Miller BIG 40 User manual

Miller BIG 40 User manual
December 1976 FORM: OM-450D
Effective With Serial No. HH005712 |
3
| MODEL STOCK NO.
BIG 40 900 955
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
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LIMITED WARRANTY
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EFFECTIVE: NOVEMBER 1, 1976
This warranty supersedes all previous MILLER warranties and 1S €X-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Miller Electric Mfg. Co., Apple-
ton. Wisconsin warrants to Customer that ail 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-Dieset engine 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 remedies
therefor shall be, 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 Miller service station or (4) payment of or credit for
the purchase price (less reasonable depreciation based upon
actual use) upon return of the goods 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 origi-
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
104 a mam 44M 4 = +
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3. All welding guns and feeder/guns 90 day»
4. All other Millermatic Fceders I year
provided that the user so notifies Miller in writing within thirty
(30) days of the date of such failure.
"41414 +4 =
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REP-
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 ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING. MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/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 TO. AND NO RE-
SELLER IS AUTHORIZED TO EXTEND MILLER'S WAR-
RANTIES TQ, ANY CONSUMER. Y
DA DISAIS DA DRE DSP
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual,
Effective With Serial No. HH026312
AMENDMENT TO SECTION 10 — TROUBLESHOOTING
NOTE
“The circuit diagramís) on this supplement replace any other circuit diagramís) appearing later in this‘
. manual. i
Amend Figure 10-1 as follows:
Z1
97314 A3d
REAR VIEW
* USED ONLY 1F REQUIRED TO =
COMPENSATE FOR YARIATIONS EQUIPMENT А | |
ux,
НЧ IRON CHARACTERISTICS GROUND sOWER /
NOTE GROUND STRAP MUST BE
INSTALLED BETWEEN ENGINE
FRAME AND WELTER FRAME
TACHOMETER
OPTIONAL)
= La x COL
WELD METERS
‚ —
LP GAS KIT AND
* TOTAL TIME METEA
(ОРТ ОМА)
| Ta
o NEGATIVE POSITIVE
+ em A m
\ N MANIFOLD A POLARITY SW
+ wal Lust Sy ETH. CORT 10MAL 3
ELECTRODE WORK
SCLENDID
VÈLYÉ
\ + +, Circuit Diagram No. CB-200 955-1Q
eo
Figure 10-1. Circuit Diagram
[tem Part No. Listed Replaced With
No. In Parts List Part No. Description Quantity
24 017 481 005 612 DOOR, side oct ttt tiie tere tetera 2
26 017 485 008 766 COVER, top ......i.-— —eonearecaornvdrereneacneremareveraro 1
33 019 231 008 777 ENCLOSURE, radiator ........ec_eesroccororromncorevo re reereen. 1
68 004 447 008 780 UPRIGHT, base - front .........r_ece.eaczoerornamecorararanter. 1
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450D Page À
Cs TABLE OF CONTENTS mu RT IZ TZ Sm
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. introduction ............_encecrczarnarerdoreeaare nr erocaren 1
1-2. General Precautions .........oeeemeorrsrsesrvarenvraronevenan a 1
1-3. Arc Welding........—..eerecoerescoerrsercarnoasoanacrvaroerarena | 3
1-4. Standards Booklet Index ...........e_e=enen-zorcecoseeenvervano.. 4
SECTION 2 — INTRODUCTION
2-1, General .........._.ecommencoaaoonnarenmonmona tte aaa aaa 5 _
2-2, Receiving-Handling ........_o.eorerceoreorr-araoreaacor acera ca 5
2-3. Description ..........eeonaczearvarendoreraocoarooacoreaaorervo 5
2-84, Safety ......1 1122 aa a 11 AL a a a 1e ea eee 11 a a a er 00 ma ne sa eu aa 006 5
SECTION 3 — INSTALLATION
3-1. Location ....11122001 2004 60 ee a a a 00 tetas rae rea aaa 6
3- 2. Weld Output Connections ..... 11.222020 0 44410 20 0 0 a RR ea ue a 1 02 0 0 7
3-3. Equipment Grounding Terminal .........._..o_ecererovroreonoroarao 7
SECTION 4 — ENGINE PREPARATION
4-1. Lubrication ........o irritate cia aaa 7
4-2. Coolant System .........oo.ecxrneroarmaneooanmeoore, envenena, 7
4-3. Preparing New Battery For Service ........-..cereemoreoreereaone». 8
4.4, Air Cleaner ...._....e eemenaoacioduroernocardedraroocarvorrarnaon» 8
4-5, FÜ ....eo..ecweecoorenmoraroserasocooracaservonrnorooaomorane 8
4 - 6. Carburetor Air Temperature Selector ........_.eere_eseonmornceocovare. 9
SECTION 5 — FUNCTION OF GENERATOR CONTROLS
5-1. 120 Volts AC Receptacle .........o -eeroroaoorvoroorcorereorarne, 9
5 - 2. Range Switch And Fine Amperage Control . .......... coin 9
5-3. Volt-Ampere Curves .........e_e.oe.sencnrreraracrerarerorcanoecro. 10
5-4, Meters — ...e.rr.areraarmnaraadonrareredoroacmaneonarenoroarer —. 10
5-5, Polarity Switch .......eooemocrererrsercorearere0recoananmreara»o 10
SECTION 6 — FUNCTION OF ENGINE CONTROLS
6-1. Choke Control .....112204 244000 4 10 40 4 00 4e 4 1 a 2 1 ua a a a 1 0 0e a ea ca 0 10
6 - 2. Start Push Button And Ignition Switch .. 11.120000 80000 0801 a au aa 0 0 0 10
6-3. Idle Control Switch .........—..__—eee.enaesdervoarenaernemoncavor—o 10
6-4. Engine Ammeter ,..........oeeermocavrrorecaarenocoraveraname 11
0-5. Temperature Gauge .......o.o_eererenvrorareecervorrrar ano Come 11
6-6. Oil Pressure Gauge ............eeeserorerecooxararererdasorreqaoa 11
6- 7. Electrical Tachometer .......122000 4024004 010 aa 0 a 1 a 0 a 0 0 1 a 00000 11
6-8. Hour Meter ...........e_oecerceaeonmerereceroraaoerreoraarracaxo 11
SECTION 7 — SEQUENCE OF OPERATION
7-1. Shielded Metal-Arc (SMAW) Welding ............. cia... 11
7-2. Starting The Engine........ooc_excxoeoresronmerecoreoronaoe nono 11
7-3. Engine Shut Down ........eqoe_ew_eceecerescsearoresaorrrermreraroao 11
SECTION 8 — GENERATOR MAINTENANCE
8-1. General tte eet aiid 4 a ae a ee sa eu aan» 12
8 - 2. Collector Ring Brushes ..... 1222224404 0044 4 1 a ea a 00 1 0 4 0 a 1 a 100 6 12
8-3. Welding Cables .....2.22220 4200 0 a eee a 4 ea sa ua a ee 0 as eus a 2 0020000 12
ZI TABLE OF CONTENTS MA
Section No, Page No.
SECTION 9 — ENGINE MAINTENANCE
9-1. Lubrication .........o_..eexcrresereronarearetarecacearoovoorarao 12
9-2. Coolant System .............e oeooanmmertodaroranoadaceravenma ena 12
9.3. Governor Service .......e ceo naaenaóaarareraoordarervaredrarordae na 12
9-4. Carburetor Fioat Setting ..........eooreamareorarannoenereodacore, 13
9-5. Vacuum Circuit Air Filter .......... paaanoodcorrramarearroroarco, 13
9-6. idle Control Time Delay Adjustment ........_._—.—eézeccxorooorrrerceoo, 13
9.7, Air Cleaner Service ......—..oremenocmortrenrnavaveaanonadore raro. 13
9-8. Idie Controt/Governor Linkage Adjustment ....... ee ree a R 15
9-9. High Altitude Carburetor Modification .............. co... 16
9-10. Key-Type lgnition Switch Lubrication .........oeeeeerenocoooreoo 17
SECTION 10 — TROUBLESHOOTING
PARTS LIST
mu SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE sum
1-1.
INTRODUCTION
We learn by experience. Learning safety through personal
experience, like a child touching a hot stove 18 harmful,
wasteful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of weld-
(ng and cutting are described in this manual. Research, devel-
opment, and field experience have evoived 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. itis 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 appiicable to the particular equipment
used and their instruction manuais, 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 into two Sections: 1
General Precautions, cornmon to arc welding and cutting; and
2 - Arc Welding {and Cutting} only).
Reference standards: Published Standards on safety are also
available for additional and more complete procedures than
those given in this manual, They are listed in the Standards
Index in this manual, ANS! Z43.1 ıs 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 asbestos} gauntiet
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear helmet with safety goggles or glasses with side shields
underneath, appropriate filter (enses or plates {protected by
clear cover glass}. This is aMUST for welding or cutting, {and
chipping} to protect the eyes from.radiant energy and flying
metai, Replace cover glass when broken, pitted, ar spattered.
See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
Medical first aid and eye treatment. First aid facilities and a
qualified first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns.
Ear piugs should be worn when working on overhead or in a
confined space. A hard hat should be worn when others work
overhead.
Flammable hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adequate ventilation. Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding {or cutting) may produce. Prevent
them with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, Zinc -, mercury -, and beryilium - bearing
and similar materials, when weided (or cut) may produce
harmful concentrations of toxic fumes. Adequate local
exhaust ventilation must be used, or each person in the area
as well as the operator must wear an air-supplied respirator,
For beryllium, both must be used.
Metals cogted with or containing materials that emit toxic
fumes should not be heated unless coating 15 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, rf necessary, while wearing an air-supplhed respirator.
Gas leaks in a confined space should be avoided. Leaked gas
in {arge 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 chiorinated 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 fradiant) energy of the arc can also decompose tri-
enloroethylene 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 trichioroethylene or perchloroethyiene.
Fire and Expiosion Prevention
Causes of fire and explosion are: combustibles reached by the
arc, flame, flying sparks, hot siag or heated material; misuse
of compressed gases and cylinders; and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors, and
through wail or floor openings, out of sight of the gogaled
operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, and
(in electncal parts) of metallic particies that can cause short
CHCUIS.
If combustibles are in area, do NOT weld or cut. Move the
work ¡f 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 wails within 35
feet may expose combustibles to sparks
d. combustibles adjacent to wails, 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 fi ames.
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 A6.0, listed 3 in Standards index.
OM-450 Page 1
Page 2
This includes: a thorough steam or caustic cleaning {or a
solvent or water washing, depending on the combustible’s
sofubility] followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom-
mended in A6.0. Waterfilling just below working level may
substitute for inerting.
A container with unknown content should be cleaned (see
paragraph above}. Do NOT depend on sense of smeil or sight
to determine if it is safe to weld or cut
Hollow castings or containers must be vented before welding
or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air may
contain flammable dust, gas, or liquid vapors {such as gaso-
line).
Compressed Gas Equipment
Standard precautions. Comply with précautions 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:
t_eaks - if gas leaks externally.
Excessive Creep + if delivery pressure continues to rise with
downstream valve closed.
Faulty Gauge - if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Repair. Do NOT attempt repair. Send faulty regulators for
repair to manufacturer's designated repair center, where
special techniques and tools are used by tramed personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit arcs that may lead to a serious accident. (See
1-3C,}
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is property 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 cylinder. It is illegal
and hazard ous.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Prohibited usé. 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
Obiects, and weather, Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify your
supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
Use ferrules or 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 sham edges, and by sparks,
slag, and open flame.
Examine hose regularly for teaks, wear, and loose connec-
tions. Immerse pressured hose in water; bubbles indicate
leaks.
Repair leaky or worn hose by cutting area out and splicing
{1-2D3). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint
less cloth.
Match regulator to cylinder. Before connecting, check that
the regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet match, NEVER CON-
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec-
tion leaks, disassemble, clean, and retighten using properly
fitting wrench.
Adapters. Use a CGA adapter {available from your supplier}
between cylinder and regulator, if one is required. Use two
wrenches to tighten adapter marked RIGHT and LEFT
HAND threads.
Regulator outiet (or hose) connections may be identified by
right hand threads for oxygen and left hand threads {with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder {or manifold valve) by turning adjusting
screw in {clockwise}, Draining prevents excessive compression
heat at high pressure seat by allowing seat to 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 {capful of Ivory Liquid" or
equivalent per gallon of water}. Bubbles indicate leak. Clean
off soapy water after test; dried soap is combustible.
User Responsibilities
Remove leaky of defective equipment from service immed-
iately for repair. See User Responsibility statement in equip-
ment manual.
Leaving Equipment Unattended
Close gas supply at source and drain gas.
Rope Staging-Support
Rope stagingsupport 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 invites trouble. The equipment carries high currents at
significant voltages. The arc is very bright and hot. Sparks fiy,
fumes rise, ultraviolet and infrared energy radiates, weld-
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standards referenced in index.
Burn Protection
Comply with precautions in 1-2,
The welding arc is intense and visibly bright. Its radiation can
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
more severe and painful. DON'T GET BURNED; COMPLY
WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sieeve clothing {particularly for gas-shieided arc) in
addition to gloves, hat, and shoes (1-2A). As necessary, use
additional protective clothing such as ieather jacket or
sleeves, fiame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated cotton.
Bare skin protection. Wear dark, substantial ciothing. Button
collar to protect chest and neck and button pockets to pre-
vent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an elec-
tric arc without protection.
Welding heimet or shield containing a filter plate shade no.
12 or denser must be used when welding. Place over face
before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be worn;
radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IM-
MEDIATELY. Replace clear cover plate when broken, pitted,
or spattered.
Flash googles with side shields MUST be worn under the
helmet to give some protection to the eyes should the helmet
not be lowered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particularly a
high intensity gas-shieided 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 tow-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for ali persons who
will be looking directiy 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 1-2B.
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill. -
Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc welding
equipment. |t 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. 11
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 metai 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 adeguate 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, enabiing 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 availabie,
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-
caily HOT - a dangerous condition that can shock, possibly
fatatly.
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 aswitchbox, connect the ground lead
to the grounded switchbox. If a three-prong plug ts added for
connection to a grounded mating receptacle, the ground lead
must be connected to the ground prong only. if the line cord
comes with a three-prong plug, connect to a grounded mating
receptacie. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
OM-450 Page 3
Page 4
2. Electrode Holders
Fully insulated electrode holders should be used. Do NOT
use hoiders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to join
weiding cable lengths.
4, Cables
Freguently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
damaged insulation to avoid possibly - lethal shock from
bared cable, Cables with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks,
5, Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units should
have insulating covers secured before operation.
6. Electrode Wire
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger IS pressed. Keep hands and body clear of wire and
other HOT parts.
7. Safety Devices
Safety devices such as interlocks and circuit breakers should
not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turning ON of power. Discon-
nect all cables from welding power source, and puli all 115
volts line-cord plugs,
14,
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 [atest revisions and comply as applicable:
1. ANS] Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, Fla. 33125.
2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA.-
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtainable from American National Standards
institute, 1430 Broadway, New York, N.Y. TO018.
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 S1B, 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.
2-1.
Welding Welding Current Ranges Open-Circuit Power Омега! Weight
Rated Current In Amperes Voltage While Dimensions (Pounds)
Output Range Coarse Ranges | Fine Range Range Welding {Inches} Net | Ship
300 Amps MIN. - 65 From Min 55 3 KVA
At 45 65 - 100 * 120 Volts AC - Length - 63”
40 Vols DC] To 100-175 | TO Max. of 29 50/60 Hertz AC | Width -24-3/4 | 1307] 1443
100% — | 400 Amps | 125-250 ach Loarse Weld Height -41-1/2”
Duty Cvele 225 - MAX. Range Volts DC Speed
Figure 2-1. Specifications
Fine
Amperage
Control (R1)
Exciter
Rectifier §
SRT)
Revolving
Field
{Exciter)
Stator
Windings
{Exciter)
чо № ноя ТТ
170 Volts
Receptacie
(RC1}
Alternator /
Regulator
idle
Control
Solenoid {GS1)
{die
Control
Switch (84) |
Starter
Solenoid
12 Volt
Battery
*Polarity
Switch {52}
Wald
Output
Terminals
Reed
| Switch E
(CR1) ‘
Key .
Ignition Ignition
Switch (51) | System
Y Optional
—|E Electrical Connectión
— — — Mechanical Coupiing
— < №» Magnetic Coupling
TB-008 826
Figure 2-2. Functional Diagram
GENERAL
This manual has been prepared especially for use in familiar
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. Ail 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 ioss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the biil 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 Numbér and
Serial {or Styie) Numbers of the equipment be suppiied.
2-3.
2-4.
DESCRIPTION
This welding generator is driven by a gasoline engine and
produces dc welding current. This unit is designed to be used
in conjunction with the Shielded Metal-Arc (SMAW) Welding
process. In addition, this weiding generator can supply up to
3 kva of 120 volts ac, 50/60 Hertz ejectrical power while
welding,
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 manuai:
OM-450 Page 5
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a hazard to per-
i sannel. 5
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-
1 ment. ]
NOTE
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
brume
--—_—_—_— — —— SECTION 3 - INSTALLATION. EA
3-1.
41.172"
Page 6
fh ==
LOCATION (Figure 3-1}
A proper instatlation site should be selected for the welding
generator if the unit is to provide dependable service, and
remain relatively maintenance free.
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
i bodily injury or loss of life. 1
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 min-
imum of 18 inches of unrestricted space must be maintained
between the welding generator front and rear panels and the
nearest obstruction, Also, the underside of the welding gener-
ator must be kept completely free of obstructions. The in-
stallation site should also permit easy removal of the cute
enclosure for maintenance functions.
—. 63" —— T° 24-3/4” —em
"Ada 2" for weather cap.
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 in-
ternal components to an overheating condition and
subsequent failure. Warranty is void if any type of
i filtering device is used. ]
Holes are provided in the base for mounting purposes. Figure
3-1 gives overall dimensions and the base mounting hole lay-
out.
On most welding generators a lifting device is provided for
moving the unit, However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under base.
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal com-
ponents to damage should the tips of the lift forks
I penetrate the bottom of the unit, 1
ENGINE END
> —
N 35 DIA.
|
59.1 78"
|
46-174"
!
34-3/4"
mm — A = off ——
-_— fp —— = ое # ео
26-15/16"
р — mm — — A
I
>
9.1/2"
a
2-7/8
4 1 1
h— 23-174" —— |e- 7/8"
— Ar
F—— 24-1 /8” — =
TB-004 200-A
Figure 3-1. Dimensions And Base Mounting Hole Layout
+
cable is 75 feet long and the work cable is 25 feet long,
select the size cable that is recommended for 100 feet at
the maximum weld current that would be used.
Table 3-1. Weld Cable Size
WELDINGL TOTAL LENGTH OF CABLE { COPPER) IN WELD CIRCUIT
AMPERES] *50 | 100 | 150 1 200 | 250 | 300 | aso | 400
32. WELD QUTPUT CONNECTIONS
The POSITIVE and NEGATIVE terminals are located behind
the lower front access panel.
Once the weld cables have been connected to the terminals,
the cables are to exit from behind the lower front access
panel through the two openings provided on the extreme
lower left and right corners (see Figure 3-2). 100 a a Ta 3 > 1 7/0 170
150 3 3 2. 1 1/0 2/0 3/0 3/0
200 2 2 1 1/0 2/0 3/0 4/0 4/09
250 1 1 1/0 2/0 3/0 4/0 4/0 2-2/0
300 [1/0 1/0 2/0 3/0 4/0 4/0 2.2/0 | 2-3/0
350 11/0 1/0 3/0 4/0 4/0 2-2/0 | 2-3/0 | 2:3/0
400 {2/0 2/0 3/0 4/0 2-2/0] 2-3/0 3-2/0 2-4/0
À -G02 702
NOTE: “A. 50 FEET OR LESS.
"B. CABLE SIZE 1S 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 OPEN-CIRCUIT VOLT-
AGE (OCv) OF THE WELDING GENERATOR MUST BE
USED. WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100
Ground VOLTS, SOME WELDING GENERATORS OF SPECIAL
Terminal DESIGN MAY HAVE HIGHER OPEN-CIACUIT
VOLTAGE.
2. Do not use damaged or frayed cables.
3. Follow the electrode holder manufacturer's instructions
for installing the electrode holder on the electrode cable,
4. Use correct lugs on weld cables to connect grounding
clamp and to connect the cable to the weld output termi-
nals.
>
TB-900 955-11-A
Fiqure 3-2. Weld Output Connections
A. Weiding Cables
5, Ensure that all connections are clean and tight.
Бо PMENT GROUNDING TERMINAL (Figure
3-2
3-3.
If welding cables were not ordered with the welding gener-
ator, the following instructions should be followed to ensure
the best welding performance:
Normally, engine-driven welding generators do not require
grounding. However, since this unit has auxiliary power plant
capability, grounding of the frame and case may be required.
A grounding terminal has been provided on the front panei
for this purpose (see Figure 3-2). For detailed grounding
used. Table 3-1 shows total cable length, which includes instructions consult your local or state codes or the latest
the electrode and work cable. Example: If the electrode issue of the National Electrical Code.
——— SECTION 4 - ENGINE PREPARATION
1. Use Table 3-1 as a guide for selecting correct cable size for
the anticipated maximum weld current which will be
IMPORTANT
See the Engine Manufacturer's manual (F-163 Engine)
for complete engine care.
brand)
New engines have very close clearance between their
moving parts. Therefore, it is recommended that !oad-
ing of the engine be kept to a riinimum during the
first 50 hours of operation. Be sure to check the oil
level several times each day during the engine break-in
period. This engine requires about 50 hours of running
time before it will be fully broken in,
4-1. LUBRICATION
This engine was shipped from the factory with its crankcase
filled with the correct amount and type of break-in oil unless
otherwise ordered. Check the oil level before attempting to
operate the engine. It should be up to the full mark on the
dipstick. Add a quality brand of detergent ail if the oil level
is low. See the oil selection chart, Table 8-1, in Section 9.
Keep Crankcase Oil
At This Level
Never Operate Engine
with Oil Below This Level
TA-900 033-3)
Figure 4-1. Oil Level
4-2,
After about 50 hours of running time, drain the break-in oil
and change the oil filter. See the oil selection chart, Table
3-1, in Section 9 for correct ou type and grade to use after
the break-in oil is drained.
COOLANT SYSTEM
The liquid capacity of the coolant system in this welding
generator is 9 quarts (U.S. Measure}. This unit is shipped
from the factory with the proper amount of water and anti- *
freeze to permit operation of the unit at temperatures down
to OCF,
IMPORTANT
If this welding generator is to be operated in tempera-
tures which are below O09F, additionai anti-freeze will
have to be added to the coolant system or the liquid in
the system will freeze and cause the engine to over-
I heat. ]
OM-450 Page 7
4-3.
Page 8
The coolant system is equipped with a 180©F thermostat, If
the thermostat should fail, ensure that the replacement has
an equal temperature rating.
IMPORTANT
If the thermostat should fail, repiace it immediately.
Do not run the engine without a thermostat. If the
thermostat remains closed, the engine will overheat. if
the thermostat remains open, or the engine is run
without a thermostat, the engine will run cold, As a
result, excess carbon will accumulate, and the oil will
i become contaminated with sludge. I
The radiator for this engine is equipped with a pressurized
cap which is rated at 7 psi. If this cap is ever replaced, ensure
that the replacement cap has a rating of 7 psi.
Caution should be exercised at all times when re-
moving the radiator pressure cap. The cap will turn to
an almost full open position, at which point a provi-
sion has been made to permit venting built up pressure
within the radiator. Allow the pressure to escape be-
fore completely removing the cap from the radiator
neck. When removing the cap, it is recommended that
a glove or rag be used to protect the operator's hand
i from possible exposure to extremely hot coolant.
PREPARING NEW BATTERY FOR SERVICE
IMPORTANT
Never attempt to operate the engine without the
battery connected. Do not attempt to remove the
battery while the engine is running.
Frame
Wet Charged Battery
Connect the negative battery cable to the negative (—)
terminal on the battery. This is all that is required to
put the battery into service providing it has not dis-
charged during transportation and warehousing. If the
battery has enough power to start the engine, it will
| charge up while the engine is running. J
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 80°F} when fully
charged. 1f the battery requires charging, see Section 4-38,
Step 4.
Dry Charged Battery
This battery is shipped in a dry state. A sufficient amount of
electrolyte is shipped along in separate containers to activate
the dry charged battery. To prepare the new battery for oper-
ation, 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 it on a level
worktable or other suitable area.
2. Fill the battery cells to the required level with electrolyte,
4-4.
4-5.
Do not dilute this electrolyte as it is premixed to the
i required strength.
3. Place a battery thermometer in one of the center cells and
check the specific gravity of each cell with a battery
hydrometer,
4. The battery should have a specific gravity of 1.260 (at
B00F) prior to installation. If this condition is not met,
charge the battery as follows:
Ensure that the battery caps are removed before charg-
ing. Failure to do so may cause the battery to explode
I should overcharging occur.
a. Use an automotive type battery charger. This battery
should be charged at about a 3.5 ampere rate until
correct electrolyte conditions are met. Lower charging
rates can be used: however, the time to obtain the
correct electrolyte conditions will be longer.
b. When the battery is charged, disconnect it from the
charger and recheck the electroiyte level. Add if neces-
sary. Install the battery caps.
¢. Rinse the empty electrolyte containers with water be-
fore discarding. Since battery acid is corrosive to
metals, do not pour into a metal sink or drain. Rinse
and mutilate the empty electrolyte container before
discarding. If acid has accidentally spilled on the
battery or work area during filling or charging, neu-
tralize with soda or ammonia solution and flush off
with clear water. Use the same procedure if acid is
spilled on clothing.
5. Reinstall the battery in the unit ensuring that the ground
cable is connected to the negative (—) battery terminal.
AIR CLEANER
This engine is equipped with a dry element type air cleaner.
The air cleaner requires no initial service,
FUEL
Do not attempt to fill the fuel tank with the engine
running. Do not fill the fuel tank completely as cold
fuel will expand when exposed to outside temperature
in a warm climate or to engine heat. [f the tank is too
full, it will overflow causing a potential fire hazard.
Never allow fuel to drain on the engine or other com-
i ponents. ]
IMPORTANT
Use a good grade of “regular,” "low-ead,” or “no-
lead” gasoline of at least 85 octane for this engine.
Fuels with a lower octane rating may cause detonation
(knocking) which could damage the engine. The “low-
lead’ or “no-lead’’ fuels lower the poilution factor and
reduce combustion chamber deposits if used exclusive-
i ly. ]
The capacity of the fuel tank is 17.5 gallons (U.S. Measure).
The fuel tank is equipped with a trap area in the bottom of
the tank. As a result, the tank will not go completely dry.
The trap holds water and dirt back from the engine. A drain
plug is located on the left bottom of the tank to drain water
and dirt from the tank if it should become necessary.
The fuel tank cap is equipped with a valve on the in-
side. This valve must be in the OPEN position at all
times or proper venting will not take place. Before
operation, examine inside of cap and ensure that valve
1 is rotated to the OPEN position. 5
Figure 4-2 illustrates typical fuel consumption under specific
load conditions. Fuel consumption will vary from one engine
to another, Different brands of fuel, operating conditions,
condition of the engine, etc., will affect the fuel consumption
of this engine.
Lo LITÉRS/HR.
IMP. GAL./HR.
U.S. GAL./HR
=
La
m
in
ti
Do
2B
Ea
Bop
8 3
8.52 187 215
7.57 17 1.0
6.62 146 175
567 1.25 1.5
4.73 1.04 1.25
3.78 08 10
2.84 0.672 0.75
198 C4 05
25 0.21 0.25
300 350 400
50 vo 150 200 2750
D.C. WELD AMPERES AT 100 DUTY CYCLE WELD
1 i | } 1 |
1.9 2.5 4.0 5.0 7.0 1.0
POWER KYA AT 100% DUTY CYCLE
¡E ATAN ADE
TB-005 606
Figure 4-2. Fuel Consumption Chart
4-6. CARBURETOR AIR TEMPERATURE SELECTOR
Manifold Stove
(Figure 4-3)
The air intake to the air cleaner is equipped with a selector
tube which allows the air to be drawn either from the sur-
rounding engine compartment air or heated air, drawn from
around the exhaust manifold of the engine. Heated air will
prevent carburetor icing in cold weather,
Air Cleaner
1 72"
> Air Selector
(Shawn in Cold
Weather Position)
TA-900 955-4
Figure 4-3. Carburetor Air Temperature Selector
Figure 4-3 shows the selector tube in the cold weather oper-
ating position. When the tube is in this position, it must
remain about 1/2” away from the air cieaner inlet.
For warm weather operation, loosen the selector tube and
slide it al! the way down against the manifold and retighten,
SECTION 5-FUNCTION OF GENERATOR CONTROLS
Fine Amperage Control 140
Range .
Switch N
\
A € VOLTS
le. i |
5-1.
weld Terminal
1 120 Volts AC
= Receptacie
/
y A
a
|
|
j
/
Negative Positive
Weld Terminal
TB-900 955-28
Figure 5-1. Generator Controls
120 VOLTS AC RECEPTACLE (Figure 5-1}
Up to 3 kva of 120 volts ac, 50/60 Hertz power is available at
this duplex receptacle for operating 120 volts ac or 120 volts
universal power tools, tights, etc., when the welding generator
is being operated at weld rpm.
The voltage will vary in accordance with the load applied 10
the 120 VOLTS AC receptacle. The voltage at various loads
may be determined from Figure 5-2.
5-2.
0 10 0220 0 40 ET 69
1 KYA 7 KVA 1 KA 1.75 KYA d 18 EVA dk YA
AC AMPERES
KYA OUTPUT
T8-002 188
Figure 5-2. AC Power Curve
RANGE SWITCH AND FINE AMPERAGE CON-
TROL (Figure 5-1)
IMPORTANT
Do not change the position of the Range switch while
welding or under load, as this causes arcing across the
contacts of the switch. This arcing causes the contacts
i to become pitted and eventually inoperative. I
The contacts of the FINE AMPERAGE control are of
the continuous type, thereby making it possible to
I adjust this control while welding. ]
The Range switch provides five coarse amperage ranges. The
range of each switch position is displayed on the nameplate.
OM-450 Page 9
5-3.
100
D € VOITS
Temperature ===. : LL
Gauge | y A © Comp
| O Switch
Engine TEE YfÑd A
Ammeter
6-1.
6-2.
Page 10
The FINE AMPERAGE controi permits the operator to
select a welding current between the minimum and maximum
values of the coarse range selected by the Range switch. The
scale surrounding the FINE AMPERAGE control is calibrated
from 0-100 percent in increments of 10. When using this con-
trol, the operator is selecting a percentage of the coarse range
in use, and not an actual amperage value.
VOLT-AMPERE CURVES (Figure 5-3)
The volt-ampere curves show the output voltage and amper-
age of the welding generator available at any point from the
minimum to maximum of each coarse range. The FINE
AMPERAGE control controls the output between the mini-
mum and maximum curves of each coarse range shown,
Load voltage is predetermined to a large extent by the arc
characteristics. With the use of the voit-ampere curves it is
possible to determine what the weld current will be at a
particular arc voltage. The volt-ampere curves show the mini-
1 1 1 de ados: ай
100 200 300 400 500 $00 F00 800
D ¢ AMPERES B-002 189
Figure 52. Volt-Ampere Curves
f
!
FF
/ Idle
L Control
1 Switch
“Start Push
/ = Button Switch
E x
= © J} Choke
oil > > Control
Pressure
Gauge TB-900 955-28
- Figure 6-1. Engine Controis
CHOKE CONTROL (Figure 6-1)
A CHOKE controi, for varying the fuel-air mixture to the
engine, is provided on the front control panel of the welding
generator. When the CHOKE control is pulied fully out, very
littie air will be admitted to the engine thru the carburetor
thereby supplying a richer mixture of fuel. This position is
required if the engine is cold when started. As the engine
warms up, it will be necessary to push the CHOKE control
inward slowly until it is pushed in as far as it will go, When
the CHOKE control is fully in, the engine should be ready for
operation.
START PUSH BUTTON AND IGNITION SWITCH
{Figure 6-1)
A START push button and key-operated ignition switch are
provided on the front panel for starting and stopping the
engine, Rotating the key-operated ignition switch fully
5-5.
SECTION 6 - FUNCTION OF
6-3.
mum and maximum curves of each coarse range. When the
FINE AMPERAGE control is adjusted, the volt-ampere curve
will fai! between the minimum and maximum curves of the
particular coarse range in use.
METERS (Optional)
This welding generator can be equipped with meters. The
meters are for monitoring the welding operation and serve as
an indication of the welding process. The meters are not
intended for exact current or voltage measurements. These
meters are internally connected tc the welding generator out-
put terminals. The voitmeter will indicate the voltage at the
weld output terminals, but wiil not necessarily indicate the
actual voltage at the welding arc. The ammeter will indicate
the current output of the weiding generator.
POLARITY SWITCH (Optional)
A POLARITY switch can be Icoated on the front panel. This
switch provides a convenient method for changing from one
polarity to the other without moving the leads from one
terminal to the other.
IMPORTANT
Do not change the position of the POLARITY switch
while weiding or under load, as this causes arcing
across the contacts of the switch. This arcing causes
the contacts to become pitted and eventually inopera-
1 tive. 1
tf the welding generator is equipped with a POLAR I-
TY switch (Optional), the weld output terminals are
| labeled ELECTRODE and WORK. 1
ENGINE CONTROLS
clockwise to Bun, and pressing the START push button will
engage the starter motor and start the engine. Once the
engine has started, release the START push button. To stop
the engine, rotate the key-operated ignition switch fully
counterclockwise to the Off position.
IDLE CONTROL SWITCH (Figure 6-1)
The automatic idling device saves fuel by allowing the engine
to idle when the welding generator is not loaded, The IDLE
CONTROL switeh controls the operation of this device,
LOCK IN Position
When the IDLE CONTROL switch is in the LOCK IN posi-
tion, the engine will remain at idie rom until an arc is struck.
When an arc is struck, the engine speed will increase to weld
rpm. Approximately 10 seconds after the arc is broken, the
engine will return to idle rpm. This time delay is adjustable
(see Section 9-6). The LOCK IN position may be used for
Shielded Metal-Arc (SMAW) Welding provided accessory
power equipment is not being operated from the 120 VOLTS
AC receptacie.
LOCK OUT Position
When the IOLE CONTROL switch is in the LOCK OUT posi-
tion, the engine will run at governed weld rpm (1800). This
position must be used whenever the 120 VOLTS AC recepta-
cle is utilized.
IMPORTANT
if 120 volts ac power equipment is going to be oper-
ated from the 120 VOLTS AC receptacle, ensure that
the equipment is “off” until the engine is operating at
full rpm. The same hoids true when returning the
engine to idle. If power tools are operated while the
engine is idling, low voltage and frequency (resulting
from the lower engine idling rpm} at the power re-
ceptacle may cause damage to the 120 volts equip-
ment. |
6-4.
6-6.
ENGINE AMMETER (Figure 6-1)
This meter, labeled AMPERES, is located on the front panel
and registers the charging current supplied to the battery by
the alternator. The meter also registers a discharge equivalent
to the amount of current being used by the engine's electrical
system when the alternator is not charging.
TEMPERATURE GAUGE (Figure 6-1)
This gauge, labeled WATER TEMP, registers the coolant
temperature and indicates when overheating occurs. The
gauge is located on the front panel.
OIL PRESSURE GAUGE (Figure 6-1)
This gauge, labeled OIL. PRESSURE, is located on the front
panel and registers the engine lubricating system pressure in
6-7.
6-8.
pounds per square inch. Normally, after the engine has
warmed up, the pressure registered by the gauge should re-
main constant for a given engine rpm. Should the pressure
fiuctuate or drop, stop the engine and do not operate the
engine again until the trouble has been remedied.
ELECTRICAL TACHOMETER (Optional)
This unit can be equipped with an electrical tachometer. The
tachometer, labeled RPM X 100, is located on the radiator
support. The tachometer registers engine speed from 0-4000
rpm.
HOUR METER (Optional)
This unit can be equipped with an hour meter. The meter,
labeled TOTAL HOURS, is located on the front panel and
registers the total hours of engine operation. This informa-
tion is useful for routine maintenance on the engine,
Never, under any circumstances, operate the welding
generator with any portion of the outer enclosure
open or removed. In addition to being a hazard to
personnel, weather protection to the internal com-
ponents of the unit will be greatly reduced, Warranty
is void if the welding generator is operated with any
1 portion of the outer enclosure open or removed. J
7-1. SHIELDED METAL-ARC (SMAW)} WELDING
1. Ensure that the engine has been prepared as instructed in
Section 4.
2. Make connections to the weld output terminals as re-
quired,
3. Rotate the Range switch and FINE AMPERAGE control
to the desired position.
IMPORTANT
Do not change the position of the Range switch while
welding or under load, as this causes arcing across the
contacts of the switch. This arcing causes the contacts
1 to become pitted and eventually inoperative. |
The contacts of the FINE AMPERAGE control are of
the continuous type, thereby making it possible to
| adjust this control while welding. 1
4. Start the engine as instructed in Section 7-2.
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 or permanent bodily
i damage. I
5. Place the IDLE CONTROL switch in the desired position
and commence welding.
7-3.
7-2. STARTING THE ENGINE
IMPORTANT
Check the engine oil level and radiator coolant level. -
Ensure that no loose parts, etc., are laying in or on the
unit. Make the necessary connections to the generator
before attempting to start the unit. Fill the fuel tank
1 with fresh gasoiine. |
1. Make all welding and electrical connections to the welding
generator.
2. Place the IDLE CONTROL switch in the LOCK in posi-
tion. This should be done to permit the engine to warm
up at idle rpm.
3. Choke the engine as necessary.
4. Rotate the key-operated ignition switch fully clockwise to
the Run position.
5. Press the START push button.
IMPORTANT
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
1 motor, otherwise the ring or pinion may be damaged. |
6, When the engine starts, release the START push button.
As the engine warms up, slowly push the CHOKE in.
ENGINE SHUT DOWN
1. Remove all weld and power loads from the unit.
2. Allow the engine to idie for a few minutes to permit the
internal engine temperature to equalize. Increase the
idling time if the engine has been operating for an ex-
tended period or at full load.
IMPORTANT
Do not operate accessory power equipment from the
120 VOLTS AC receptacle during the engine shut-
down-idiing period.
| —. |
3. Rotate the key-operated ignition switch fully counter-
clockwise to the Off position.
OM-450 Page 11
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
| negative (-) battery cable from the battery, |
8-1. GENERAL
The efficiency of the welding generator depends a great deal
on the care and attention given it. By following a definite
schedule of inspection and service, failure caused by negiect
can be avoided.
Occasional blowing out of the unit with clean, dry com-
pressed air is recommended. This should be performed perio-
8-2.
8-3.
SECTION 8 - GENERATOR MAINTENANCE —
dically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere.
COLLECTOR RING BRUSHES
The brushes should be inspected periodically. Brush life is
very good under normal conditions. If the generator has been
operating in an extremely dusty or dirty location, a close
check of the brushes for freedom of movement and cleanli-
ness shouid be made weekly. Under normal use the slip rings
will discoior to a dark brown. If it should become necessary
to clean the slip rings, use 2 3/0 or finer sandpaper followed
by a crocus cloth. Never use emery cloth as part of the emery
will embed itself into the rings and in turn destroy the carbon
brushes.
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.
Refer to the engine handbook for detailed information
concerning maintenance on this engine. While the
handbook is a general coverage type publication, it
does contain vital maintenance instructions for this
engine,
Lame анна онннннииннннннннний
9-1. LUBRICATION
IMPORTANT
This engine may use oil during the break-in period
{first 50 hours of operation). Check the oil level
several times a day during this period. The load on the
engine should be kept as light as possible during the
| break-in period. I
After about 50 hours of running time on the break-in oii,
drain the oil and change the oil filter. Premium heavy duty
oil, manufactured by any one of the major oll companies,
should be used as a replacement oil. Table 9-1 gives a list of
recommended grades and types of oil to use to keep oil level
up during break-in and to use after the break-in oil is drained.
The capacity of the engine with a filter change is 4-1/2
quarts, without a filter change, 4 quarts, Check the dipstick
to make sure oil level is up to the required operating level.
in normal operation, the oil should be changed after about
50 hours with a filter change every 150 hours. The oil should
be drained after the engine has been warmed up to normal
operating temperature, thus promoting foreign particle sus-
pension in the oil and removal when the oil is drained. For-
eign particles tend to settle at the bottom of the crankcase
when the oil is allowed to cool, avoiding removal and con-
taminating the new oil.
Table 9-1. Oit Selection Guide
Above 90 degrees Fahrenheit SAE 30 or 10W-30
Not lower than 32 degrees SAE 20 or 20W
10W-30 or 10W-20
As low as 10 degrees SAE 20W
above zero Fahrenheit 10W-30 or 10W-20
As low as 10 degrees SAE 10W
below zero Fahrenheit 10W-30 or 10W-20
Lower than 10 degrees SAE SW or SW-20
below zero Fahrenheit
9-2. COOLANT SYSTEM
If the engine is to be operated in a temperature below OOF,
ensure that a good grade of ethylene glycol anti-freeze is
Dems 117]
9-3.
added to the coolant system. Change the coolant solution as
often as necessary. The coolant system capacity is 9 quarts
(U.S. Measure).
During the break-in period of a new engine, one of the
greatest dangers is overheating. There are several possible
causes of overheating, but the basic causes are a lack of
engine lubrication and coolant circulation,
At the first sign of overheating, shut the engine down and
make a thorough check to determine the cause.
Temperature of the engine coolant is requlated by a thermo-
static valve located in the outlet at the front of the cylinder
head. This unit retards the flow of coolant until a predeter-
mined temperature is reached, usually varying between
1709F and 1809F. When the desired temperature is achieved,
the valve opens and free circulation of the coolant through
the system begins.
IMPORTANT
If the thermostat should fail, replace it immediately.
Ensure that the replacement has an equal temperature
rating. Do not run the engine without a thermostat. If
the thermostat remains ciosed, the engine will over-
heat. If the thermostat remains open, or the engine is
run without a thermostat, the engine will run cold. As
a result, excess carbon will accumulate, wetstacking
will occur, and the oil will become contaminated with
| sludge. I
IMPORTANT
The engine fan and alternator belts are subject to
normal wear and should be checked for proper tension
periodically. Check and readjust tension after the first
50 hours of operation, and whenever beits are re-
I placed. I
GOVERNOR SERVICE
The governor speed setting and sensitivity setting are factory
set to obtain correct weld rpm and engine response to chang-
ing load conditions. The governor speed control setting is
factory locked with a lead seal. Do not remove this seal un-
less absolutely necessary.
The governor, as used in conjunction with this engine,
does not have a “No Load Surge’ adjustment as de-
i scribed in the Engine Manual, i
9-4.
The engine is factory set to operate at 1050 rpm idle speed
and 1800 rpm when it comes up to weld speed. For informa-
tion concerning governor adjustment, refer to the Engine
Manual, Fuel Systern Section.
CARBURETOR FLOAT SETTING
Zenith Carburetor
Do not bend, twist, or apply pressure on the float
bodies. The float bodies, when viewed from the free
end, must be centered between and at right angles to
the machined surface, and must move freely on the
float axle.
(DD оннноанананеннний
To ensure correct fuel level in the float chamber, check dis-
tance (dimension A, Figure 9-1} from top of floats to
machined surface of throttie body (no gasket) with throttle
body inverted. This dimension should be 1-5/32 inches plus
or minus 1/32 inch. To increase or decrease distance from the
top of the float bodies to the machined surface, use a long
nose pliers and bend the float lever 2t a point close to the
float body.
TA-900 955-7
Figure 9-1. Carburetor Float Setting
В. Marvel-Schebler Carburetor
To ensure correct fuel level in the float chamber, check dis-
tance (dimension B, Figure 8-2) from top of floats to gasket
face with throttle body inverted. This dimension should be
1/4”, To increase or decrease distance from the top of the
float bodies to the gasket face, use a long nose pliers and
bend the float lever at a point close to the float body. The
edge of the float should be kept paratlel with the gasket.
Figure 9-2. Carburetor Float Setting
9-5.
VACUUM CIRCUIT AIR FILTER
To provide clean air for the vacuum circuit, a brass fitting
type air cleaner is provided on the underside of the idle con-
trol valve. See Figure 9-2 for, location on the engine. This
brass fitting will have to be removed and cleaned in a suitable
solvent periodically to ensure proper engine operation.
9-6.
9-7.
1
|
|
|
|
TEE EEE op CU Split A A N EE
eo —_
Brass Fitting Located
On Underside OF (dle
Control Valve.
TA-900 955-10A
Figure 9-3. Vacuum Circuit Air Filter Location
IDLE CONTROL TIME DELAY ADJUSTMENT
(Figure 9-4)
In Engine Compartment
I 1
I ke Manif |
O nta e Manifold |
Screw “a” |
pm
Adjust Clockwise 1/8” |
Turn At A Time To in- |
crease ldle Time Delay.
TA-900 955-3A
Figure 9-4. Idie Control Time Delay Adjustment
Operation of the idling device is automatic when the IDLE
CONTROL switch is in the LOCK IN position. When the
engine is started, engine speed will remain at idle until an arc
is established, at which time the engine immediately comes
up to weld rpm. When the arc is broken, a time delay will
exist before the engine returns to idle rpm. The length of this
time delay is controlled by the setting of Screw “A” in
Figure 9-4. This screw is located on the vacuum line fitting
going into the intake manifold of the engine. Figure 9-4
shows the adjustment of this screw.
AIR CLEANER SERVICE {Figure 9-5)
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. An engine con-
sumes several thousand cubic feet of air per hour when oper-
ating. If dirty air gets into the engine, it can wear out a set of
piston rings within a few operating hours.
A dirty air cleaner element is usually accompanied by a loss
of power and black smoke in the engine exhaust. Servicing of
OM-450 Page 13
the element is accomplished in the following manner: Re-
move the filter element lock assembly and seal. Inspect the
gasket on the end of the element for damage. Clean the
element as indicated in Figure 9-5. Wipe out the inside of the
air cleaner housing before installing a new or cleaned ele-
ment. Do not use the element if the seal is damaged or
missing.
IMPORTANT
Do not operate engine without the air cleaner element
in place. It is recommended that the element be re-
placed after ten washings or 3 months, whichever
i comes first, |
When it becomes necessary tO service the air cleaner in
the field, follow the Steps in Figure 9-5. It is recom-
mended that a spare element always be kept on hand
for replacement. New elements are available from your
| distributor. }
For a temporary expedient
in the field, the element
can be cleaned by tapping
the side or the end care-
fully against the paim of
the hand.
CAUTION: Do not tap ele-
ment against a hard surface.
The element may be damaged
by doing so.
5.
Shake out excess water from the
element and allow to air dry.
CAUTION: Do not attempt to remove
excess water by using compressed air.
Page 14
Compressed air, not to ex-
ceed 100 Ibs. of pressure
can clean the element. in-
sert nozzle inside the ele-
ment and blow out dust.
Clean dust from the out-
side of the element by
holding the nozzle at least
6 inches from the ele-
ment.
An even fine pattern of light
through the element, when a
light is held inside the element,
indicates that the element is
clean. Any large spot of light in-
dicates that the element is dam-
If compressed air is not
available, or if soot, oily
vapor, or any dirt is pres-
ent which cannot be re-
moved by compressed air,
then the element is to be
washed. Agitate element
in warm water containing
a non-sudsing detergent.
CAUTION: Do not use water
hotter than the hand can
stand; solvents or oil; fuel oil,
or gasoline,
7.
To minimize down time, created
by waiting for the element to dry,
it 1s suggested that the newly
cleaned filter be replaced by a
similar standby unit.
aged and, therefore, is unfit for
further use. Replace the element.
Figure 9-5. Air Cleaner Service
Reverse flush with clean
water to thoroughly rinse
all loosened foreign ma-
terial from the filter.
oe a
+
de +
tam did EDLs
a
-
+
< а оч аа ке Е
=
TA-900 716-7
A—5See Figure 9-1
10 De =
9 17
12
14
25 24
Carburetor
Governor
Vacuum
Matar
Unit
TC-003 226
Figure 9-6. Idle Control/Governor Linkage Adjustment And High-Altitude Carburetor Modification
9-8. IDLE CONTROL/GOVERNOR LINKAGE ADJUST- 3. Loosen the alignment screw (7) and position the arm
(8) radially and lateraily until the following conditions
are simultaneously met:
MENT (Figure 9-6)
In the event that proper engine idle and/or weld rpm is not |
being attained, perform the following procedures to calibrate A. Position the arm (8) laterally so that the carbu-
the engine for proper idle and weld rpm: retor linkage socket (4) does not touch the
throttle stop plate {2} throughout its entire
1. Adjust the length of the governor linkage {item 1, travel.
i - | | | н
ee that Ihe To acuer me finkage (1) B. Position the arm (8) radially so that the arm (8)
loosen the linkage securing nuts (5) and remove the ony oie Tine drawn Derpendicular to
hardware (6) securing the finkage socket(s) {4} to the the enter of the throttle shaft ru
governor and carburetor. Rotate the linkage socket(s) ;
(4) accordingly to obtain the 1/32” gap. Clockwise Tighten the alignment screw (7) and recheck the ad-
rotation of the linkage socket{s) (4) will shorten the
governor linkage (1) and reduce the gap. Conversely,
counterclockwise rotation of the linkage socket{s) (4)
with lengthen the governor linkage (1) and increase
the gap.
justments made in Steps 1 and 2.
Ensure that body limbs are clear of the fan and the
2. Rotate the linkage socket{s) {4} slightly until the vacuum motor unit before starting or working on the
socket(s) {4} are parallel but in opposite directions engine.
with respect to each other, Secure the linkage socket Й ue ——— |
nuts (5) to lock the position of the linkage socket(s}
(4). 4. Recheck all connections made thus far. Place the
IDLE CONTROL switch in the LOCK QUT position.
IMPORTANT Start the engine and allow it to reach normal operating
temperature (about five minutes). Ensure that the
CHOKE control is pushed fully in at this time.
Check the linkage (1) for freedom of movement
throughout its entire travel, If the linkage (1) is bind- 5. Pull the arm (8) toward the front of the welding gener-
ing due to the linkage socket(s) (4) being cocked ator to the idle position. Maintain pressure on the arm
relative to each other, repeat Step 2. {8) to butt the idie screw (10) against the stop (3)
Cromwell throughout the following adjustments:
OM-450 Page 15
Page 16
A. Rotate the idle screw (10) to obtain 550 mm.
Clockwise rotation of the screw (10) will in-
crease engine rpm, whereas counterciockwise
rotation of the screw {10} will decrease engine
rpm.
B. Rotate the idle mixture adjustment screw {11)
clockwise until the engine begins to falter or
roll: then rotate the screw (11) counterclock-
wise until the engine operates smoothly. Rotat-
ing the screw {11} clockwise restricts the air
flow, making the air-fuel mixture richer. Rotat-
ing the screw (11) counterclockwise admits
more air, making the air-fuel mixture leaner,
6. Manually pivot the vacuum motor arm (14; until screw
(16) butts against the vacuum motor unit mounting
plate. If this is not possible due to the idle screw (10)
butting against the stop (3) before the screw (16)
butts against the mounting plate, adjust screw (16) so
that screw (16) butts against the vacuum motor unit
mounting plate before idle screw (10) butts against
stop (3).
IMPORTANT
Ensure that the screw (16) butts against the mounting
plate BEFORE the idle screw {10} butts against the
stop (3) prior to placing the [IDLE CONTROL switch
L in the LOCK IN position. I
7. Place the IDLE CONTROL switch in the LOCK IN
position. Operation of the idling device is automatic
when the IDLE CONTROL switch is in the LOCK IN
position. Once the engine is started, engine speed will
remain at idle until an arc is established, at which time
the engine immediately comes up to weld rpm, When
the arc is broken, a time delay will exist before the
engine begins to return to idle rem. The length of this
time delay is controlled by the setting of the time-
delay screw “A” in Figure 94, If the engine does not
go to idle speed after about ten seconds, adjust the
time-delay screw (A) for the desired time delay. This
screw is located on the vacuum line fitting going into
the intake manifold of the engine. Figure 94 shows
the adjustment of this screw.
8. When the engine has gone to idle speed, adjust screw
(16) until 1050 rpm is obtained.
Do not readjust the idle rpm screw (10) when adjust-
| ing the vacuum motor idle rpm. 1
IMPORTANT
Check the linkage (12) for freedom of movement
throughout its entire travel. If the linkage {12) is bind-
ing due to the linkage socket {14) being cocked rela-
tive to the linkage (12) fixed end, adjust the length of
I the linkage and repeat Steps 6, 7, & 8. I
9. Place the IDLE CONTROL switch in the LOCK QUT
position. Loosen the governor speed adjusting screw
securing nut (19). Adjust.the governor speed adjust-
ment screw (20) until a high idle rpm of 1800 is ob-
tained. Tighten the securing nut (19) to maintain the
governor speed setting.
9-9.
9-10,
10. Check the governor engine regulation by applying and
removing the engine load. If a governor sensitivity ad-
justment is deemed necessary, loosen one of the two
locking nuts {21) and proceed with the following in-
structions:
A. IF REGULATION RANGE IS TOO BROAD -
Decrease the governor spring (22) tension by
sliding the sensitivity adjustment screw (23)
inward.
B. IF REGULATION RANGE IS TOO NARROW
— Increase the governor spring {22) tension by
sliding the sensitivity adjustment screw (23)
outward.
C. IF ENGINE SURGES (HUNTS) UNDER
LOAD — Increase the governor spring (22) ten-
sion by sliding the sensitivity adjustment screw
(23) outward.
11. Tighten the two locking nuts (21) to maintain the
desired governor sensitivity, Readjust the governor
sensitivity by repeating Step 10.
Whenever the governor sensitivity (Step 10) is ad-
justed, the governor speed (Step 9) must be re-
adjusted. Whenever the governor speed (Step 9) is ad-
justed, the governor sensitivity (Step 10) may need
| readjustment. I
HIGH-ALTITUDE CARBURETOR MODIFICATION
(Optional) {Figure 9-6}
The carburetor can be equipped with an adjustable main jet
for high-altitude operation {about 4000 ft). Minor adjust-
ment will be necessary for proper operation at a particular
altitude. Whenever a carburetor adjustment is deemed neces-
sary, see Figure 9-6 and proceed as follows:
Loosen the main adjustment screw locking nut (25). Apply a
near-full engine load to the welding generator. Rotate the
main adjustment screw {24) clockwise until the engine begins
to falter and lose RPM. Rotate the main adjustment screw {24)
counterclockwise until the engine operates smoothly; then
continue counterclockwise rotation for 1/4 turn. Rotating
the screw (24) clockwise restricts the fuel flow, making the
air-fuel mixture leaner. Rotating the screw (24) counter-
clockwise admits more fuel, making the air-fuel mixture
richer. Remove the engine oad. Tighten the locking nut {25).
IMPORTANT
Restricting the fuel flow to the point where the mix-
| ture is too lean wilt cause valve burning. I
KEY-TYPE IGNITION SWITCH LUBRICATION (if
Applicable)
Periodically, depending on the location of the unit and the
amount of moisture in the air, or when binding is noticed,
remove the key and lubricate the IGNITION switch by
spraying a generous amount of lubricant into the key slot.
Wipe excess off the nameplate. It is recommended that a non-
gumming lubricant with anti-oxidant properties be used.
—_—— "—m—— ECTION 10 - TROUBLESHOOTING ———"—"— mens
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 per-
forming 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 weld output.
Poor contact between slip rings
and brushes.
Clean the slip rings. See Section 8-2.
Replace the brushes.
Range switch (53) between
positions.
Place Range switch (83) properly in desired position,
Erratic weld current.
Damp or defective electrodes.
Use new, dry electrodes.
Loose or dirty connections.
Check connections both inside and outside of welding
generator.
Check leads and contacts of the
Range switch (83).
Discoloring of brass contacts could indicate heating caused
by loose connection. Replace contact or switch plate.
Engine speed remains at idle rpm
when arc is struck.
Magnetic field not closing reed
switch (CR 1).
Replace reed switch {CR 1}.
Coil of idle control solencid valve
burned out.
| Apply 12 vdc to solenoid coil € check for proper operation.
Filter on solencid piugged.
Clean filter. See Section 9-5 for cieaning procedure.
Engine will not return to idle rpm
when arc is broken.
idle control valve closed.
Open valve by turning in a counterciockwise direction,
Idle contro! valve plugged.
Remove and clean.
Leak in vacuum line.
Check line.
Shorted Idle Control switch {84}.
Check switch (S4) with ohmmeter.
No output at 120 VOLTS AC
receptacle (RCT).
Poor contact between slip rings
and brushes.
Clean the slip rings with 3/0 sandpaper, and, if necessary,
install new brushes.
Rectifier (3R1) defective.
Check rectifier (SR1) and replace if necessary.
No output at weld terminals;
output normal from 120 VOLTS
AC receptacle {RC1).
Poor contact between siip rings
and brushes.
Clean the siip rings with 3/0 sandpaper, and, if necessary,
install new brushes.
Defective FINE AMPERAGE
control (R1).
Check FINE AMPERAGE control (R1). Replace if necessary.
Rectifier (SR2) defective.
Check rectifier (SR2) and replace if necessary.
Engine ran fine but slowly
stopped; unable to restart engine,
Fuel tank cap vent in CLOSED
position.
Examine inside of fuel tank cap and rotate valve to the
OPEN position.
OM-450 Page 17
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MODEL/STOCK NO. SERIAL/STYLE NO, DATE PURCHASED
PARTS LIST
HI "TES
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Figure A — Main Assembly
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TR-900 955-E
OM-450 Page 2
Page 3
Item Dia.
Factory -
No. Mkas. Part No, Deseription Quantity
Figure A Main Assembly
1 017 430 STRAP, holddown - fuel tank .......... eter eae 2
2 010434 STRIP, rubber 1/2 x 2x 4-1/2... RR 2 4 ea 1 00 0 0 2
3 006 698 TANK, fuel (consisting of} ........220204 0404 010 aa 10 1 0 0e 0446 1
4 018858 CAP i eee rte eee 1
602 938 PLUG, galvanized - pipe 1/8 MPT (used on bottom of fuel tank)... 1
5 018 158 FUEL LINE, {used with Zenith carburetor) (consisting of} ...... 1
6 010870 .NIPPLE, brass 1/8 MPT ..........0es.0neraadrreceercza»o 1
7 010318 .VALVE,shut-off .......—...e..aeseereeadidarerooreanmoeco 1
8 006 014 .FITTING, brass - flared inverted elbow M 1/4 x 1/8 NPT ...... 1
9 010289 .CONNECTOR, brass 1/4 TEG 1/8 PT ....... iii... 1
10 010387 .LINE, fuel ........._.eeceeareconenavenrrerereaaecoreo 1
++007 829 LINE, fuel .........e _.e.eeoeroesverraverseccerereranae aero 1
+006 014 FITTING, brass - flared inverted elbow M 1/4 x 1/8 NPT ....... 2
++010 870 NIPPLE, brass 1/8 MPT .............. 0020. 00aaeredrev... 1
+010 318 VALVE, shut-off ............e.emraroododarer.aararroros 1
+010 289 CONNECTOR, brass 1/4 TBG 1/8PT .............—.e.seevo 1
11 017 479 SEAL, fting eye ... iii ett tte ee tte rea 1
12 031868 BRACKET, mtg-air cleaner 2202024212 La aa ea 1 ea a ua 0 00 1
13 018765 AIR CLEANER, intake (consistingof} ..................... 1
14 018859 CAP «oe ee ee rea aa 1
15 D10433 .NUT,wing ...... —..._esseroacora reraraaroerevatdecerno> 1
16 *017 309 ELEMENT .......... e .0srevrveacaraeararoneoene recorro. 1
17 018861 .BODY ......e.eereseerarareoornvaaareooranoareaane mo 1
000272 .CLAMP, air cleaner .........es.enearmoraroreanrveroon. 1
18 010 861 CLAMP, hose ...........—ee.emaereereredearercersrrrermara 5
010862 CLAMP, hose 1-13/16 - 2-1/2 cilamp dia. ..........e.e.e=ee.. 1
19 018365 HOSE, intake - air ..........ommarranmermerderzoneareacane. 1
20 023 626 CABLE, battery - Positive .......e..eecencocraer:redorero. 1
21 022 899 DOOR, access - battery cir itt ieee ties a 120» 1
22 017421 CATCH, door ...........o.eeresseronarazorereanravavreo 2
23 010515 BOLT,J5/16-18 1.111111 244 44 44 44 4 4 4 a La ea a 0 1 a ae sa 0» 4
24 017481 DOOR, side .....,200 120124 4 a 4 a 2 4 4 4 4 1 11 0 a 0e ea 8 2 0 1 10 000 0 2
25 035 968 WASHER, neoprene 5-7/8 OD x 3-5/8 ID x 1/16 .. AS 1
26 017485 COVER 2ER RR 1 eV a a a 44 1 ea aa 0 0» 1
27 027 529 PIN, cotter 174 - 3-1/2 111111100110 2 14 4 eV LL Le 4 ae a eee a ee 6 6
28 012487 LABEL, pushdowntouniatchdoor ....................... 2
29 027572 GUARD, fan - left hand iii iii 1
30 *017 363 HOSE, radiator - Upper RR 1
31 028 404 RADIATOR (consisting of) .....22224 0444404 144 414 14 01006 1
32 031 254 | CAP, radiator «oo. viet ie tte tar teat etree 0 0 1
33 019231 ENCLOSURE, radiator ......_._eeerereereorererecorareoo 1
34 027573 GUARD, fan - right hand ........._.ceeoreredceccoesoereeererne 1
35 006 015 FITTING, pipe - brass drain cock 1/4 NPT .........e—.—eo_—eese. 1
36 006 037 HOSE, radiator - lower .......oee.eeoremesonorererervcorao 1
37 BLADE, fan (included with engine - see engine parts list) ....... 1
38 BELT, V (included with engine - see engine parts list} .......... 1
39 031980 ENGINE, gasoline (consistingof) ....... cca. 1
40 018757 . CONTROL, weld & idle vacuurn {See Fig. BPage 5) .......... 1
41 020 365 .STOVE, manifold ...........2ereseresxsia sere carece. 1
42 017594 .CLAMP, StOVE eK RER 2 La 0 0 4 4 0 ee ae a 0 1
43 +039 238 . SENDER, temperature Datcon or |
43 +025 453 SENDER, temperature.........o_o eermeeererxvrocreremeeo. 1
44 039 240- . SENDER, oil pressure Datcon or
44 +025 884 . SENDER, oil pressure .........oeearaaorrrorrerearerere 1
45 025 182 .BRACKET, mtg -alternator ............._e.é.eeeerecoareo. 1
46 605 429 .ALTERNATOR, 35 ampere 12 volts ........... re cervaróa 1
026 837 . INSULATOR, terminal - nylon (use with alternator leads} ..... 1
47 605430 .PULLEY, single belt ...........ecxecxeroderareredreorerco. 1
48 025181 . TUBING, steel 5/8 OD x 12 ga wall x 1/2 ................. 1
49 027541 _.PIPE,exhaust......12200 4104 004 444 ea 11 41 60 1 ee 1 0 0 00 8000 1
[tem Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure A Main Assembly (Cont'd.)
50 017389 .CAP, weather Мо. 4 ...... ana coaonoarcorvnvanora eee 1
602 898 . NIPPLE, brass-pipeclose 1/8MPT ....... cc iii, 1
51 Figure C GENERATOR ASSEMBLY (SeePage 6) ..................... 1
52 017477 ROD, holddown - battery ....... ec_m_emeommeraroar ear mareado 2
53 Batt *015 709 BATTERY, 12 volts 53 ampere hour .........e—._e—eeeveroreoo 1
54 023641 CABLE, battery - negative ..........220 2440008000 1 0 50 a 0400 1
55 017 431 HOLDER, battery .........o_oeooocoogorerorcararmaronencora 1
56 023 892 CABLE, ground - engine .......er_ecw_ewreosnorerecorearervarca 1
57 004 444 UPRIGHT, base - center .......ee.ee_eoceorreverozszoreszovere 1
58 | MOUNT, engine {included with engine - see engine parts list} ..... A
59 010266 SPRING ..........—.oe_eóxmeorcdcoreaamnorarvvarerorernavz,. 2
60 017420 LATCH, door .........._.eé.ee.esnerareresrooroo rare se cer. 2
61 22 027 982 STABILIZER.....Ñ.........ereavorarareervenarenaoanac ca 1
62 000553 MOUNT, dual stud - generator .........._eeereoorsoracereeeo 2
63 031 961 INSULATION, rectifier .........r—ennnenrcaorerocorarerenve, 1
64 035860 RECTIFIER ASSEMBLY (consisting Of) .........—.e.eresmoreoo 1
65 SR1.2 035 704 .ARECTIFIER, integrated 6 amp 600 volts ..............ceee.s 2
66 031926 .HEATSINK.....L.2202 04124 44 1e 2 0e 0 10 0e a 0 0 se 0 0 01 a 500 0 1
VR1 038 493 VARISTOR, 3 joule 390 voits .......224414000 0082111 1120 1
67 004 291 BASE .....L220 1401111 41 4 4 a 4 a 4 4e 0 6 RER a a 0 ee aaa 1
68 004 447 UPRIGHT, base - front .......1212 40200000 0 4 500 00 a 100800 00 1
69 Figure D PANEL, front - with components (See Page 8) .............—.... 1
70 004 556 1DOOR, access - front lower ......._.. o..eeesmacorrecame re 1
70 005 631 DOOR, access - front tower (used with polarity switch) .......... 1
71 R2,3 030060 RESISTOR, WW adj 375 watt 20 ohm 1... 122000000000 aa 00000» 2
72 z1 036 259 REACTOR (consisting of) ..........e_.-e=venracoravacarea»o 1
025 138 .COIL, reactor - left hand ...........oerenernnorcoreecnR. 1
025 139 .COlL, reactor - center ann EEG 1
025 140 .COIL, reactor - right hand ........o.—ecoreenerecsrararoaronm. 1
73 028218 FRAME, mtg - stabilizer & reactor .......ee.—eeereanervoramos 1
74 VS1i 025 932 SUPPRESSOR, 0.75uf10ochmw/leads .,.....c. vei. 1
75 027 105 STRIP, cotton 1/8x 1x 20 .............eseeomeamoraaerarne, 2
024 480 KIT, label (includes all labels). ............ _—.—.ec_—emocronmaoo.. i
*Recommended Spare Parts
+These parts are used as alternates. When ordering replacement parts be sure to order the same part as the unit was
manufactured with.
Parts for Optional Equipment — See Page 10
++ These parts are used when welding power source is equipped with a Marvel-Schebler carburetor,
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 4
Item Dia, Factory
No. Mkgs. Part No. Description Quantity
Figure B 018 757 Control, Weld & Idle Vacuum (See Fig. À Page 3 Item 40)
TT 92 017417 LINKAGE ASSEMBLY .....................................) 1
93 604 393 =»ECEPTACLE,screw 3/16 dia. ........... e... .ea0ara8rerereaoa.. 1
94 604 392 RIVET, round head 3/16 х 3/4 ieee eee 1
95 603931 RECEPTACLE, screw 1/4 dia. ........Ñ.e.... ee ._enecaaoearer.aorona i
96 603 470 VALVE, needie - shut Off iii. 1
97 010 859 BUSHING, brass 1/4 MPT 1/8 FPT ee een. 2
98 020 963 TUBING, copper 3/16 OD x 13-1/2 RR 1
99 018 097 CHAMBER, vacuum ........eo oersrenconororaiovereaarorenve rea 1
100 020 962 HOSE, rubber 7/64 [D x 27/64 OD x 4 ...............0a2200aoa. 1
101 010561 TEE, brass 1/8 x 1/8 ........ ..—eo_esrmerxorerareoaramoorararoren 1
102 020 964 TUBING, copper 1/8 OD X 1 ............ RER a 1
103 SR4 031252 RECTIFIER, selenium ..........eeeasa0n0da dora zaoronaoacueoo 1
104 GS1 003304 VALVE, 12 voits dc 2 way 1/4 IPS port 1/8 orifice ........... eo "e. 1
105 023 030 BREATHER, brass - vent 1/4 MPT 1114210 244 4 a 144 La 0e a a aa eee Le 1
106 603 802 RIVET, round head 1/4 X 2 1211112044 4 14 4 RK RR 00 a 1
107 017 544 BRACKET, mtg - vacuum chamber .......e oee.0.oenredarerorernes. 1
108 015713 GROMMET rubber 5/16 ID RR RR KR 7
109 018 160 LINKAGE ASSEMBLY (consisting Of) ...0.0..0.000000 0 aa ee aa 4e i
110 024 799 .BALL JOINT, 1/4-28 thread eK 1
111 018098 .BOLT, hook .............a.asorxererrerarenenooerarorororre ra i
112 010334 .CLIP,clevis..........om_0ea0n0oredorareorronaconreroar va voor, 1
N
98
96
~~)
A |
> al — 100
101
93
92 —
102
103
12
111
109
110, 108 107
106 105 104
Figure B — Control, Weld & Idle Vacuum
97
TA-018 757-C
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure C Generator Assembly (See Fig. A Page 4 item 51)
116 025271 ENDBELL .....e.oo.o-nosanaasaroraroovacannadndreuvrrao, 1
117 SR3 025517 DIODE ASSEMBLY, reverse polarity {consistingof) ............ 1
118 025 305 .INSULATOR 1.122202 4 4 a 4 0e 0 0 0 0 1 1 44 a aa a 1 a en ee 1 ee 0e 2
119 037957 . DIODE, 275 ampere 250 voltsreverse polarity ................ 3
120 025 306 INSULATOR iii i i titties ister ss nannannn 5
121 026 203 CHANNEL, neoprene 1/4 x 11-1/2 1.222411 4 44 8 4 0 8 8e sea vu» 1
122 **035 285 STATOR RR 0 a 0 ae na 4 a a 4 aa a a aa aa 08 1
123 039207 BAFFLE, air.........orreeraeoecanernveoaoraatercorermo—o 1
124 032 311 GUARD, generator ,,.....eor_eeceresreserororwror aca 1
125 **003 632 ROTOR (CONSISTING Of) ...........oreerarrsoooranonr eran 1
126 024 617 RING, retaining ........—.—omxexecorooorervesoranovorvaornoaca 1
127 024 616 .BEARING ....eeoeecxesaraocarroarenmarodaronorvorearneaca 1
035775 . KEY, steel 3/8 x 3/8 x 1-1/2 112224200010 a 10 as a aa a een» 1
128 035917 FAN 222022 44 4 a ae 4 a 1 4 0e a 0 a 0 a ea ae ea eee as ea a 0 se eu a ane» 1
129 025 525 ROD, threaded end 3/8-16 x 29-7/160 .......10200100 0040 u aa eue» 6
130 010021 CLAMP, 9/16 dia. x 11/32 hole 112212021000 ae ua ua au a ua en 1
131 018614 BRUSH SET (consisting of) ............e—..eerooooocasarara 3
132 018665 .CAP ........reecsreanacrnona ra rarcoarocos:ereraaeranesa 1
133 600270 .BRUSHHOLDER ......... _eesoomararanerevanervaaonero ea 1
134 *020 034 .BRUSH...............0....0... .asencAdo.areorenaananao 1
135 025 321 BRACKET, mtg - brushholder ........eoeo-_eee—_osxvroroaaom. 1
136 SR3 025516 DIODE ASSEMBLY, straight polarity (consisting of)............ 1
137 025 305 INSULATOR ...........rescedocramaearoreroorredrervrcao 2
138 037 956 . DIODE, 275 ampere 250 voits straight polarity ............... 3
pn ——
— — a"
131
"134 133 132
TD-007 743
Figure € — Generator Assembly
* Recommended Spare Parts.
** Rotor and Stator are available on an Exchange Basis. Contact Service Department for Details.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 6
TC-020 383
161
162
163
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure D Panel, Front With Components (See Fig. A Page 4 Item 69)
151 Neg 039 046 TERMINAL, power output - black (consisting of) .............e.. 1
152 601 879 . NUT, steel - hex jam 1/2-13 ............. Cetera 1
163 039 044 BUS BAR LL... 1110121140 4 aa 02 a a a 0 a 00 0 eee ea a au ae a a aa na ae» 1
154 601880 .NUT, steel - hex full 1/2-13 ............—.eom—eenreosmavoverereo 1
155 039045 .TERMINAL BOARD, black ......... o cseocoervceorcono nara. 1
156 601976 .SCREW, cap - steel hex hd 1/2-13x 1-1/2 ..................... 1
157 039043 .CLIP, spring - bus bar .......— —.og_eo_ere-wwerecororamo2aroereroo 1
158 53 005015 SWITCH, range (See Fig. D1 Page 9) .............—.eoexervocaneo. 1
159 R1 *605 960. RHEOSTAT, WW 300 watt 34 ohm ........e.e._ecrezrerenevdecrorera 1
160 54 *01180i SWITCH, toggle SPST 10 ampere 125 volts ............eeecxeceo. -1
161 RC1 604 176 RECEPTACLE, duplex - ground 2P3W............_.eocoocreve.. 1
162 CRI 034 876 RELAY, switch (consisting Of) .........._—.eeocorariorererereare 1
022 230 .SWITCH, relay .......vreceooearonororenamóaorranoonernver, 1
163 51 005 372 SWITCH, ignition - key type without start 2P ........... _———eone. 1
164 Pos. 032 047 TERMINAL, power output - red {(consistingof} .................. 1
165 601976 .SCREW, cap - steel hex hd 1/2-13 x 1-1/2 12241112 aa aa aa een 1
166 039 043 .CLIP,spring- bus bar ........._..o_eeceo ceconareaaaoraraardo 1
167 039049 TERMINAL BOARD, red..........ooeecr_ereooocoonanionanoo 1
168 601 879 .NUT, steel - hex jam 1/2-13 ...............0022a 2... enana 1
169 039 044 BUS BAR ........... —.ress0esereroroc ooenreecerarocaaa ono 1
170 601 880 . NUT, steel - hex fuil 1/2-13 111111212104 14 4 0 4 ae aa a 1 aa aa 0 1
171 FPBI 011767 SWITCH, push button - start .......... RAA R KR KK E 1
172 031 858 PANEL, front - Upper ......_.r_e—eereaacoaooredonaranoao oorena 1
173 NAMEPLATE (order by stock, model and serial number) .......... 1
174 019790 CONTROL, push - pull. ..................a.noracaoroona aun va 1
175 +039 241 GAUGE, oil pressure Datcon or
175 +025 451 GAUGE, oil pressure .........e.-e._.e-enmaodonmoone—onarmaroaro 4 0 1
176 +039 237 METER, amp 60-0-60 Datcon or
176 +030 530 METER, amperage 60-0-60.........._—oe—eemreceorenzoormereoco 1
177 +039 239 GAUGE, temperature Datcon or
177 +025 452 GAUGE, temperature ............_—.—_—.eerosere -—omec _eroenvono 1
178 019755 HANDLE, rheostat........ _—.e_eo_eororeraarroereoornrenevarano 1
602 178 5SCREW, set 1/4-20 x 3/8 ........... RR RR HR 1
179 019 754 HANDLE, range switch ........100 04101 a 12 a Lane RAR 1
180 010836 PIN, spring 3/16 x 1-1/4 ee ee esa 1
*Recommended Spare Parts
+These parts are used as alternates. When ordering replacement parts be sure to order the same part as the unit was
manufactured with.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 8
Item Factory
No. Part No. Description Quantity
Figure D1 005015 Switch, Range (See Fig. D Page 8 Item 158)
181 005 001 BRACKET, mounting - switch (without spring) .............. e... 1
182 010671 SPRING, extension ,.........._ HR RR 4 4 4 a 0 0 8 a 4 V1 RR RK RK à 1
183 017428 LOCATOR, quadrant 1.121210 RER еке к. . ]
184 004 998 CONTACT BOARD ASSEMBLY, switch - range (consisting of) ........ 1
185 100 623 . GUIDE, contact board - movable rien es 3
186 100 622 .SHIM,guide-contactboard ........... citrine ir inn. 3
187 0119809 . CONTACT BOARD, movable switch .. ....... inn, 4
188 004 999 CONTACT BOARD, stationary ....L.1121 12114 na ae LL Le aa ea A 2
189. 011645 . CONTACT ASSEMBLY, movable (consistingof} .................. 3
190 011075 ..SPRING, pressure ........_.oeeeerecnoedarearerecneooaraorrenvea 1
191 011953 ..CONTACT ................... a a ae 4 8 ee ae eee ae au ea eu 0 0100 2
192 911074 ..SPRING, pressure .. 112420044101 40 a a 44 4 1 ae 0 84 a ee aa a a aa a La» 1
193 011 644 .CONTACT, stationary ........... Le 1 a a 0e a 1 eu ea san a ca aa cn ue» 15
189 193
181 182
: |
TB-011 273 TE-011 100
Figure DT — Switch, Range
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
Dia. Factory
Mkgs. Part No. Description Quantity
Parts for Optional Equipment (See Page 10)
A 025 663 METER, amperagedc 0-400 ........._r_re_eresrecsesacrvercccoeo
026 943 INSULATOR,ammeter .........—..oeonesonmocvreonraderverco
RC2 032897 RECEPTACLE, grounded - twistlock 3P3W (remote current control}
027 851 COVER, polarity switch . .............. PS
52 027 841 SWITCH € TERMINAL BOARD ASS'Y (consisting of) .........
027 847 . BRACKET, mta - switch & terminal board ..................
038311 . MOUNTING PAD, insulating - polarity switch . . . .............
011281 .PLATE ASSEMBLY, polarity switch (consistingof} ...........
010082 .. SPACER, between mountingpad & switch _.................
010805 ..HANDLE.........—resexveraevoodsrororeeccenaacorororevna
011948 ..GUIDE, molded.........._._oecíeeroerereseasrorearcdrendan .
019603 ..KNOB,round.......2 2102000 La 12 a a ea 1e a 1e ee a eue»
024 694 . BEARING ..L.2 14042 aa a 00 0 au 0 a 0 a 028444 00 a ea eu 000 0
038 769 ,. PLATE movable -with contacts .........c oti inernonnen.
103633 ..BAR,contact......ñc_oeorooreorororerrrvecrvoveosnrorrro
103634 ..BSO0ARD, mtg - components .........eo_e—recarenveroonooo.
604 318 ..NUFT, steel - self locking hex 1/4-20 ...........o_ ra uen»
039046 . TERMINAL, power output - black (consisting of) .............
039044 ..BUSBAR.........2221121 112212 0 0 a 0 ea 4 0 a 0 a a ea a aa a 0
039 045 .. TERMINAL BOARD, black .........c. viii
601976 ..SCREW, cap - steel hex hd 1/2-13 x 1-1/2 ..................
601 880 .. NUT, steel - hex jam 1/2-13 ............—e-esrrearervdcrar:
601879 ..NUT, steel - hex fuli 1/2-13 iii ieee ann
039 043 ..CLIP, spring - bus bar............. eee eerie.
Shunt 030080 15HUNT, meter 400 amp 500 MV .........—ereesrnocreaoaooraa
56 011 620 SWITCH, toggle SPST 16 ampere 125 volts (remote current control)
V 026638 1METER, voltage de 0-100 .............0.—eo_—remrocveanvoraro
TAC 027 491 TACHOMETER, electric 12 valts ........eooeeoecor_eresmvrrrerco
017390 BRACKET, mtg-tachometer ..........r—eervosroscorecdrooo
020 374 BRACKET, mtg - tachometer to engine ............___eeecrecoo
TT 032936 METER, hour 12 voltsdc ..............—._eosrcesereernneao
028 262 MUFFLER, exhaust .........oec_ecrooraosrsararaorornarecnerwoo
027 561 1NMUFFLER, exhaust - low noise .........—...eooéncrevrcererccoo
027540 NIPPLE, pipe - black 1-1/2 x 2 111200001040 4 a 0 0 a 0 a aa au 0»
062 180 CARBURETOR, high altitude ...........o_oo_rerereaaosaararna
061 387 GASKET, carburetor - high altitude ............ ieee
010 429 JET, carburetor -highaltitude . .............. cc. iia...
010875 CLAMP, muffier 2 inch dia. ..........ooooeenracararaosoraoo
015700 BRACKET ASSEMBLY, mtg-muffler ......................
027 564 SPACER, anti-noise - mtg muffler .........é.e..ec_eecersarroo
= = №} a A LL le A AL e ld e BD) e Nr A A lr rd ed
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-450 Page 10
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