Miller BLUE STAR 1E User manual

Miller BLUE STAR 1E User manual
March 1978 FORM: OM-423B
Effactive With Serial No. HJ117438
MODEL
Blue Star 1
Blue Star 1E
Blue Star 2
Blue Star 2E
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OWNER'S miller
MANUAL ™"
MILLER ELECTRIC MFG. CO.
718 5. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54912 USA
NWSA CODE NO. 4579
PRINTED IN US.A.
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LIMITED WARRANTY
EFFECTIVE: FEBRUARY 20, 1978
This warranty supersedes all previous MILLER warranties and is ex-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY —Miller Electric Mfg. Co., Apple-
ton, Wisconsin warrants to Customer that all mew and unused
Equipment furnished by Miller is free from defect in
workmanship and material as of the time and place of
delivery by Miller. No warranty is made by Miller with
respect to engines, trade accessories or other items manu-
factured by others. Such engines, trade accessories and other
items are sold subject to the warranties of their respective
manufacturers, if any, The manufacturer's warranty on
engines is for a period of one year.
MILLER warranty does not apply to components having
normal useful life of less than one (1! year, such as spot
welder tips, relay and contactor points, MILLERMATIC
parts that come in contact with the welding wire including
nozzles and nozzle insulators where failure does not result
from defect in workmanship or material,
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)
replacement or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station or 14)
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 expense. All transactions are F.O.B.
Appleton, Wisconsin, Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the
warranty claim procedures to be followed,
As a matter of general policy only, Miller may honor an
original 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:
DER
1. Arc welders, power sources, and components. . 1 year
2. Original main power rectifiers . ............ 3 years
{Labor — 1 year only)
3. All welding guns and feeder/guns .......... 90 days
4. All other Millermatic Feeders ............. 1 year
provided that the user so notifies Miller in writing within thirty
(30) days of the date of such failure.
5. Replacement or repair parts exclusive of labor 60 days
ANY EXPRESS WARRANTY NOT PROVIDED
HEREIN AND ANY IMPLIED WARRANTY, GUARANTY
OR REPRESENTATION AS TO PERFORMANCE, AND
ANY REMEDY FOR BREACH OF CONTRACT WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY
IMPLICATION, OPERATION OF LAW, CUSTOM OF
TRADE OR COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY ОВ OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT
TO ANY AND ALL EQUIPMENT FURNISHED BY
MILLER 1S EXCLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED iN THE USE AND MAINTENANCE
OF WELDING EQUIPMENT AND NOT, FOR CONSUMERS
OR CONSUMER USE, MILLER WARRANTIES DO NOT
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
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EXTEND MILLER'S WARRANTIES TO, ANY
CONSUMER.
Nl Zt cle Rl RC MU тай r Ae
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.
AMENDMENT TO SECTION 2 — INTRODUCTION
Add the following NOTE block, applicable to models with power factor correction only, after the specification chart:
NOTE
| “The power factor correcting capacitors supplied in this product contain no PCB's. The dielectric materiat !
is an OSHA Class IH B fluid having a flash point of 4409F. (2279C.). Each individual capacitor is protected
; by an internal UL recognized pressure sensitive disconnect and an internal fuse.” +
AMENDMENT TO SECTION 11 — TROUBLESHOCTING
| NOTE |
v
The circuit diagramís) on this suppiement replace any other circuit diagramís) appearing later in this!
manual. I
Amend Figure 11-3 as follows:
START
12V BAT O» TO STARTER \
; RCH .
= + 2 |
ae оф TO IGNITION COIL Y,
De
54 0— TO REGULATOR RECTIFIER = o
WELD
7 | Ss
OTE: 18 SEC POWER
o——
55
IDLE |
WELD
WINDING
DC-Z
SOLENOID 33 |
IDLE / - EE
y 5 —
| o -£ 0000 GO POSITIVE
H
33)
PC1 TERMINAL IDENTIFICATION
A B OD OF H J L
alclcha): kil
MANN
22 RO NEGATIVE
|
Circuit Diagram No. A-079 756
Effective With Serial No. HJ173317 And Following
Figure 11-3. Circuit Diagram For Electric Start Models With Kohler Engine
OM-4238 Page A
Item Dia. Part No. Listed Replaced With
No. Mkgs. In Parts List Part No. Description Quantity
19 $2 020 251 059 687 SWITCH, control - excitation .......e...ereovreoserooaooa 1
32 C3 605 957 059 523 CAPACITOR, paner oil 20 uf 500 volts de .........._.e..eoo 1
129 052 403 011 644 CONTACT, stationary - switch . ........e.eeeeceesssoareaoo 1
54 011 801 053 359 SWITCH, toggle SPST 20 amp 125 volts .......e.ñe _eree.o 1
073 891 RESISTOR, WW fixed 256 watt 3ohm ...._..eoeeesreorcooa 1
605 741 BRACKET, mounting - resistor ........ ——.o_eerere-—zaaaa 2
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-423B Page В
——————————_" TABLE OF CON TE ENT ]——]—————— | ;o———][;;;;—]|]—;.L .;;Z];———Ñ
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction ... 1120401020 4 4 4 8 4 1 RE
1-2. General Precautions . 1.121244 42006 4 4 4 4 a au a ee a aa 02 8e 4 da ce 2 6
1-3. ArcWelding......2204420000 4844 12 64 4 a ee 1 a a eee ee ea a ee 1 tea
1-4, Standards Booklet Index .. 1.120104 0 4 4 4 404 4 4 40 4 0 4 a 4 0 a 0 3 4 eeu
ay = -
SECTION 2 — INTRODUCTION
, General ....... ca .ermeereasrerarrarm mnogorcas EL Le ea a 8811 a 10 0
‚ Receiving-Handhing .....22200 040 aa aa 4e ea a a ea ee 2 ea 11 0 011 1200 6
. Description .....2242044 0004 ee 0 irre adres rare eae eae
Cateye ee a a 8 Le a a es a 4 a aa eu ee 0e 10000
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SECTION 3 — INSTALLATION
3-1. Location .....111142 11 1 LL LL A AL LL 410 ea 4 a 1 10 KK RR
3 - 2, Equipment Grournding Terminal ..122 04884 40 0 4 810 04 aa
3-3. Weid Output Connections ....1 12202044 4 4144 4 a 4 +4 a 4 en 404 0 a ea ee 0 0
~~ wd Oh
SECTION 4 — ENGINE PREPARATION
1. Engine Lubrication Li a a 1 La ea ee a 1 1 a 50 ue
2, Fuel 11.210104 144 4 10 44 4 4 ee a 4 a a 4 4 ee a tre eee ete
3. Air Cleaner LL. i ii tase a aaa
4. Preparing New Battery FOr Service 2..2... , 2..2... кк кк кака oem...
o o oy
4
4
4
4.
SECTION 5 — FUNCTION OF GENERATOR CONTROLS
5-1. Weld/Power Switch ....1 0124 442 4 4 4 ea 4e 1e 4 ee 0 0e 1 0 pa a 1 1 ee a a ea 0 0
5-2. Range Switch .......e._eeeoerereneorereaaneretia,orararcearorce—
5-3. Fine Amperage Control «LL. tiie i tree caret es aaa.
5-4, Auxiliary Power Receptacies ........e eee eredrraremacarero o anrero
9 - 5. Volt-Ampere Curves ....... e e ..ariredarercerw e enraarreceearroar. 1
QO Www
SECTION 6 — FUNCTION OF ENGINE CONTROLS
6-1, Choke Control ...............2.. .enedrieserarverdsrenmerereeeno 10
6-2. Throttle Control ........... REKEN a 4 a 4 ana ee La aan a 10
6 - 3. Run/Stop Switch, ...... e... A La 14 A Aa ea Lee a 4 1 Aa da a ae LL à 10
6- 4. Start Pushbütton ......202200 14 4414 4 4 a 1 4 4 a 4 4 4 1 1 0 a a ee 1 ee ea a a eee 0 10
6-5, Stop Switch ........e._._.e e 4 4 44 41 4 4 8 4 4 4 4 4 ee a 4 0 0 4 a a 0 ue 4 4 a a aan + 10
6 - 6. [die Control ...1.1.212 0001111120 LL 44 44 La La a 4 8 ea ee a a 1 La 0 00 0 10
SECTION 7 — SEQUENCE OF OPERATION
. Shielded Metai-Arc (SMAW) Welding ... 112112004444 11044 44 4 a a La aa + 10
-2. Auxiliary Power Plant Operation .. 1.112020 0 004000044410 6 44 4 a pe een 11
. Starting The Engine... 1.120440 4 8014 44 44 04 4 a ee ee eae 11
, Engine Shutdown 1.114400 004 44 44 SLA A4 14 4 a a 1 4 квн, 11
ded A wg
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SECTION 8 — GENERATOR MAINTENANCE
8-1. General oo te eee renoanvxrreaoarnovarenovereonao 12
8-2. Collector Ring Brushes... ..... iii eee ieee 0 12
8-3. Welding Cables ii RN ee ie 12
Section No. Page No.
SECTION 9 — ENGINE MAINTENANCE
9-1. Lubrication ......eoeéreosrrorcrscssrnarrareareor—erasvranarvacA»D. 12
9-2, Cleaning The Engine ........._r_eoxecectecroaare.. aa a a a ana 000 12
9-3. Spark Plug «vou riot ia ae eases aaa 12
9-4, Air Cleaner .......ecoereoaronanearernoeeaacerédedarmernarenvem=—a. 12
9-5, Governor ......o.e.eeoenmocorrdannaeadareroarecadeareanan e dar 12
9-6. Periodic Service .........ecrenvrecarereoeesame. PE 13
9-7. Engine Speed Adjustments 220.400 0000000 an eee 0e 000100000000 13
9-8. Spark Arrestor 1.220204 00106 0 ea 4 ea usa 0e 0 0 a et ee ee 80020000 13
SECTION 10 — GENERATOR TROUBLESHOOTING
SECTION 11 — ENGINE TROUBLESHOOTING
PARTS
mum SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE ===
1-1.
1-2,
INTRODUCTION
We learn by experience. Learning safety through personal
experience, tike a child touching a hot stove is harmful,
wasteful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of weld-
ing and cutting are described in this manual. Research, devei-
opment, and field experience have evolved reliable equipment
and safe instailation, operation, and servicing practices. Acci-
dents occur when equipment is improperly used ar main-
tained. The reason for the safe practices may not always be
given. Some are based on common sense, Others May require
technical volumes to explain, It is wiser to follow the rules.
Read and understand these safe practices before attempting
10 install, operate, or service the equipment Comply with
these procedures 2 applicable to the particuiar equipment
used and their instruction manuals, for personal safety and
for the safety of others,
Failure to observe these safe practices may cause serious in-
jury or death. When safety becomes a habit, the equipment
can be used with confidence,
These safe practices se divided into wo Sections: 1 -
General Precautions, common to are welding and cutting; and
2 - Arc Welding (and Cuttngiteniy).
Reference standards: Published Standards on safety are also
available for additional and moré compiete procedures than
those given in this manual. They are listed in the Standards
index in this manual, ANSI Z49.1 is the most complete.
The National Electrica! Code, Occupational Safety and
Health Administration, local industrial codes, and iocal in-
spection requirements also provide a basis for equipment in-
stallation, use, and service.
GENERAL PRECAUTIONS
Burn Prevention
Wear protective clothing - leather {or asbestos) gauntlet
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avaid entry of
sparks and siag.
Wear helmet with safety goggles or glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear cover glass). This is a MUST for weiding or cutting, {and
chipping} toc protect the eyes from radiant energy and flying
metal. Replace cover giass when broken, pitted, or spattered.
See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as giectrode 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 bums.
Ear plugs should be wom when working on overhead orin a
confined space. A hard hat should be wom when others work
overhead.
Flammable hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adequate ventilation. Severe discomfort, iliness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding (or cutting) may produce. Prevent
them with ajequate ventilation as described in ANSI Stan-
dard Z49.1 listed 1 in Standards index. NEVER ventifate
with oxygen,
Lead -, cadmium -, zinc -, mercury -, and beryllium - bearing
and similar materials, when welded (or cut) may produce
harmful concentrations of toxic fumes. Adequate local
exhaust ventilation must be used, or each person in the area
as well as the operator must wear an air-supplied respirator.
For beryllium, both must be used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating is removed from
the work surface, the area is well ventilated, or the operator
wears an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided. Leaked gas
in large quantities can change oxygen concentration danger-
ously. Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source to
prevent possible accumulation of gases in the space if 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 chigrinated solvents can be decomposed by the
heat of the arc lor fiame) to form PHOSGENE, a highly toxic
gas, and other {ung and eye irritating products. The ultra
violet (radiant) energy of the arc can also decompose tri-
chloroethylene and perchloroethylene vapors to form ph os-
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 trichloroethyliene or perchloroethyiene.
Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached by the
arc, flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cyiinders; and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the goggled
operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean ahd operable, free of oil, grease, and
(in electricai parts) of metallic particles that can cause short
Circuits.
If combustibles are in area, do NOT weld or cut. Move the
work if practicable, to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage areas, ventilators, [f the
work cannot be moved, move combustibles at least 35 feet
away out of reach of sparks and heat; or protect against
ignition with suitable and snug-fitting, fire-resistant covers or
shields,
Walls touching combustibles on opposite sides should not be
welded on {or cut). Walls, ceilings, and floor near work
should be protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable fire ex-
tinguishing equipment during and for some time after weld-
ing or cutting if:
a. appreciable combustibles (including building construc-
tion) are within 35 feet
b. appreciable combustibles are further than 35 feet but can
be ignited by sparks
с. openings (concealed or visible) in floors or walls within 35
feet may expose combustibles to sparks
d. combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions have
been taken.
After work is done, check that area is free of sparks, glowing
embers, and flames.
An empty container that held combustibles, or that can pro-
duce flammable or toxic vapors when heated, must never be
welded on or cut, unless container has first been cleaned as
described in AWS Standard A6.0, listed 3 in Standards index.
OM423 Page 1
Page 2
This includes: a thorough steam or caustic cleaning {or a
solvent or water washing, depending on the combustible's
solubility) followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom-
mended in AB.0. Waterfilling just below working level may
substitute for inerting.
À container with unknown content should be cleaned {see
paragraph above). Do NOT depend on sense of smell or sight
to determine if it is safe 10 weld or cut.
Hollow castings or containers must be vented before welding
or cutting. They can explode.
Explosive atmospheres. Never weid or cut where the air may
- contain flammabie dust, gas, or liquid vapors (such as gaso-
line).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, PRECAU-
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the regula
tor from overpressure; it is not intended to protect any
downstream equipment. Provide such protection with one or
more relief devices.
Never connect a regulator to a cylinder containing gas other
than that for which the regulator was designed.
Remove faulty regulator from service immediately for repair
{first close cylinder valve). The following symptoms indicate
a fauity regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to rise with
downstream valve closed.
Faulty Gauge - if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Repair. Oo NOT attempt repair. Send faulty regulators for
repair to manufacturer's designated repair center, where
special techniques and tools are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit arcs that may lead te a serious accident, (See
1-3C.}
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas
marked on them; de not rely on color to identify gas con-
tent. Notify supplier if unmarked. NEVER DEFACE or aiter
name, number, or other markings an a cylinder. It is illegal
and hazardous,
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Prohibited use. Never use a cylinder or its contents for other
than its intended use, NEVER as a support or roller.
Locate or secure cylinders so they cannot be knocked over.
Passageways and work areas. Keep cylindérs clear of areas
where they may be struck.
Transporting cylinders. With a crane, use a secure support
such æ a platform or cradie. Do NOT lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag-
ne ts.
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
exist.
Protect cylinders particulary valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
cylinders,
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify your
supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refil! 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 leaks, wear, and loose connec-
tions. Immerse pressured hose in water; bubbles indicate
leaks.
Repair leaky or worn hose by cutting area out and splicing
{1-203}. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint
less cloth.
Match reguiator to cylinder. Before connecting, check that
the regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet march. NEVER CON-
NECT a reguiator 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, ¿lean, and retighten using properly
fitting wrench,
Adapters. Use a CGA adapter {available from your supplier)
between cylinder ahd regulator, if one is required. Use wo
wrenches to tighten adapter marked RIGHT and LEFT
HAND threads.
Regulator outlet (or hose) connections may be identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shank} for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder (lor manifoid 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 tao side of regulator while opening cylinder valve.
Open cylinder valve stowly so that regulator pressure in-
creases slowly. When gauge is pressurized (gauge reaches requ-
lator maximum) leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
possible ieak, 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 teaks on first pressurization and regulary there-
after. Brush with soap solution (capfui of Ivory Liquid” or
equivalent per gallon of water!. Bubbles indicate leak, Clean
off soapy water after test: dried soap is combustible.
User Responsibilities
Remove leaky or defective equipment from service immed-
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 staging-support should not be used for welding or cut-
ting operation; rope may burn.
ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc
Welding, properly done, is a safe process, Dut a careless opera-
tor invites trouble. The equipment carries high currents at
significant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weld-
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standards referenced in index.
Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. 11s radiation can
damage eyes, penetrate iightweight clothing, reflect from
light-colored surfaces, and bum 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 longsleeve clothing (particuiarly for gas-shielded arci in
addition to gloves, hat, and shoes (1-24). As necessary, use
additional protective clothing such as leather jacket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre-
vent entry of sparks.
2. Eve and Head Protection
Protect eyes from exposure to arc. NEVER look at an elec-
tric arc without protection,
Welding helmet or shieid containing a filter plate shade no.
12 or denser must be used when weiding. Place over face
before striking arc.
Protect filter plate with a ciear 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 1M-
MEDIATELY. Replace clear cover plate when broken, pitted,
or spattered.
Flash gogoies 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 18 struck. Looking
a1 an arc momentarily with unprotected eves Iparticutary a
high intensity gas-shielded arc} can cause a retinal burn that
may ieave a permanent dark area in the field of vision.
2. Protection of Nearby Personne!
Enciosegd welding area. For production weiding, a separate
room or enclosed bay i$ best. in open areas, surround the
*Trademark of Proctor & Gamble.
operation with low-reflective, noncombustible screens or
panels. Allow for free air circulation, particularly at floor
level.
Viewing the weld, Provide face shields for all persons who
will be locking directly at the weld.
Others working in area. See that all persons are weanng flash
goggles.
Before starting to weld, make sure that screen flaps or bay
doors are closed.
Toxic Fume Prevention
Comply with precautions in 1-28,
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
Fire and Explosion Prevention
Comply with precautions in 1-2C.
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 а
fire.
Never strike an arc on a cytinder or other pressure vessel, It
creates a brittle area that can cause a violent rupture or lead
to such a rupture later under rough handling.
Compressed Gas Equipment
Comply with precautions in 1-2D,
Shock Prevention
Exposed hot conductors or other bare metal in the welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor, DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur-
face when welding, without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insuiation 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 eiectrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such as
welding power source, control, work 1able, 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, ¢r tO a pipe carrying ANY
gas or a flammable liguid such as oil or fuel.
Three-phase connection. Check phase requirement of equip-
ment before installing. If only 3-phase power is available,
connect single-phase equipment to only two wires of the
3-phase line. Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become electri-
cally HOT - a dangerous condition that can shock, possibly
fatally.
Before weiding, check ground for continuity. Be sure conduc-
rors are touching bare metal of equipment frames at connec-
tions.
If a line cord with a ground tead is provided with the equip-
ment for connection to aswitehbox, connect the ground lead
to the grounded switchbox. If a three-prong plug is added for
connection to a grounded mating réceptacle, the ground lead
must be connected to the ground prong only, If the line cord
comes with a three-prong plug, connect 10 a grounded mating
receptacle. Never remove the ground prong from a piug, or
use a plug with a broken off ground prong.
OM423 Page 3
Page 4
2. Electrode Holders
Fully insulated electrode holders should be used. Do NOT
use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to join
welding cable lengths,
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively wom 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.
71. Safery 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 pull all 115
volts line.cord plugs.
1-4.
Da not open power circuit or change polarity while welding,
if, In an emergency, it must be disconnected, guard against
shock burns, or flash from switch arcing,
Leaving equipment unattended. Always shut OFF and dis-
connect all power to equipment.
Power disconnect switch must be available near the welding
power source.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANSI Standard 249.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, Fla. 33126,
2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA-
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtatnable from American National Standards
Institute, 1430 Broadway, New York, N.Y, 10018.
3. American Welding Sacietry Standard A8.0, 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 Atiantic
Avenue, Boston, Mass. 02210.
5. NFPA Standard 518, 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 22 CFR, Part 1910, Subpart OQ, WELD-
ING, CUTTING AND BRAZING.
———————— SECTION 2 - INTRODUCTION
Manual Start Models Manual Start Models Electric Start Electric Start
With Kohler With Tecumseh Models With Models With
Engines Engines Kohler Engines Tecumseh Engines
Rated Output @ 60% 200 200 200 200
Duty Cycle Amperes Amperes Arnperes Amperes
35-220 35-220 35-2
Amperage Range Amperes ae Amperes Putin
Min - 40 Amps Min - 40 Amps Min - 40 Amps Min - 40 Amps
40 - 50 Amps - 40 - 50 Amps 40 - 50 Amps
Welding Amperage Ranges | 45. 70 Amps | 45. 70Ambs | 45. 7OAmps | 48. 70 Amps
60 - 95 Amps 60 - 95 Amps 60- 95 Amps 60 - 95 Amps
30-125 Amps 80 - 125 Amps 80-125 Amps 80 - 125 Amps
110 - 165 Amps 110 - 165 Amps 110 - 165 Amps 110-165 Amps
145 - Max Amps 145 - Max Amps 145 - Max Amps 145 - Max Amps
Amperage Adiustment | Re Ae | Within Each range | Within Each ange
Maximum Open-Circuit Voltage 80 Volts (RMS) 80 Voits (RMS) 80 Volts (RMS) 80 Volts (RMS)
ve Y
Auxiliary Power 115 or 230 Volts AC* {1115 or 230 Volts АС* | 115 ог 230 Volts АС* ! 115 or 230 Volts AC*
Idle RPM 1650 1650 1650 1650
Power RPM (No Load) 1800 1800 1800 1800
Weld RPM (No Load) 3000 3000 3000 3000
Height {Inches} 27 27 27 27
Width {Inches} 21-172 18-1/2 21-1/2 18-1/2
Lenath (Inches) 47 47 47 47
Net Weight (Pounds) 390 423 515 463
Shipping Weight (Pounds) 440 473 565 513
*Depending On How Ordered
Figure 2-1. Specifications
Part OF
Electrical Connection
Dar
a Electric Start Modela Wich Kohler Engines Ornby
sas Maus Beart Mode Only
TB-008 935-A
Figure 2-2. Functional Diagram
OM423 Page 5
2-1. GENERAL
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
2-2. RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill wiii be fumished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
2-3. DESCRIPTION
This welding generator is driven by à gasoline engine. When
used as a welding generator, the unit produces a dc output
for Shielded Metal Arc (SMAW} Welding. When used to pro-
duce auxiliary power, the unit produces an ac output of up
to 3 kva at 115 or 230 volts {depending on how ordered),
50/60 Hertz, to power lights, tools, etc,
24. SAFETY
Betore the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completely.
38-1/2
211/27 —
A
All Dimensions Are in Inches
47
"Models With Tecumseh Engines Are 18-1/2 Inches Wide At Widest Point
SECTION 3 - INSTALLATION
7/16 Dia-
(8 Holes)
This wilt help avoid possible injury due to Misuse or improper
welding applications.
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a hazard to per-
| sonnet. 1
IMPORTANT
Under this heading, instatlation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
i ment. J
NOTE
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
E —————————]———.—.—;——]; ;—í——]—D
ENGINE END
E
—
N 14-3/4
tu , | 32-5 /8
Ч /2
|
+
+
me
—— об
| | | 5-1/4
Liars IL 9/16
.— 15 — ===
T8-052 101
Figure 3-1. Dimensional Drawing And Base Mounting Hole Layout
3-1. LOCATION (Figure 3-1)
A proper installation site should be selected for the welding
generator if the unit is to provide dependable service, and
remain relatively maintenance free.
Ш caution’ |
If this unit is to be operated indoors, it should be
located in a place where the exhaust fumes from the
engine can be vented out of the building. Failure to
comply with proper venting may result in serious
1 hodily injury or loss of life. |
Раде ©
IMPORTANT
The engine exhaust system on this welding generator
has not been equipped with a spark arrestor uniess it
was specifically ordered as an optional accessory. A
spark arrestor, maintained in effective working order,
is mandatory if this weiding generator is to be
operated in a Nationai Forest, or on California
grasstands, brush, or forest covered land (see Section
4442 of California Public Resources Code). For other
q areas, check your state and local laws. y
A proper installation site permits freedom of air movement
into and cut of the welding generator, and also least subjects
the unit to dust, dirt, moisture, and corrosive vapors. A
minimum of 18 inches of unrestricted space must be main-
Negative Weld ==
Output Terminal
tained between the welding generator front and rear panels
and the nearest obstruction. Also, the underside of the
welding generator must be kept completely free of ob-
structions. The installation site should also permit easy re-
moval of the outer enclosure for maintenance functions,
IMPORTANT
Do not place any filtering device over the intake air
passages of the welding generator as this would
restrict the volume of intake air and thereby subject
the internal components to an overheating condition
and subsequent failure. Warranty is void if any type of
L filtering device is used. i
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 wiil expose internai compon-
ents to damage should the tips of the lift forks pene-.
| trate the bottom of the unit. I
EQUIPMENT GROUNDING TERMINAL (Figure
3-2)
Mormally, engine-driven welding generators do not require
grounding. However, since this unit has auxiliar; power plant
= > Positive Weld
Zi Output Termina!
ANI
|
Equipment
<= <= <= «<=
da Grounding
Li E Terminal
TA-052 100
Figure 3-2. Equipment Grounding And Weld Output Terminals
3-3.
A.
capability, grounding of the frame and case may be required.
A grounding terminal has been provided on the front panel
for this purpose. For detailed grounding instructions, consult
your local codes or the latest issue of the National Electric
Code.
WELD QUTPUT CONNECTIONS (Figure 3-2)
CAUTION | L
N BL 3,
Ensure that the unit is shut down before making weld
| output connections. 1
Location
The POSITIVE and NEGATIVE weld output terminals are
located on the lower portion of the front panel.
Weld:ng Cables
if welding cables were not ordered with the welding gener-
ator, the following instructions should be followed to ensure
the best weiding generator performance.
1, Use Table 3-1 as a guide for selecting correct cable size for
the anticipated maximum weld current which will be
used. Table 3-1 shows total cable length, which includes
the electrode and work cable. Example: [f the electrode
holder cabie is 75 feet long and work cable ts 25 feet long,
select the size cable that is recommended for 100 feet at
the maximum weld current that is to be used.
2. Do not use damaged or frayed са ес,
3. Follow the electrode holder manufacturer's instructions
for installing the etectrode holder on the electrode cable.
4. Use correct lugs on the weld cables to connect the
grounding clamp and to connect the cable to the weld
output terminals.
5. Ensure that all connections are clean and tight,
Table 3-1. Welding Cable Sizes
WELDINGL TOTAL LENGTH OF CABLE { COPPER) IN WELD CIRCUIT
AMPERES[ "50 | 100 | 150 | 200 | 250 | 300 | 350 | 400
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 | 10 | 2/0 3/0 3/0
200 2 2 1 1/0 |20 | 3/0 4/0 4/0
250 1 1 1/0 12/0 |3/0 | 4/0 4/0 2.2/0
A-007 624
NOTE: “A. 50 FEET OR LESS.
*B. CABLE SIZE 15 BASED ON DIRECT CURRENT (BC),
60% 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 WITHÉTAND THE OPEN-CIACUIT VOLT-
AGE (OCV} OF THE WELDING GENERATOR MUST BE
USED, WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100
VOLTS, SOME WELDING GENERATORS OF SPECIAL
DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE,
——— SECTION 4 - ENGINE PREPARATION ————
NOTE
See the Engine Manufacturer's manual for complete
| engine саге. я
To reduce potential fire hazards, inspect the engine for
fue! and/or oil leaks prior to putting the unit into
service. Continue to check for leaks during the break-
in period and periodically thereafter. Qil seepage may
exist at the main bearing seals beyond the normal
I break-in period. I
4-1.
ENGINE LUBRICATION
This engine was shipped from the factory with the crankcase
filled with the correct amount of premium quality break-in
oil. Check the gil level before attempting to operate the
engine. If the oil level is low, add standard recommended
engine oil to the break-in oii to bring the oil level to the full
mark.
IMPORTANT
New engines have very close ciearance between the mov-
ing parts, Thus, it is recommended that loading of the
engine be kept to a minimum during the first 25 hours
of operation. This engine requires about 25 hours of
q running time before becoming fully broken in, ]
OM423 Page 7
Drain the break-in oil after the engine stops using oil. The
engine must be run a minimum of TO hours and a maximum
of 25 hours with break-in oil. 1f the engine is run at high
initial load, or the environment is dusty or dirty, drain the
break-in oil before 25 hours of operation. Continued opera-
tion of the engine in high temperature environments (above
909F or 320C) wili also necessitate draining the break in oii
before 25 hours of operation.
{IMPORTANT
Check oil level daily. During the break-in period,
check the oil levei several times per operating day as
new engines may use oil until the piston rings etc.
have seated, 1f cil must be added to the Break-in oii,
use an Cil type and weight as explained in the follow.
ing paragraph and Figure 4-1.
A
When changing the break-in oil, use a good detergent type oil
having an A.P.I. service designation of CC, SC, SD or SE.
Refer te Figure 4-1, “Temperature-Gil Viscosity Guide”, for
proper weight oil to use in various operating temperatures.
The oil capacity is 4 U.S, pints for the Kohler engine or 3
US. pints for the Tecumseh engine. Always check the oii
level after a change with the dipstick in the oil filler tube.
| Ea
| |
SAE 30
} 1 309F
(-1.11@C}
SAE 10W-30
{
y
SAE 5W-20
IN 09F
(-17.89C)]
PEPE
USE API
SERVICE
CC, SC, SD
OR SE OIL
(€
TA-900 044-2
Figure 4-1. Temperature - Qil Viscosity Guide
4-2. FUEL
Page 8
CAUT eE |
в
Never attempt to fill the fuel tank with the engine
running. Do not fill the fuel tank compietely as cold
fuel will expand when exposed to outside temperature
in a warm climate or to engine heat. If the tank is too
full, it will overfiow causing a potential fire hazard.
Never allow fuel to drain on the engine or other com-
1 ponents, я
IMPORTANT
Do not mix ~if with the gasoline. Use a good grade of
‘regular, ‘vw iead”, or “no lead” gasoline of at least
90 octane for this engine. Fuels of lower octane rating
may cause detonations (knocking) which could result
in damage to the engine. The "low lead” or "no lead”
fuels {cwer the polution factor and reduce combustion
1 chamh: - deposits if used exclusively. ]
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 engine, etc., will affect the fuel consumption of
this engine.
4-3.
ОЖ
т 4 à
Еее
EF 5
7.57 1.7 2.0
add 4h 1.75
347 1.2% 1.5
wry 104 1.25
179 oR 1.0
2.14 47 0.75
14 54 6.5
95 oz 0.25
o 25 0 73 00 135 IX 175 200 723 250
OC WELD AMPERES AT &0% DUTY CYCLE
Г T T T T T 1
2 0.5 1.09 15 20 2.8 49
POWER KVA AT ЮО DUTY CYCLE 88-057 288
Figure 4-2. Fuel Consumption Chart
AIR CLEANER
This engine is equipped with a dry element type air cieaner.
The air cieaner requires no initial service,
PREPARING NEW BATTERY FOR SERVICE (Elec-
tric Start Models Only)
IMPORTANT
Never attempt to operate the engine without the bat-
tery connected. Do not attempt to remave the battery
| while the engine is running. !
Wet Charged Battery
NOTE
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. 3
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 require charging. The battery should have a specific
gravity reading of 1.260 {at 809F]} when fully charged. if the
battery requires charging, refer to Section 4-3B., Step 4,
Dry Charged Battery
This battery is shipped in adry state, A sufficient amount of
electrolyte is shipped along in separate contamers to activate
the dry charged battery. To prepare the new battery for
operation, proceed as follows:
—— kÚ—Ú];
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,
Do not dilute this electrolyte as it is premixed to the
I required strength. |
3. Place the battery thermometer in one of the center cells
and check the specific gravity of each cell with a battery
hydrometer.
rates can be used: however, the time to obtain the
correct electrolyte conditions will be longer.
b. When the battery is charged, disconnect it from the
charger and recheck the electrolyte level. Add if neces-
sary. Install the battery caps.
4. The battery should have a specific gravity of 1,260 (at
800F) prior to installation. If this condition is not met,
charge the battery as follows:
с. Rinse the empty electrolyte containers with water
before discarding. Since battery acid is corrosive to
metals, do not pour into a metal sink or drain. Rinse
and mutiiate the empty electrolyte container before
discarding. If acid has accidentally spilled on the bat-
tery or work area during filling or charging, neutralize
with soda or ammonia and flush off with clear water.
Use the same procedure if acid is spilled on clothing.
Ensure that the battery caps are removed before charg-
ing. Failure to do so may cause the battery to explode
L should overcharging occur. ]
a. Use an automotive type battery charger. This battery
shouid be charged at about a 3.5 ampere rate until
correct electrolyte conditions are met. Lower charging
— SECTION 5- FUNCTION
Fine Amperage Controt
N
5. Reinstall the battery in the unit making sure that the
negative (—) terminal of the battery is connected to the
ground cable.
OF GENERATOR CONTROLS
54. AUXILIARY POWER RECEPTACLES (Figure 5-1)
Auxiliary power receptacles are located on the front panei.
When operated at power rpm the welding generator will pro-
vide up to 3 kva at 115 or 230 volts ac (depending on how
ordered), 50/60 Hertz. The unit may be used to operate
lights, power tools, etc.
Auxiliary Power
Receptacles
Range
Switch —f
IMPORTANT
Ensure that all electrical equipment is disconnected
from the auxiliary power receptacles before starting or
stopping the engine, When starting or stopping, the
engine produces low voltage and frequency which
I could cause damage to connected equipment. : I
IMPORTANT
~~
=
Weid /Power Switch
3
x
idle Control
(Electric Start Models With
Kohler Engines Only)
TA-052 100
r
Figure 5-1. Front Panel
5-1. WELD/POWER SWITCH (Figure 5-1)
PERAGE trol 1 f
The position of the WELD/POWER switch and the engine Be tie en ЕН a a wer родом
Throttle determine whether the generator will produce a tacles. 1 the control is set at any other position, the
weld current or an auxiliary power output, If the welding output may be lower than 115 or 230 volts. Low volt-
generator is used to produce a weld output, the switch must age could cause damage to motors, fluorescent bal-
be in the WELD position. if the unit is used as an auxiliary tasts, etc. '
power generator the switch must be in the POWER position. Coll
. The output voltage will vary with the load applied to the
5-2. RANGE SWITCH (Figure 5-1) receptacles. The output voltage at various loads may be deter-
mined from Figure 5-2.
The Range switch provides seven coarse amperage ranges. The A 140
range of each switch position is displayed on the scale sur- ó
rounding the Range switch handle. > 130
м 120 E
IMPORTANT =
© по
© |
Do not change the position of the Range switch while « 100 | : :
welding or under load, as this causes arcing across the 0 > 10 15 20 25 30 35
contacts of the switch. This arcing causes the contacts AC POWER AMPERES B-052 259
to become pitted and eventually inoperative. .
Figure 52. AC Power Curve
5-3. FINE AMPERAGE CONTROL (Figure 5-1) 55. DUTY CYCLE (Figure 5-3)
The duty cycle of a welding generator is the percentage of a
ten minute period that a welding generator can safely be
operated at a given output. This welding generator is rated
The FINE AMPERAGE control permits the operator to
select 8 welding current between the minimum and maximum
values of the coarse range selected by the Range switch, The
scale surrounding the control is calibrated from 0-100 per-
cent in increments of five. The scale represents a percentage
of the coarse range selected, not an actual amperage value.
When the welding generator is used to produce auxiliary
power, the FINE AMPERAGE contro! must be set to 100.
NOTE
The FINE AMPERAGE control may be adjusted
| while welding. I
at 60 percent duty cycle. This means that the welding gener-
ator can be safely operated at rated load for six minutes out
of every ten. Puring the remaining four minutes, the unit
should idle to permit proper cooling, If the welding amperes
are decreased, the duty cycle will increase. Figure 4-2 enables
the operator to determine the safe output of the welding
generator at various duty cycles.
IMPORTANT
Exceeding the indicated duty cycle will cause damage
to the internal components of the welding generator.
Dr]
OM423 Page 9
5-6.
6-1.
6-2.
5-3.
6-4.
[RATED OUTPUT
300 т MODEL
ï
1
150 |
I
= [o] I
ot I
w 200 —
: DOTA
a | BLUE STAR SERIES
= |
a 150 +
ыы |
= I
[
1
|
1
100 |
15 30 49 50 &0 70 30 90 100
% DUTY CYCLE
B-0572 994
Figure 5-3. Duty Cycle Chart
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 current range. The
FINE AMPERAGE control controls the output between the
CHOKE CONTROL
A Choke control is provided for varying the fuel-air mixture
to the engine. When the Choke control is rotated fully
counterclockwise, very little air wiil be admitted to the
engine thru the carburetor, thereby Supplying a richer mix.
ture of fuel. This position is required if the engine is cold
when started. As the engine warms up 1t will be necessary to
rotate the Choke control clockwise stewly until it is rotated
as far as it will go. When the Choke control is rotated fully
clockwise the engine shouid be ready for operation.
THROTTLE CONTROL
The Throttle control provides the operator with the capa-
bility of selecting either WELD or POWER engine speed,
To obtain WELD rpm (3000), push the Throttle control
down until it rests against the stop, To obtain POWER rpm
(1800), pull the Throttle control up unti it rests against the
stop.
RUN/STOP SWITCH (Electric Start Models Only)
The RUN/STOP switch is located on the left side of the
welding generator. When the switch is in the RUN position,
the ignition system is allowed to function and battery voitage
is applied to the revolving field to excite the generator.
When the switch is in the STOP position, a ground is applied
to the ignition system causing the engine to stop if it has
been running.
NOTE
To prevent the battery from discharging, ensure that
the RUN/STCP switch is left in the STOP position
3 when the welding generator is not in use. I
START PUSHBUTTON (Electric Start Models Only}
The START pushbutton is located on the left side of the
welding generator. When the pushbutton 1s depressed the
starter will engage. The pushbutton must be released as soon
as the engine has started to prevent damage to the starter,
minimum and maximum curves of each coarse amperage
range that is shown.
Load voltage is predetermined to a large extent by the arc
characteristics. With the use of the volt-ampere curves it 15
possible to determine what the weld current will be at a
particular arc voltage. The voit-ampere curves show the mini-
mum and maximum curves of each coarse current range.
When the FINE AMPERAGE control is adjusted, the volt
ampere curve will fail between the minimum and maximum
curves of the particuiar coarse amperage range in use.
80
70
60
2 50 -
S ao = \
>,
Wu NN
Bao FWA Ra ae
20 E \ Na ® `` ~
10 E NN к E
oe —
Ч TN = |
2 50 109 150 200 250 300 350 400
6-5.
PL AMPERES
Figure 5-4. Volt-Ampere Curves
B-052 242
SECTION 6-FUNCTION OF ENGINE CONTROi 5 —>—=—=—==reemmmemmenus
STOP SWITCH (Manual! Start Models Only)
The STOP switch is located on the breaker point cover. To
stop the engine, depress and hold the STOP switch until the
engine ceases 10 rotate.
IDLE CONTROL (Electric Start Models With Kohler
Engines Only) (Figure 6-7)
IMPORTANT
To prevent possible damage to the connected equip-
ment, ensure that the IDLE CONTROL switch is in
the LOCK OUT position before connecting equipment
to the auxiliary power receptacies,
The automatic idling device saves fuel by allowing the engine
to idle when the generator is not loaded. The IDLE CON-
TROL switch controls the operation of the device.
AUTOMATIC {DLE Position
When the IDLE CONTROL switch is in the AUTOMATIC
IDLE position and the Throttle is in the WELD position the
engine will remain at idie rom (1650) until an arc is struck.
When an arc is struck, the engine speed will increase to weld
rom (3000). Approximately 10 seconds after the arc is
broken, the engine will return to idle rem, This time delay is
non-adiustable.
The AUTOMATIC IDLE position may be used for Shielded
Metal Are (SMAW) Welding,
LOCK OUT Position
When the IDLE CONTROL switch is in the LOCK OUT posi-
tion engine speed is controlled by the Throttle. The switch
must be in the LOCK OUT position when the ¿nit ts used to
produce an auxiliary power output,
Page 10
Never operate the unit with the wrapper removed. If
the wrapper is removed, a hazard exists to personnel
I from moving and electrical components. I
a CAUT ION: ; |
7-1.
SHIELDED METAL-ARC SMAW) WELDING
1 Connections for direct current straight polarity (DCSP).
a. Connect the electrode cable to the NEGATIVE weld
terminal on the weiding generator.
b. Connect the work cable to the POSITIVE weld
terminal on the welding generator,
2. Connections for direct current reverse polarity (DCRP).
a. Connect the electrode cable to the POSITIVE weld
terminal on the welding generator.
b. Connect the work cable to the NEGATIVE weld
terminal on the welding generator.
3. Connect the work clamp to the object to be welded and
place the desired electrode into the electrode holder,
4. 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
i to become pitted and eventually inoperative.
The FINE AMPERAGE control may be adjusted while
i welding.
5. Place the WELD/POWER switch in the WELD position,
6. Start the engine as outlined in Section 7-3.
7, Place the Throttle control in the WELD position.
8. For electric start models with Kohler engines only: Place
the idle control switch in the desired position,
Prior to welding, it is imperative that proper protective
clothing {welding coat and gloves) and eye protection
{glasses and/or welding hefmet) be put on. Failure to
comply may result in serious and even permanent
q bodily damage. 3
9. Commence welding,
10. When welding is completed, place the IDLE CONTROL in
the LOCK QUT position (electric start models with
Kohler engines oniy) and shut the engine down as out-
lined in Section 7-4.
7-2. AUXILIARY POWER PLANT OPERATION
1, Place the WELD/POWER switch in the POWER position.
2. Rotate the FINE AMPERAGE control to 100.
IMPORTANT
Rotate the FINE AMPERAGE control to 100 before
connecting equipment to the auxiliary power recep-
tacles, 1f the control is set at any other position, the
output may be jower than 115 or 230 volts. Low volt-
age could cause damage to motors, fluorescent bal
I lasts, etc. I
74.
IMPORTANT
Ensure that all electrical equipment is disconnected
from the auxiliary power receptacles before starting or
stopping the engine. When starting or stopping, the
engine produces low voitage and frequency which
1 could cause damage to connected equipment. 1
3. Start the engine as outlined in Section 7-3.
or
4. Ensure that Throttle is in the POWER position.
5. Connect the equipment to the auxiliary power receptacles
and commence operation.
6. When the operation has been compieted, disconnect the
equipment from the receptacles and shut down the engine
as outlined in Section 7-4.
STARTING THE ENGINE
1. For electric start models with Kohler engines only: Place
the IDLE CONTROL switch in the LOCK QUT position.
IMPORTANT
To prevent possible damage to the connected equip-
ment, ensure that the IDLE CONTROL switch is in
the LOCK OUT position before connecting equipment
E to the auxiliary power receptacies. I
2. Ensure that the fuel tank is full and the oil level is ade-
quate (see Section 4),
3. Rotate the Choke control fully counterclockwise {a lesser
degree of rotation is required if the engine is hot).
4, Place the Throttle control in the POWER position.
5. For manual start models: Give a quick steady pull on the
rope.
For electric start models: Place the RUN/STOP switch in
the RUN position and depress the START pushbutton.
Release the pushbutton as soon as the engine has started.
IMPORTANT
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
motor, otherwise the ring or pinion may be damaged.
Limit continuous cranking of the starter to 30
seconds, if the engine does not start within this time,
allow the starter motor to cool down for two minutes
i before reengaging it. I
6. Once the engine has started, slowly rotate the Choke
control clockwise.
7. Allow the engine to run for a few minutes at POWER rpm
before applying a lead or changing the Throttle setting.
This is necessary to allow the engine to warm up and to
ensure proper lubrication.
ENGINE SHUTDOWN
1. Remove all weld and power loads from the welding
generator,
OM423 Page 11
8-1.
ances SECTION 9 - ENGINE MAINTENANCE
9-1.
3-2.
Page 12
2. Place the Throttle control in the POWER position. Allow
the engine to run a few minutes at POWER rpm, with the
load removed, This will allow internal engine température
to equalize.
3. For manual start models: Depress and hold the STOP
switch until the engine ceases to rotate.
If any work is to be done on the rotor of the gen-
erator, remove the spark plug from the engine, This
will prevent engine compression from turning the
rotor and catching the repairperson’s hand between
the rotor fan casting and the stationary adapter cast-
ing. Also on electric start models disconnect the
1 negative (-) battery cable from the battery, J
GENERAL
The efficiency of the welding generator depends a great deal
on the care and attention given it. Ву 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-
Dressed air is recommended. This shouid be performed
periodically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere.
LUBRICATION
IMPORTANT
This engine will require at least 25 hours of running
time to become fully broken in. During this period,
the load on the engine should be kept as light as poss:-
ble, The oil level should be checked a number of times
during an operating day, as some engines will use oil
1 during the break-in period,
Refer to Section 4-1 and Figure 4-1 to determine the proper
type and weight of oil to use in this engine.
In normal operation, oil should be changed after 25 hours of
operation, The oil should be dramed after the engine has
been warmed up to normal operating temperature, thus
promoting foreign particle suspension in the oil and removal
when the oil is drained. Foreign particles tend 10 settle on the
bottom of the crankcase when the oil is aliowed to cool,
avoiding removal and contaminating the new oil.
CLEANING THE ENGINE
This air-cooled engine operates most efficiently when kept
ctean, Maintain cleanliness at ail umes. Wipe ou spilis from
engine immediately to avoid zccumuration of dust.
SPARK PLUG
IMPORTANT
Do not attempt to clean the spark plug electrode by
sandblasting, Particles of abras:ve may stick to the
spark pig, enter the engine, and cause damage to the
internal engine components. The spark plug gap
1 should be kept at 025”. !
8-2.
8-3.
9-4.
4. For electric start models: Place the RUN/STOP switch in
the STOP position.
SECTION 8 - GENERATOR MAINTENANCE emmm mau
COLLECTOR RING BRUSHES
The brushes shouid be inspected periodically to ensure their
proper function. The brush life is very good under normal
conditions. Jf the generator has been operating In an
extremely dusty or dirty location, a close check of the
brushes for freedom of movement and cieanliness should be
made weekly, Under normal use the slip rings will discolor to
a dark brown, If it should become necessary to clean the slip
rings, use a 3/0 or finer sandpaper followed by a crocus cloth.
Never use emery cloth as part of the emery will embed itself
into the collector rings and in turn destroy the carbon
brushes.
WELDING CABLES
Check connections periodicaily for tightness. The cables
should be inspected frequentiy and al! breaks in the insula-
tion shouid be repaired with electrical insuiating tape or the
cables should be replaced. `
The ares around the base of the spark plug should be cleaned
prior to removal of the spark plug to avoid getting dirt into
the engine.
Remove the plug periodically and clean the electrode with a
wire brush or knife blade, Take care not to crack the porce-
lain insulator on the spark plug.
AIR CLEANER
The air cieaner is one of the most important parts of the
engine from the standpoint of engine iife. If dirty aw gers
into the engine, iT can wear out a.set of piston rings witn a
few operating hours.
This engine is equipped with a dry paper type filter element.
Dry paper element type cleaners can be cleaned by removing
the element and tapping lightly, causing ioose dirt to fail off.
The element should be repiaced if dirt does not drop o
easily. `
The paper element shouid he nandled with care to avoid
perforations. Removing the dirt with compressed air can rup-
ture the paper element. Check to ensure that gasket surfaces
of the element are not bent cr damaged in any way. Cúosket
surfaces must seal tightiv at the top and bottom of the
cleaner shell to prevent foreign matter from entering the
carburetor.
Whenever the air cleaner is removed, caver the air intake hole
to prevent dirt from falling (10 the carburetor.
GOVERNOR
The govermor has been set at the factory and should not
require further adjustment. if the governor works ioose or is
disconnected, adjustments should be made by a factory
authorized service station.
If one of the sorings attached tc the governor arm works
loose or is disconnected, reattach the spring exactiy as illus-
trated in Figure 9-1 or 9-2.
9-6. PERIODIC SERVICE
Table 9-1. Periodic Engine Maintenance Chart
Each Every Every Every Every
PERFORM SERVICE AT INTERVALS INDICATED {X} Day 25 Hours 50 Hours 100 Hours 500 Hours
CHECK OIL LEVEL (maintain in safe operating range) ...... .. X -
CLEAN EXTERNAL SURFACES .....erareresonnarnace»ro .. X
REPLENISH FUEL SUPPLY (Use clean, fresh fuel) ......... . XX
CHANGE OIL (Use API Service SC, CC, or SD of proper |
weight} .......—..o_oeéeomorenveroaaarodamoercarawenmarraferearonoo X
CHECK AIR CLEANER ELEMENT ....... 20 ae ae > ee a 0 4 a fes 10 01 4 fe a se a eee [еб X
SERVICE SPARK PLUG (gap for 025") .........eeneraccdfaaarenaofranracoarere na rerecamooocefecnra X
SERVICE BREAKER POINTS {gap 020”) ..............eJ.....0a0deceneroocacanleroeeacaaaadencocecanonocalrecooo X
NOTE: Intervals stated are for good, clean operating conditions — perform services more ‘frequently if dusty or dirty conditions prevail.
The efficiency of the engine depends a great deal ón the care
and attention given it. By following a definite schedule of
inspection and service, engine failure caused by negiect can
be avoided. Service periods are based on hours of running
time and are for normal operating conditions. For extreme
conditions of load, dust, dirt, etc., service more often,
9-7. ENGINE SPEED ADJUSTMENTS
Before proceeding with engine speed adjustments,
ensure that the points and Plug are clean and properiy
gapped and adjust the carburetor as outlined in the
i Engine Owners Manual. I
The engine speeds have been factory adjusted and will not
require frequent readjustment. After tuning the engine, check
the speeds with a tachometer. With no load applied, the idle
speed should be 1650 rom, the power speed 1800 rpm, and
the weld speed 3000 rpm. If necessary adjust the speeds as
follows:
A. For Models With a Kohler Engine:
tale
Solencid *
Coil
die
Splenoid — Idle Speed
Armature* Г Adjustment
Adjustment Tea
Screws
Governor
Arm
Mu —]]]—Ñ
Г Carburetor
h
J
Power Speed
Adjustment
Wetd Speed
Adjustment
*Elactric Start
Models Only
Throttle
TA-008 9553
Figure 9-1. Engine Speed Adjustments (Kohler Engine}
« Start the engine as outlined in Section 7.3.
à. Ensure that the Throtte is against the stop in the POWER
position.
3. Place the WELD/POWER switch in the POWER position
{for electric start models ensure the IDLE CONTROL
switch is in the LOCK OUT position).
A, Rotate the nuts on the Power Speed Adjustment until the
engine runs at 1800 rpm.
5. Release the governor arm, The engine should return to
power speed (1200 rem).
6. Place the Throttle in the WELD position. Ensure the
Throttle is against the stop.
7. Place the WELD/POWER switch in the WELD posi-
tion.
8. Loosen the Weld Speed Adjustment screw on the
Throttle. Adjust the Throttle control cable until the
engine runs at 3000 rpm. Tighten the adjustrnent
screw,
9. For electric start models only:
Loosen the idle
solenoid Armature Adjustment screws.
19. Push the governor arm towards the carburetor to cause
the engine to icdie. While hoiding the arm against the
spring tension, rotate the Idle Speed Adjustment screw
until the engine runs at 1650 rpm. For electric start
models only: Slide the idle solenoid armature towards
the idle solenoid coil until the flat face makes contact
with the coll; tighten the Armature Adjustment
Crews.
11. Ensure that when the IDLE CONTROL switch (elec-
tric start models with Kohler engines only} is in the
AUTOMATIC IDLE position the engine runs at 1650
rpm {no load). If not, repeat Steps 9 and 10.
B. For Models With a Tecumseh Engine:
1 a
Governor — i
bo
Arm
TT
d=",
al
idle Speed
Adjustment
Li —— Carburetor
| El |
ly ACTO e
Power Speed “RS |
Adjustment :
Ji
и 7
=o
i i ño
~ 4 E ;
: Weld Speed ha
Adjustment DA
Throttie
TB-008 854
Figure 9-2. Engine Speed Adjustments {Tecumseh Engine)
1. Start the engine as outlined in Section 7-3.
2. Ensure that the Throttie is against the stop in the POWER
position.
3. Place the WELD/POWER switch in the POWER position,
4. Rotate the Power Speed Adjustment screw until the
engine runs at 1800 rpm.
5. Push the governor arm towards the carburetor to cause
the engine to idle. While holding the arm against spring
tension, rotate the Idle Speed Adjustment screw until the
engine runs at 1650 rpm,
(M423 Page 13
6. Release the governor arm. The engine should return to
power speed (1800 rpm).
7. Place the Throttle in the WELD position. Ensure the
Throttle is against the stop.
8. Place the WELD/POWER switch in the WELD position,
9. Rotate the Weld Speed Adjustment screw until the engine
runs at 3000 rpm.
9-8. SPARK ARRESTOR (Optional)
IMPORTANT
The engine exhaust system on this welding gneerator
has not been equipped with a spark arrestor unless it
was specifically ordered as an optional accessory. A
spark arrestor, maintained in effective working order,
is mandatory if this welding generator is to be
operated in a National Forest, or on California
grassiands, brush, or forest covered land (see Section
4447 of California Public Resources Code). For other
i areas, check your state ang local laws, y
Internal combustion engines operating in a highly combus-
tibia environment are a common fire hazard. Glowing carbon
particles blown out with the exhaust can retain sufficient
heat to ignite materials, While no practical spark arresting
device will stop all sparks, this device will minimize fire
hazards by removing and trapping most solid particles
provided that it is properly maintained.
The carbon trap should be serviced weekly or every 50
operating hours, whichever occurs first, The entire spark
arrestor should be inspected every 1000 operating hours or
three times per season.
Inspection
1. Visually examine the outside of the device for holes,
cracks, or metal corrosion.
2. With the engine stopped, took inside the spark arrestor
outlet tube with a flashlight or other light source. Visually
examine the vanes and the outlet tube for metal or weld
failure. The vanes must be firmly attached to the inlet
tube and the outlet tube must be completely intact {this
is an important factor in maintaining spark arresting
efficiency).
3. Check the mounting clamp to ensure that the spark
arrestor is securely mounted. Replace the spark arrestor if
inspection reveals any signs of failure.
Servicing The Carbon Trap
Service the device in an area where there is no danger
1 from flying sparks or hot carbon particles, I
1, Stop the engine and allow the exhaust system to cool,
2. Remove the cleanout plug from the bottom of the spark
arrestor with a wrench. НК a crust has formed over the
hole, break it loose with a screwdriver or similar tool.
3. Start the engine and run it at idle rom to blow collected
particles aut the cleanout hole. If particles are slow to
discharge, momentarily cover the end of the exhaust
stack.
4, Stop the engine. Replace and secure the cleanout plug.
— SECTION 10. GENERATOR TROUBLESHOOTING —————
Hazardous voltages are present on the internal cir-
cuitry of the welding generator while the engine is
running. Shut down the engine before attempting any
inspection or work on the inside of the unit, Troubie-
shooting of internal circuitry should be performed by
qualified personnel only.
rere ————
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in this
welding generator.
It is assumed that proper installation has been made,
according to Section 3 of this manual, and that the welding
generator has been functioning properly until this trouble
developed.
Use this chart in conjunction with the circuit diagram while
performing troubleshooting procedures, tf the trouble is not
remedied after performing these procedures, the nearest
Factory Authorized Service Station should be contacted. In
all cases of equipment malfunction, the manufacturer's
recommendations shouid be strictly followed.
TROUBLE PROBABLE CAUSE
REMEDY
Battery discharges between uses
(electric start only},
RUN/STOP switch
RUN position.
(S4) ей in
Ensure RUN/STOP switch (54) is left in the STOP position
when the unit is shut down.
twhitegrayish substance).
Build-up of acid on top of battery
Clean battery with soda solution; rinse with clear water.
Infrequent use.
Periodically
months}.
recharge battery (approximately every 3
Defective battery.
Replace battery.
receptacles.
AMPERAGE control {R1).
No power output at power | WELD/POWER switch (31) Place WELD/POWER switch (51) in POWER position.
receptacles. weld position,
Throttle in WELD position. Place throttle in POWER position.
Limit switch {S2} on throttle not | Adjust tab so that switch (62) closes when throttle is in
closing. POWER position.
Low power output at power | Low setting on Rotate FINE AMPERAGE control (Rt) to 100.
speed 11800 rpm),
Engine running below required
Check air filter; clean if necessary.
Clean and adjust points and plug. Adjust carburetor (see
Engine Owners Manual).
Adjust engine speed (see Section 9-5),
Page 14
TROUBLE PROBABLE CAUSE REMEDY
Low weld output. Throttle in POWER position. Place throttie in WELD position.
Engine running below required | Check air filter; clean if necessary,
speed (3000 rpm).
Clean and adjust points and plug. Adjust carburetor (see
Engine Owner's Manual).
Adjust engine speed (see Section 9-7).
Erratic weld output. Damp, defective, or wrong type | Try different electrodes.
electrodes,
Improper connection to | Check and tighten loose connections.
workpiece.
Erratic weld and power output. Dirty slip rings and/or worn $ Clean slip rings and/or replace worn brushes (see Section
brushes. 8-2).
The engine does not return to idle | Fuse (F1) open (can be caused by 1 "Replace fuse (F1). Check idle solenoid {F81). This solenoid
rem when the arc is broken and | a defective idle solenoid FS1). should have approximately 5 ohms resistance across the coil,
the IDLE CONTROL swtich (55) and very high resistance from either side of the solenoid to
is in the AUTOMATIC IDLE ground {frame of machine). If these conditions are not met,
position {electric start models replace the idle solenoid (FS1).
with Kohler engines only}.
*1f it becomes necessary to repiace any fuse in the welding generator, ensure that a fuse of the proper size is used.
——) SECTION 11- ENGINE TROUBLESHOOTING emumÑ===Jsq2ÑÑmqoa=m=———
FAILURE TO START
CARBURETION
Poor grade ACT a Care Plug rly, Breaker contr ptzed
at tue Fuel pump нар арт Condenser rn or fused,
Irmproper Fioodæd on pectrodes. | | Soark plug insulation bad.
venidas | [Chet Or Gum halting Weak tattery | 1Hrokan ignition abie.
No fuel float needle vahe ar ma
Damaged HS needs vane.
Eyl bre стос
Aor yen) Lller cap plugs.
Manitold gasket leak
Mytther choque,
KNOCKING
CARBUKETION MECHANICAL OVERHEATED
Pooe grade of tual Heavy 1020 at slow рева || Blocked air flow. 1
OC tare rating (0 1Dvr Carbon or [dad deposi in |
cy reer Mead,
Loo connecting rod, |
Loc mam baw ings.
Buried OU SON meting гос.
Мое г юм ай рн. |
WET OP NDR irre dena, |
Imeroper p;riion lit, |
Y ale lat LOG Great, |
Walvis sticking, i
MISSING |
[CARBURETION] COMPRESSION
| Water in fuel, Socking vabees, [ Imeropar hear range 1 plug,
Aur als 1 Ester. Loose or broken park plug || Loose plug,
Detective ficar mechad: Cyhoder head gagat laaking, i Poor insulation on plug.
Choke contrôl parthy closed. Warped or broken valves. Spark plug gap incorredt.
Vapor look, Valve Sof regs weak or broken, | | Worn and leaking ignition calles.
Weak park,
Loos slectrical Com lions.
Sreaker pornis pitted of warn.
Breaker pauls sticking.
improper tension of Hhreaker point
prim.
Impropér breaker point gap.
Bag condenar.
Warn out plug,
Detective ignition sait,
Соц) ©? того" арены ies.
OVERHEATING
CARBURETION] [LUBRICATION | [ MECHANICAL
Low grade of fuel, Chi supply ow. Engine overionded
ngine operaied while Dirty ar Income Catpor degosits in
deronarno, die to ! ade ota, | ene.
‘ow octane tusl or | EP a lubiieaung | |Restrieted exhaust.
heavy load, + Trstem. | Var ea],
Irburetor SET tog lean. AEINCIOS gr clear
fogged sir filter, Васи Сын ©? Бе ак
Leak in intake tyitem.
T8-007 750
SURGING
CARBURE TION GOVERNOR |
i
1
Cardycetar Hogd ig. Bricky canfrair
Improper sdjustrrent 1er lubricar,
Intaka aks
OM423 Page 15
ENGINE
FLYWHEEL
PULSE COIL
Laas) Laas
POWER WINDING
000000000000 UQUY YU
REVOLVING FIELD
UVUOUUUOOUOQUDOQUDUUOUOUD
(vem)
DC-Z
WELD
WINDING
POSITIVE
37
Je) NEGATIVE
Circuit Diagram No. CA-902 205-1B1
Figure 11-1. Circuit Diagram For Manual Start Models With Kohler Engines
RC1
| 7
re | | 17
| о ENGINE PULSE L
ENG | ASS COIL - or |
IGN, lo
Ww
ё Bo 1
ol
+ Le, ll bee
- 1 | 19
090, Logo 200,
POWER WINDING
JO000000U0 0000000 U 0000
REVOLVING FIELD
JO0000000000000 00000
WELD
WINDING
DC-Z
5000 0 POSITIVE
22 NEGATIVE
Circuit Diagram No. CA-902 347-1A1
Figure 11-2. Circuit Diagram For Manual Start Models With Tecumseh Engines
Page 16
START
124 BAT. OL gu TO STARTER
— + o. IGNITION COIL
NE > E то
540— TO REGULATOR RECTIFIER
WELD
’ 51
55
AUTC,
IDLE
38
FSISIDLE
El SOLENOID , 33
37! |
Ro K - |
31° PC:
35
x
nn m
fa)
3
PCy TERMINAL IDENTIFICATION
A B D FE H J L
WELD
WINDING
DC-Z
POSITIVE
27
elcleli lull
MT a
Tama) NEGATIVE
Circuit Diagram No. CA-902 135-1F
Figure 11-3. Circuit Diagram For Electric Start Models With Kohler Engines
12Y. BAT.
aba" 1
START
dis 2
Olle TO STARTER
TO REGULATOR-RECTIFIER
WELD
aso)
WELD
WINDING
AC-Z
PP лол,
DC-Z
E POSITIVE
ZO NEGATIVE
Circuit Diagram No. CA-902 260-1C
Figure 11-4. Circuit Diagram For Electric Start Models With Tecumseh Engines
OM423 Page 17
FORM: OM-423B
March 1978
Effective With Serial No. HJ117438
e
a 1)
a
дж
PARTS
LIST
Fig B
10 11 12 14
OM-423 Page 1
TD-062 526-À
Figure A — Main Assembly
Quantity
Item Dia. Factory - :
No. Mkgs. Part No. Description Tm roe os
Figure A Main Assembly
1 54 011611 SWITCH, toggle DPDT 15 amp 125 volts .......... 1 1
2 039 547 BRACKET, mounting - switch starter ............ 1 1
3 Start 011767 SWITCH, push button -starter ............. cc... 1 1
4 052 950 COVER, battery box ............ cio t. 1 1
5 052 170 CABLE, battery - positive .. 122421200400 848424 + 1 1
052 168 CABLE, battery - positive ...-.. 112242114000 00 40 1 1
6 052 553 COVER, cable - red post battery ................ 1 1
7 Batt "003425 BATTERY, 12 volts 30 amp ........eovecireno. 1 1
8 052 167 CABLE, battery - negative ......._—.oeeomcxermenas 1 1
9 052 374 SHELF, battery box ........eeceeneaiuoraoada ra 1 1
052 949 SPACER, battery box ...0.0 400000000. RR 1 1
10 015712 GROMMET, rubber 5/8 ID x 7/8 mounting hole .... 1 1 1 1
11 Figure 8 GENERATOR ASSEMBLY (see Page 4) .......... 1 1 1 1
12 005 005 CONNECTOR, body - terminal ................. 7
РС1 039434 CONTROL, weld/idle -electronic . .............. 1
F1 012634 FUSE, miniature - glass 3amp ........... es... 1
053 925 HOLDER, fuse .. 112120220000 0 ea arc a 0e 1 aa 000 1
54 011801 SWITCH, toggle SPST 10 amp 125 volts ,......... 1
053 781 BRACKET, mounting -switch . ................. 1
13 007 950 ENGINE, gas - manual start {Kohler}{consisting of) .. 1
13 053 200 ENGINE, gas - electric start {Kohler }{consisting of} . . 1
13 008 116 ENGINE, gas - manual start (Tecumseh)(consisting of} 1
13 008 987 ENGINE, gas - manual start (Tecumseh) (consisting of) 1
14 . CONNECTOR, {included with engine - see engine
parts list} .....2200 204000 0e aa ea a ee ac an 000» 1
15 034 264 CONTROL, push/pull {consistingof) ............ 1 1
16 021916 ..CONTROL, push/pull ............_eres--—aaa - 1 1
17 604 226 .. CHAIN, furnace No. 17 (7 links req'd. -
order by foot) .. ie aie, 1ft. 1ft
18 604 227 .. HOOK,S blunt 3/4 inch ......... ........... 1 1
FS1 064 382 .SOLENOID ... 11222004 aa <a 0 a aa a a a ne 11 41 0e 0 1
19 5852 020 251 .SWITCH, control - excitation (consisting of) .... 1 1
19 52 032 852 .SWITCH, control - excitation {consisting of} ...... 1 1
20 015503 ..BRACKET, mounting - switch limit............ 1 1
20 032 854 ., BRACKET, mounting - switch limit............ 1 i
21 027 878 ..SWITCH, limit - leaf actuating SPDT ........... 1 1
21 034 168 .. SWITCH, limit 1111122204 14 44 a 1 a a a ee au eee ae 1 1
22 032 867 . FITTING, pipe - black elbow street 1 NPT ...... A 1 1
23 007 201 . FITTING, pipe - galvanized nipple L 1-1/4 NPT x6. 1 1
23 032866 .FITTING, pipe - black nipple 1 NPT x 5 ......... 1 1
24 007 141 .MUFFLER, exhaust - engine .................. 1 1
24 015621 .MUFFLER, exhaust - engine .........eee cerro. 1 1
25 039544 | BRACKET, support-exhaust ................. 1 1
26 039508 CLAMP, pipe Tinch.......e_r—ecreseererereroes 1 1
603 945 .KEY, woodruff 1/4 x 7/3 ............revarea. 1 1
008 916 .SCREW, cap - steel socket hd 5/16-24 x 7/8 ...... 1 1
008 917 , WASHER, flat - steel 2-1/4 OD x 11/32 ID x 3/16 . 1 1
602 207 . WASHER, lock - steel split 1/4 ................ 1 1
003455 .KEY, woodruff 1/4 x 3/4 SAE No. 91 ........... | 1 1
27 034 354 BRACKET, mounting-engine ............«..-.. 1 1
C1 053296 CAPACITOR, ignition Q.5uf ............... .... 1
28 017 836 SPACER, steel 2sq 7/16 hole x 1/4 .............. 2 2 2 2
OM-423 Page 2
Quantity
Item Dia. Factory _ Model |
No. Mkgs. Part No. Description E Te TE ee
Figure A Main Assembiy (Cont'd.)
29 007 098 MOUNT, engine... ....eerrnevverese mena, 2 2 2 2
30 009 932 BASE... 1111204 4 ae 44 4 41 aa 0 a ea 4 a 0 ae 40 0 1 1 1 1
31 007 197 BRACKET, mounting - capacitor ..........--——w... 1 1 1 1
32 C3 605 957 CAPACITOR, paper oil 20 uf 600 volts ........... 1 1 1 1
33 Ва 008 951 RESISTOR, WW adi 180 watt 12 ohm .........e.. 1 1 1 1
34 006 978 MOUNT, generator - bottom ................... 1 1 1 1
35 C4 931670 CAPACITOR, ceramic 0,5 uf 500 voitsdc ......... 1 1 1
36 D8 027 369 DIODE, rectifier 3 amp 600 volts straight polarity .. 1 1 1 1
СТ 035 454 TRANSFORMER, current 500/17. ............... 1
37 AGCZ 009941 REACTOR..........r.eseroerecrveneorear une 1 1 1 1
38 022 309 TUBING, steel 5/8 OD x 12 ga wall x 2 ........... 1 1 1 1
39 006 977 MOUNT, generator - 10D ......eeoerrrereramieao 1 1 1 1
40 009 943 !+5AFFLE, alr- lower ......_eeeesererore nena. 1 1 1 1
41 603 124 STRIP, rubber (orderby foot) ....... civ rons 4 ft. 4 ft 4 ft. 4 ft.
42 010116 GROMMET, rubber 3/8 ID x 1/2 mounting hole . ... 1 1 1 1
43 DC-Z 009933 STABILIZER... iii iii iia 0 6 1 1 1 1
44 032 878 CLAMP, steet 9/16 dia x 13/32 hole ............. 1 1 1 1
45 Figure C PANEL, front - w/components ................. 1 1 1 1
46 035 135 PANEL, side - right hand ............... cus 1 1 1 1
47 035 136 PANEL,side-lefthand ............... ccc... 1 1 1 1
48 009 971 WRAPPER ..... iii ee eae aaa 1 1 1 1
Parts For Optional Equipment
009 560 XSPARK ARRESTOR, exhaust .......ereceemanra 1 1 1 1
052 294 FITTING, pipe - galvanized coupling 1-1/4 NPT .... 1 1
605 207 FITTING, pipe - galvanized nipple close 1 NPT ..... 1 1
009 749 FITTING, pipe - galvanized coupling 1 NPT ....... 1 1
052425 FITTING, pipe - galvanized nipple L 1 NPT x 2..... 1 1
052401 CLAMP, pipe 1-1/4 oi iene cian 1 1
005 544 COMPOUND, adhesive/sealant .................. 2 2 2 2
*Recommended Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
Quantity
Item Factory Mode! ‘
No. Part No. Description EE =
Figure В Generator Assembly (See Fig. A Page 2 Item 11}
61 010222 CONNECTOR, rectifier-cell .,............... 2 2 2 2
62 017763 ENDBELL, generator .........r.-—romsrera 1 1 1 ]
63 **007 934 STATOR, generator (115 volts model) ......... 1 1 1 1
63 **008 476 STATOR, generator (230 volts model} ......... 1 1 1 1
64 009975 BAFFLE, air-stator .......e._.eñeecxorreoeeorxa 1 1 1 1
65 **032 704 ROTOR, generator (consistina of} ............. 1 1 1 1
66 024 617 . RING, retaining - external .................. 1 i 1 1
67 024 800 .BEARING, ball ........._eoe-recrooererenoo. 1 1 1 1
68 017 624 FAN, rot0or .. .. RR KK 1 1 1 1
602348 .KEY, 1/4x 1/4x 3/4. 11111240 a 1 aa 11 11 04 + 1 1 1 1
69 052 220 GUARD, fan-rotor ......... cine... 1 1 1 1
70 017 742 ADAPTER, fan - rotor ,............e_ eee... 1 i
70 021934 ADAPTER, fan -rotor....,.....204 11002000 1 1
71 035 718 ADAPTER, engine .......—.—.—osremmorereooreo 1 1 1 1
72 1603 945 KEY, 1/4 x 7/8... Ra 1 1
73 1602 226 WASHER, flat - steel 7/16 1D x 2-1/4 3D x 3/16 . 1 1
74 1602 215 WASHER, lock - steel split 7/16 .............. 1 1
75 t602 018 SCREW, cap - steel socket hd 7/16-14 x 1-1/2 ...,. 1 1
76 004 994 BRACKET, mounting - brush holder .........,. i 1 1 1
77 005614 HOLDER, brush-w/tabs .................... 2 2 2 2
78 *003 921 BRUSH, w/spring .. «cc vv ieee ein 2 2 2 2
79 003 923 CAP, holder-brush ............ ou... 2 2 2 2
80 004 993 BAR, retaining - brush holder ................ 1 1 1 i
*Recommended Spare Parts.
**Rotor and Stator are available on an exchange basis. Contact Distributor for Details.
fThese items included with engine (item 13) on Tecumseh engines.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TD-052 525
Fiqure B — Generator Assembly
OM-423 Page 4
93—Fig C1
115
70-052 526
Figure C — Panel, Front - W/Components
Page 5
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure C Panel, Front - W/Components {See Fig. A Page 3 Item 45)
91 NAMEPLATE (order by stock, model, and serial numbers) ........... 1
92 009 999 ¡PAÑNEL, front ......eemeerceresnorasrasnoarorgadanoamorvermo an aa i
93 S3 005 563 SWITCH, selector (see Fig. C1 Page 7) ......220000 00402 a 0 a a aa a aa un 1
94 Ri 007 400 RHEOSTAT, WW 100 watt 30 ohm ........eoererengarenzanervero 1
95 RC1 604176 RECEPTACLE, straight - dupiex grounded 2P3W (115 voits models) ... 1
95 RC1 604103 RECEPTACLE, dupiex - grounded 2P3W (230 volts models) .......... 1
96 51 011622 “SWITCH, toggle 3PDT 15 amp 125 volts ...........__.e0oranrecooeo 1
55 053359 SWITCH, toggle SPST 20 amp 125 volts ac {Kohler electric
models only). .........eeee.reeeasanvconre asa esnoanonnaanooña 1
97 SR2 009987 RECTIFIER, silicon diode (see Fig. C2 Page 7) .........eeer=—recaro 1
98 SR1 035914 RECTIFIER, integrated 25 amp 400 volts ......._..._w_eeceeesoxooomoo 1
99 039 047 TERMINAL, power output - red (consisting of) ,.........._eoer cue. 1
100 601 879 .NUT, steel - hex full 1/2-13 ...........—.esecrecredorczereracedos 1
101 039044 .BUSBAR .........eeenvsreveroarnearareorodavanoresoegoaaoo 1
102 601880 .NUT, steel - hex jam 1/2-13 .L..1112 020410 4 a aa 0 4 14 a a ua a a 4 1 4 ue 1
103 039049 TERMINAL BOARD, red.........e_—eesveroorenedarovemaneora 1
104 053 032 CLIP, spring - bus bar ......_ec_ereserverecorercrearar o eraaoeoo 1
105 601976 .SCREW, can - steel hex hd 1/2-13 x 1-1/2 .. 0. inn. 1
106 039 046 TERMINAL, power output - black {consistingof) .................. 1
107 601976 .SCREW, cap - steel hex hd 1/2-13 x 1-1/2 ..... iii. 1
108 053 032 CLIP, spring - bus bar ........eeeñecweserderenvearesnooesaoadenmaoo 1
109 039045 TERMINAL BOARD, black ......._eoxeogadsareraanesoononanon 1
110 601 830 .NUT, steel - hex jam 1/2-13 .........ersnevosedareconarcace rra 1
111 039 044 .BUSBAR .......eorveccesnmmorrecaosenvedsosoreomorenmanmooreno 1
112 601 873 .NUFT, steel - hex full 1/2-13 1... 12220000 2 0 4 a aa ee ua ua a 0 a aa an . 1
113 024 356 KNOB, pointer ........—.—eeoreorrescamadoneasntorreavaorosaeo 1
114 010 647 PIN, spring - compression ......e.e._esrsocorneretooraveorana ro 1
115 006 927 HANDLE, switch - range .....eeoe.rreondnorvedsrdareoosradrerdoosms 1
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-423 Page 6
tem Factory
No. Part No. Description Quantity
Figure C1 005563 Switch, Selector (See Fig. C Page 6 Item 93)
121 005 562 BRACKET, mounting- switch 1.122412 014 4 04 4 a a a 4 et a 0 a eu aa un à 1
122 005561 SHAFT, rotor .........._.eemerarrorarn 2 arrarereroerneracerec. 1
123 005 564 iiNSULATOR, screw - switch 1020204 4 642 4 0 4 eee 4 a 0 0 a 0e ea au eee 110» 1
124 505 276 SCREW, cap - steel hex hd 1/4-20 x 1-1/4 11.111211 2 44 11 ea a aan a 0 1
125 005 559 CONTACT BOARD, movable - switch 1.111.124 4 040 ee ea 4 aa ea a aa a 0 1
126 005560 CONTACT, switch -movable .... 111244200021 0 40 a a 4 a teins 1
127 008 485 SPACER, contact -Switch ......._.._e.-ecoerecraxsaeorerartei aa ee en 1
128 005 566 CONTACT BOARD, stationary - switch... 202120040084 кино, 1
129 052 403 CONTACT, stationary - switch .....12122 000 0402 4 a 4 a 0 14 a ea ea a 1 a 0 7
130 052 405 SPRING, pressure - contact SWITCH .......e _eesoxdarearescore nea 1
131 052 404 CONTACT, movable - switeh ......202 20048111 aa a a ae a a a ea a 0 ee 1
132 005 557 BUS BAR, switch -range ...,,.oe-—eocenverervcorrarnoronereae, 1
133 005 558 SPRING, selector -switch ........—-e.—e-—er_e=m—rerocanmesovveraererno 1
131
132
141 142 143
o
TC-082 524
Figure CT — Switch, Selector 148
TA-052 523
Figure C2 — Rectifier, Silicon Diode
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure C2 009987 Rectifier, Silicon Diode (See Fig. C Page 6 Item 97)
141 009970 BRACKET, mounting - rectifier .......1.122201000 22000 a nana 2
142 C58 031689 CAPACITOR, ceramic 0.01 ut500voltsde ....... ..... . ... a... 4
143 026 947 INSULATOR ......... ..sm0edrarore vd: aaresdvcrenvóderavrene, 2
144 037 306 DIODE, rectifier 150 amp 300 volts reverse polarity ................ 2
145 000 601 SUPPRESSOR, rectifier (consisting of) ....... cc. ein iin.. 1
146 R2 030726 . RESISTOR, WW fixed 5 watt 1000 ohm ........... 0 iii... 1
147 VS1 024 471 ,.,SUPPRESSOR, 1 uf 2.70hm 1122201100 44 4 4 4 4 a a ae ue 4 a a a a 4 eau + 1
148 037 305 DIODE, rectifier 150 amp 300 volts straight polarity ................ 2
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 7
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