 3000 rpm (no load speed). if
engine rpm drops below 2600, engine servicing is indi-
cated. Place Throttle Control in WELD position.
Erratic weld current.
Damp or defective electrodes.
Use new dry electrodes.
Work or electrode connections loose.
Secure connections.
Jack plugs loose in receptacles.
Secure jack plugs.
Jack plugs in wrong receptacle for
electrode in use.
Connect jack plugs to proper receptacles.
Low power plant output. {Power
plant models only).
Fuse F1 open,
Replace fuse F1 (Fuse Fi ís located next to the 120/
240 volts ac terminal strip.
Fine Amperage control R1 not set to
100,
Set Fine Amperage control R1 to 100.
No weld or power output.
Dirty slip rings.
Clean slip rings by using an oxide-inhibitor and cleaner
type spray [contact cleaner), or by using fine sandpaper
or a commutator stone, (In many cases, momentarily
increasing engine rpm will restore operation.)
*If it becomes necessary to replace any fuse in the welding generator, ensure that a fuse of the proper size is used,
Page 12
| FAILURE TOSTART |
CARBURETION
}
[compression]
Hreaker points pitted
or fused.
Spark plug insulation bad.
Hreaker arm shicking.
Improper ming.
Poar grade Restricted air cleaner Plugs we?
af tuel Fuel pump diaphragm о! фигу
Water Choke Condensation
in fuel Flooded on electrodes
Gum Ort or gum holding Weak bariery
in {ues iloat needle valve
{art Damaged HS needle valve.
in tuel Fuel ine clogged.
Improper A vent, Fidler cap plugged
volatility Maniold gasket leak.
Na fuel Muller clogged.
Broken ige 100 cables
lgniLon cables
disconnected.
Cytinders dry.”
Sheking valve,
Loose or broken spark ptugs.
Cvylinde: head gasker teaking.
Piston rings stuck
Warped or broken valves
| KNOCKING |
CARBURETION
MECHANICAL
| IGNITICN |
Poor grade of fuel
Octane rating 10 low
Heavy load al slow speed.
Carbon or tead deposits in
cylinder head.
Loose connecting rad,
Loose main bearings,
Worn or loose piston pin.
Worn gr loose timing gears.
Improper piston 10.
Valve lash 100 qreat
Valves sticking,
Rurned au! connecting rod
Breaker points
100 far advanced
{ MISSING |
CARBURETION
Water in fuel
Gum im luel
Improper carburetor
Dirty fuel system.
Inoperative fuel pump
{Dut on mechanical}.
Air leaks 10 system.
Vapor lock.
Improper needle valve.
tmpioper fuel mixture.
Delertive float mechanism
Inoperative choke central
[coMPRESSION]
—— —
Scared cylinders,
Improper valve lash.
Sticking valves.
Loose or broken spark plugs.
Cytinder head gasket leaking.
Piston rings stuck.
Warped or broken valves.
Sand hole in casting.
Valve springs weak or broken,
OVERHEATING |
1
Emproper heat range in plug.
Loose plug,
Poor insulation on plug.
Spark plug gap incorrect.
Worn and 'eaking ignition cables.
Weak spark.
Loase electrical connections,
Breaker points pitted or worn.
Breaker points sticking.
Improper tension af breaker point
spring.
Improper breaker point gap.
Bad condenser,
Weak coil,
Worn cut plugs.
Defective ignition switch.
Grounding of ignition atcassor ies.
Moisture
Defective distributor cap.
[CARBURETION] | LUBRICATION]
(MECHANICAL | |
1
IGNITION |
1
Low grade of fuel.
Engine operated while
detonating, due to
low actane fuel or
heavy Icad. system,
Improper carburetor Bad ou pump.
selting. Worn parts in
Plugged air filter,
Oil supply low.
Dirty or incorrect
grade of Oi*.
Plugged fubricating
tubricating system,
Leak in intake system,
Engine averloaded.
Carton deposits in
engine.
Rastricted exhaust.
Choke control partially
pulied cu.
Valves leaking.
Restricted air cleaner,
Recirculation at hot air,
Improper break in.
|
SURGING i
CARBURETION
Timing
incorrect.
GOVERNOR
intake teaks.
Carburetor flooding.
Improper adjustment.
Sticky controls
Improper lubrication,
SECTION 11 - ENGINE TROUBLESHOOTING ============2===———=>
OM-410 Page 13
115 м. ОС
y ] V-
EQUIPMENT +
GROUND - 22
= 21 |
R : IC
D1 w
+++ 3
67 = 220% 8
o А+ -
4
Я CAD)
ñ / ¡E 70000000
{ / 5 REVOLVING FIELD
i -_
TOR Ss COLLECTOR 0000000. 00000000
5 RINGS
т LOTO LTTOO LA OUI
m
a WELD
D3 53 в \\у БС.
"a 9
¥ Rs ADDED WHEN REQUIRED TO AC-Z 15
COMPENSATE FOR MATERIAL 14 lo
VARIATION.
37
16 26
27
28
17 29
A
H L L H
WORK ELECTRODE
Circuit Diagram No. CB-800 435-2H
Figure 11-1. Circuit Diagram For Manual Start Welding Generator
+
TO IGN.
SWITCH
TOTAL TIME METER
OPTIONAL "UT
h
33 1"
RCH
115 V. DC
V+ -— Y-—
| TO"BATTERY" TERMINAL
EQUIPMENT + 22 O GN STARTER SOLENOIC
GROUND 12 V BAT
= 2} : ;
36 * [= 37 |
D | HIE |
1 Ра
+ 37 +
67 CHARGE ы
woo. HEY] ET)
500000
62
SRA EXCITER
Do
COLLECTOR
J31d ONIATTOASE H3), 10X3
STATOR OLLET
8 | WELD
Ph 63 WDG.
3 ыы
¥ Rc ADDED WHEN REQUIRED TO AC-Z 5
COMPENSATE FOR MATERIAL | 4 G
VARIATION. =
КР
16 26
| 27
28
29
A ]
H L L H
WORK ELECTRODE
Circuit Diagram No. CB-900 447-1G
Figure 11-2. Circuit Diagram For Welding Generator With Electric Start
‚Раде 14
BREAKER
BOX
FROM al py 1 "
MAGNETO | 53 33
THROTTLE
SW.
33
НС, ат
115 DC
Y* y +
22
EQUIPMENT ==
GROUND
= 27
Di
+
67 m
uf
m
®
2
Im
| 5 / REVOLYING FIELO
SR 62 EXCITER gi , *
a STATOR = COLLECTOR
& RINGS
>
7 | WELD
r 8
03 63 < WOG
a 9
* As ADDED WHEN REQUIRED TO AC-2 75
COMPENSATE FOR MATERIAL 14
VARIATION. o
37
16 | 26
| 27
| 28
| 17 a
H L L SH
WORK ELECTRODE
Circuit Diagram No. CB-900 441-2K
Figure 11-3. Circuit Diagram For Manual Start Welding Generator With Power Plant
POWER |= ™ — — — — =
SAFETY. THROTTLE |
SWITCH SWITCH |
TO IGN. BREAKER
SWITCH | Box
TOTAL TIME METER |
(OPTIONAL) 153 |
x di
=D
&
=
AC1
TO" BATTERY" TERMINAL
0 ON STARTER SCLENOIG
12 Y. BAT,
E— m
— e o | ==
EQUIPMENT
GROUNG
9
m CHARGE 239 7 LS
a WG. ce 28
ol
I
Хх
m
у 5 REVOLVING FIELD
mr -
EXCITER <= !
= COLLECTOR
STATOR zZ RINGS _
7 ГОО ГОС ГОДОВ
m WELO
Da 53 5 e WDG.
9
AC-Z 5
X As ADDED WHEN REQUIRED TO 74
COMPENSATE FOR MATERIAL
VARIATION, <> 37)
16 26
a7
28
17
A
H L L H
WORK ELECTRODE
Circuit Diagram No. CB-900 450-1H
Figure 11-4, Circuit Diagram For Welding Generator With Electric Start and Power Plant
OM-410 Page 15
January 1977 FORM: OM-410G
Effective with Serial No, HG061707
Ч ==
4 —
aN dd TE |
Чт СОСО
E ge
== С O
=
= = ———
=
с — Ln —
MODEL/STOCK NO, SERIAL/STYLE NO. DATE PURCHASED
PARTS LIST
INTE
т UN D
USA
NWSA CODE NO, 4579
18
9
20 15
OM-410 Page 1
Includes items
16 & 17
TD-900 459-18
30 29 24 32
Figure A — Main Assembly
Quantity
Model
Weld Weld/Power
60 Hz, 50 Hz.
200 200E | 200L 200LE[ 200L | 200LE
Item Dia. Factory Manuall Electric Manual| Elactric| Manual | Electric
No. Mkgs. Part No. Description Start | Start | Start | Start | Start | Start
Figure A Main Assembly
1 004 648 CABLE, battery - negative ...... EEE i 1 1
2 Ван 003 426 BATTERY, 12 volts 30 amp ..... 2.0 1 1 i
3 004 647 CABLE, battery - positive ........... 1 i 1
004 775 GUARD, terminal - battery .......... 1 i 1
4 035 141 COVER, top .... inn, 1 1 1 1 1 1
4 035778 COVER, top {used with TT) ......... 1 1 1 1 1 1
5 015670 TANK, fuel (consisting of)........... i 1 1 1 1 1
6 015721 CAP, fueltank ................... 1 1 1 1 1 1
7 014951 STRAP, mounting - fuel tank .. ....... 2 2 2 2 2 2
8 602 898 NIPPLE, brass - pipe close 1/8 MPF ,... 1 1 1 1 1 1
9 015602 FILTER, fuel ......... cco... 1 1 1 1 1 1
10 010 731 NIPPLE, brass - pipe 1/4 hose shank
1/8MPT 111114111114 4 a aa» 1 1 1 1 1 1
11 603 124 STRIP, rubber - baffle (order by foot! .. 4ft. 4ft. 4ft. 4ft. 4ft. 4 +t.
12 035471 BAFFLE, air ................... .. 1 1 1 1 1 1
13 015712 GROMMET, rubber 5/8 1D-7/8 hole
1/18 groove se en 1 1 1 1 1 1
14 010610 CONNECTOR, clamp -cable 1/2 ...... | 1 1 1 1
15 035 290 ENGINE, gas-manual start (consisting of) 1
15 007 706 ENGINE, gas-recoil start ............. i
15 035 300 ENGINE, gas-electric start (consisting of) 1
15 035 284 ENGINE, gas-manual start (consisting of) 1 1
15 007 704 ENGINE, gas-recoil start 1 1
15 035 256 ENGINE, gas-electric start (consisting of) 1 i
16 010865 .CLAMP, hose 13/32 to 7/16 clamp día 2 2 2 2 2
17 603 106 . HOSE, braided 1/4 ID x 1 (order
byfoot) ........... внук нкеу,. 1ft. ft. 1ft. MAR 1ft. 1 ft.
18 “605 802 .MUFFLER, exhaust ............... 2 2 2 2 2 2
19 602 945 . NIPPLE, galvanized 1 MPT x 4 inches lg 7 2 2 2 2 2
20 019603 .KNOB, ball ..................... 1 1 1 1 1 1
21 016561 .COVER, switch -limit ............. 1 1 1 1
22 52 027 878 .SWITCH, limit - leaf actuator SPDT .,.. 1 1 1 1
015720 | PLUG, manifold - vacuum booster .... 1 1
005 498 | NIPPLE, galvanized 1/2 NPT x 4 ..... 1 1 1 1 1 1
| 005 499 | CAP, pipe - galvanized 1/2 NPT ...... 1 1 1 1 1 1
23 601 976 SCREW, cap - steel hex hd 1/2-13
х 1-1/2 2, икс к леев ука еее аь, 4 4 4 4 4 4
24 602 246 WASHER, flat steel standard 1/2...... 5 5 5 5 5 5
25 Figure C GENERATOR ASSEMBLY (See Page 6} . 1 1 1 1 1 1
26 601 993 SCREW, cap - steel hex hd 1/2-13
X 2-1 2 ea 1 1 1 1 1 1
27 602 217 WASHER, lock - steel external 1/2 .... 1 1 1 1 1 J
28 020 359 SHIM, endbell 16 ga or
28 103723 SHIM, endbell 1/8 ................. As Reg'd.
OM-41C Page: 2
Quantity
*Recommended Spare Parts.
Model
Weld Weld/Power
60 Hz. 50 Hz.
200 | 200€ | 200L | 200LE | 2001. | 2001 E
Item Dia. Factory ManuallElectric| Manual|ElectriclManual | Electric
No. Mkgs. PartNo. Description Start | Start | Start | Start | Start | Start
Figure A Main Assembly (Cont'd)
29 602 216 WASHER, lock - steel split 1/2 .......... 5 5 5 5 5 5
30 601880 NUT, steel - hex jam 1/2-13 ............ 5 5 5 5 5 5
31 AC-Z 035 434 REACTOR 1142204 4404 44 44 a a a 40 1 1 1 1 1 i
32 R3 030 641 RESISTOR, WW adj 75 watt 4 ohm ...... i 1 1
33 035 138 BASE .... rr. e..ecasoróenarrtareren i 1 1 1 1 1
34 Figure B PANEL, front - with components (See
Page 4) 11111214 14 44 44 0 4 4 a a 4 a 1 4 a 4 a 40 1 1 1 1 1 i
35 039608 PLUG, jack - red (consisting of) ,........ 2 2 2 2 2 2
36 101219 PLUG, jack ...... 2... 0 seaarereeoana 1 1 1 i 1 1
37 019833 .STRIP, copper 0.010 x 2-1/2x 3/4 ...... 1 1 1 1 1 1
38 602 178 .SCREW, set - steel socket hd 1/4-20x 3/8 2 2 2 2 2 2
39 010521 . WIRE, tie ...... ccna, 1 1 1 i 1 i
40 602814 | INSULATOR, jack plug-red .......... 1 1 1 1 1 1
41 602 160 .SCREW, self tapping-fillister hd 8/32 x 1/4 1 1 1 1 1 1
42 035 135 PANEL, side - righthand. .............. 1 1 1 1 1 1
43 003474 SHELF, batterybox .................. 1 1 i
44 035 136 PANEL, side - left hand ............... 1 1 1 i 1 1
45 017 222 HOLDDOWN, battery ................ 1 1 1
035 7608 LABEL KIT (includes all labels) ,........ 1 1 1 i 1 1
Parts for Optional Equipment
AT 025 726 METER, amp - weld 0-300 scale ........ 1 1 1 1 1 i
Ch 006 044 CAPACITOR, ceramic 0.1 uf 500 volts
de {TDG 1 1 1
CT1 036 609 TRANSFORMER, current 300/56 ........ 1 1 i 1 i 1
V1 025 602 METER, voltac 0-100 scale ............ 1 1 1 1 1 1
V2 025604 METER, volt de O- 100 scale ,........... 1 1 i 1 7 1
TT 035 779 METER, hour 43130 volts de ........... 1 1 i
TT 025718 METER, hour 12 volts de .........e se... 1 1 1
020 288 BRACKET, mounting - hourmeter ....... 1 1 i 1 1 1
016 164 WRAPPER, meterbox ................ 1 1 i 1 1 1
016 165 PANEL, front-meterbox .............. 1 1 1 1 1 1
016 166 PANEL, rear- meterbox .............. i 1 1 1 1 1
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
| | Quantity
Item: Dia. Factory Model
No. Mkgs. Part No. Description Weld |Weld/Power
Figure B Panel, Front - With Components {See Fig. A Page 3 Item 34)
61 039 826 RECEPTACLE, jack plug - black (consisting of) ............. 1 1
62 039798 . NUT, terminal - black .......... iii 4 a ea ee» 1 1
63 010191 .WASHER, flat - nylafil 5/8 ID x 1-1/40Dx1/8............ 1 1
04 604 668 .NUT, steel - self locking hex 1/2-20.............. aa 1 1
65 020015 | RECEPTACLE, jack plug ........... 2... 2... reco, 1 1
66 601 881 . NUT, steel - hex jam 1/2-20 1.110111 LVL 4 44 a 4 a ea a ae 1 1
67 035 142 PANEL, front ......... se. 000x000 aaa ara 1 1
68 039 801 RECEPTACLE, jack plug - black (consisting of) La a 4 4 8 aaa 7 7
69 601 881 .NUT, steel - hex jam 1/2-20 1110110 14 0 4 44 4 4 44 a 4 4 1 aa 00 1 1
70 038 198 . RECEPTACLE, jack plug ..... aaa Ce aaa 1 1
71 604 668 . NUT, steel - self locking hex 1/2-20........ ceo... 1 1
72 010191 .WASHER, flat - nylafil 5/8 ID x 1-1/40Dx 1/8 ............ 1 1
73 039 796 . NUT, terminal - black . ......... i. 1 1
74 St 011622 SWITCH, toggle 3PDT thamp 125volts ................... 1
75 RT 000 101 RHEOSTAT, WW 50 watt 16 ohm ....................... 1 1
76 RC? 039864 RECEPTACLE, duplex - grounded straight 2P3W ............ 1
77 R5 028 839 RESISTOR, WW adj TOO watt 10 ohm ..........e.eeceervero. 1 1
78 000 045 HARDWARE, mounting - resistor (RS) 000 ккала... 1 1
79 NAMEPLATE (order by stock, model, & serial numbers) ...... 1 1
80 RC1 034952 RECEPTACLE, straight 3P3W snap in..... SA a 1 !
1
81 024 366 KNOB, pointer ....... кл. i vse
TC-019 269-C
Figure B — Panel, Front - With Components
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS,
OM-410 Page 4
Quantity
1184
Page 5.
Model
Weld Weld/Power
60 Hz, 50 Hz.
200 200Е | 200L Y200LE | 200L | 200LE
Item Dia, Factory Manual | Electrie|Manual | Electric | Manuat | Electric
No. Mkgs. Part No. Description . Start | Start | Start | Start | Start | Start
Figure C Generator Assembly (See Fig. A Page 2 Item 25)
91 014 376 WRAPPER, stator ............... 1 1 1 1 1 1
92 **035 167 ROTOR ASSEMBLY, generator
(consisting of) .................. 1 i i 1 1 1
93 024 617 . RING, retaining .............. we 1 1 1 1 1 1
94 024 800 .BEARING, ball ..............,. 1 1 1 1 1 1
602348 ‚KEY, 1/4 x 1/4 х 3/4 ..,......... 1 1 1 1 1 1
95 604 680 . SCREW, cap - steel hex hd 5/16-18
х 778 LL LL La a a a 4 4 1 a a 4 a eee aa à 4 4 4 4 4 4
96 602 211 . WASHER, lock - steel split 5/16 ... 4 4 4 4 4 4
a7 017 724 , FAN, rotor ........eoooéen ecu. 1 1 1 i i 1
98 017 618 ADAPTER, fan - rotor ............ 1 1 1 i 1 1
99 010 681 KEY, woodruff 1/4x 1 ........... 1 1 1 1 1 1
100 017 702 ADAPTER, engine ............... 1 1 i i 1 1
101 010 601 SCREW ASSEMBLY, adapter - fan
{consistingof} .................. 1 1 i 1 1
102 602 226 .WASHER, flat - steel 7/16 ........ 1 1 1 1 1 1
103 602 215 .WASHER, lock - steel split 7/16 .,. 1 1 1 1 1 i
104 602018 .SCREW, cap - steel socket hd
1 1 1 1 1 1
116
7/16-14x 1-1/2.... ee... e
— Figure C — Generator Assembly -
TD-020 792-1B
Quantity
Model
Weld Weld/Power
60 Hz, 50 Hz,
200 | 200E | 200L | 200LE { 200L | 200LE
tem Dia. Factory Manuai |ElectriciManual | Electricanual FElectrio
No. Mkgs. PartNo, Description Start | Start | Start | Start Cor Start
Figure C Generator Assembly (Ses Fig. A Page 2 Hem 25 (Contd)
105 035 137 BRACKET, mounting - terminal
board ............. cc iia, 1 1 1 7 1 1
106 D9 027 856 DIODE, 22 amp 200 volts reverse
polarity ........ o sede ee. 1 1 1
107 012571 HOLDER, fuse - miniature ........ 1 1 1 i
108 Fi "012618 FUSE, miniature - glass 5 amp ..:... 1 1 1 1
109 CB 027 889 CIRCUIT BREAKER, auto reset
250 volts 10 amp .........ee ere. 1 1 1
110 1T 034 955 BLOCK, terminal 45 amp 4 pole 1 1 1 1 1
111 007 260 BRACKET, mounting - brushholder . 1 1 1 1 1 1
112 005 614 HOLDER, brush - w/tabs ......... 3 3 3 3 3 3
113 “003 921 BRUSH, wspring ............... 3 3 3 3 3 3
114 003 923 CAP, holder -brush .............. 3 3 3 3 3 3
115 007 249 STRIP, retaining - brushholder ,.... À 1 1 1 1 1
116 **039 099 STATOR, generator .............. 1
116 **039 097 STATOR, generator ,............. 1
116 **039 098 STATOR, generator .............. 1
116 **039 100 STATOR, generator ...,........... 1
116 **039 101 STATOR, generator .............. 1
116 **039 096 STATOR, generator .............. 1
117 020 908 ENDBELL, generator. ............ 1 1 - 1 1 1 1
118 SRA 039 124 RECTIFIER, silicon diede
Iconsisting of) .................. 1 1
119 D1-3 037572 . DIODE, 50 amp 400 volts straight
polarity «oii ieee a 3 3
122 020 847 . WASHER, shoulder 5/16 ID x
TB OD E 4 4
118 SR4 039 123 RECTIFIER, silicon diode
(consistingof) .:......... 1 1 1 1
119 D1-3 037 572 . DIODE, 50 amp 400 volts straight
polarity ..... coir | 3 3 3 3
120 VR1 039122 .VARISTOR, 150 volts w/ieads .. .. 1 1 1 1
121 582 035 704 . RECTIFIER, integrated 6 amp 600 >
volts... ee arena 1 1 1 1
122 020 847 . WASHER, nylon - shoulder 5/16 tD x
7/8 Ор .........,, 2..5... 4 4 4 4
*Recommended Spare Parts
**Rotor and Stator are available on an exchange basis, Contact Factory Service Department for details,
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-410 Page 6
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