Miller BLUE STAR 180K User manual

Miller BLUE STAR 180K User manual
 и March 1992 FORM: OM-436A
iller Effective With Serial No. KB110695
®
MODEL: Blue Star® 180K
OWNER'S MANUAL
» IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before installing, MILLER ELECTRIC Mfg. Co.
operating, or maintaining this equipment. This unit and these instructions are for - ;
use only by persons trained and experienced in the safe operation of welding | F-O-Box 1073
: o > | Appleton, WI 54912 USA
equipment. Do not allow untrained persons to install, operate, or maintain this unit. | 1," 414.734.0851 |
Contact your distributor if you do not fully understand these instructions.
i
|
cover! 1/92 - 58-144 336-A PRINTED IN USA
y
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
LIMITED WARRANTY — Subject to the terms and conditions
hereof, MILLER Electric Mfg. Co., Appleton, Wisconsin war-
rants to its Distributor/Dealer that all new and unused
Equipment furnished by MILLER is free from defect in
workmanship and material as of the time and place of delivery
by MILLER. No warranty is made by MILLER with respect to
engines, trade accessories or other items manufactured by
others. Such engines, trade accessories and other items are
sold subject to the warranties of their respective manufacturers,
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase, except Deutz engines
which have a one year, 2000 hour warranty.
Except as specified below, MILLER's 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.
MILLER shali be required to honor warranty claims on war-
ranted 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:
1. Arc welders, power sources, robots, and ........ 1 year
components
2. Loadbanks .. ....... .... oo 1 year
3. Original main power rectifiers ............... 3 years
(labor — * year only)
All welding guns, feeder/guns and torches .... 90 days
All other MILLERMATIC Feeders ............. 1 year
Replacement or repair parts, exclusive of labor. 60 days
Batteries . . ...... 6 months
“NDA
provided that MILLER is notified in writing within thirty (30) days
of the date of such failure.
As a matter of general policy only, MILLER may honor claims
submitted by the original user within the foregoing periods.
O
This warranty supersedes all previous MILLER warranties and is exclusive with na other guarantees or warranties expressed or implied.
In the case of MILLER's breach of warranty or any other duty
with respect to the quality of any goods. the exclusive remedies
therefore shall be, at MILLER's option (1) repair or (2) replace-
mentor, where authorized in writing by MILLER in appropriate
cases, (3) tne 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 expense. MILLER's option of repair or replacement will be
F.Q.B., Factory at Appleton, Wisconsin, or F.O.B. ata MILLER
authorized service facility, therefore, nc compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REFRE-
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW. CUSTOM QF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN-
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE.
WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER 15 EXCLUDED AND DISCLAIMED
BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERC'AL/ANDUSTRIAL
USERS AND FOR OFERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLER'S WARRANTIES DO NOT
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLER'S WARRANTIES TO, ANY CONSUMER.
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for
loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or
equipment manufacturer's Transportation Department.
When requesting information about this equipment, always provide Mode! Designation and Serial or Style Number,
Use the following spaces to record Mode! Designation and Serial or Style Number of your unit. The information is located on
the rating label or nameplate. |
Model
Serial or Style No.
Date of Purchase
mille 6 41
ERRATA SHEET October 19, 1992 FORM: OM-436A
Use above FORM number when ordering extra manuals.
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions
to data appearing later in this manual.
CHANGES TO SECTION 7 — ELECTRICAL DIAGRAMS
Replace Figure 7-1. Circuit Diagram For Welding Generator (see Page 4 on this Errata Sheet)
Replace Figure 7-2. Wiring Diagram For Welding Generator (see Pages 2 and 3 on this Errata Sheet)
CHANGES TO SECTION 10 — PARTS LIST
Change Parts List as follows:
Dia. Part Replaced
** Mkgs. No. With Description Quantity
. 39-11 .. CR3... 090104 ..... 149 823 .. RELAY, encl 12VDC SPST 30A (Eff w/KC308105) ...... 1
. 39-11 .. CR4 ... 090104 ..... 115693 .. RELAY, encl 12VDC SPDT 30A/20A (Eff w/KC308105) .. 1
..39- ... CR6 ..... Added ..... 115693 .. RELAY, encl 12VDC SPDT 30A/20A (Eff w/KC308105) .. 1
‚ 40-6 ........... 143220 ..... 143 220 .. O-RING, (included w/endbell)
‚ 40-19 .......... 142 980 ..... 153 301 .. ENDBELL, gen (consisting of) ..................... 1
Ce ee eee ea 143220 .... O-RING, 2.859 ID x .1396S .....................1
. 41-10 .. C1,2....087110..... 156 289 .. CAPACITOR, elctit 240uf250VDC .................. 3
. 41-11 2.000.000. 141035 ..... 154 946 .. ENCLOSURE, mtg components (Eff w/KC308105) ..... 1
, 41-16 .. PLG3 .. 135556..... 135 134 .. CONNECTOR, rect 9P/3 plug (Eff w/KC308105) ...... A
LL La LL 1111 a ae LL 114 066 .. CONNECTOR, rect skt 20-14ga .................... 9
. 41-18 .. RC3 ....116045..... 135 133 .. CONNECTOR, rect 9P/3 rcpt (Eff w/KC308105) ....... 1
RAA AS 113633 .. CONNECTOR, rectpin20-14ga .................... 9
**First digit represents page no — digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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RINGS
Figure 7-1. Wiring Diagram For Welding Generator Effective With Serial No. KC308105
OM-436A Page 2
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502-154 542
OM-436A Page 3
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NOILAU 313Y1d39033 NYOIHSY HLNOS
OM-436A Page 4
ARC WELDING SAFETY PRECAUTIONS
А WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more compiete safety information that will be found in the
Safety Standards listed on the next page. Read and follow ait Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
| ELECTRIC SHOCK can kill. 5. Properly install and ground this equipment according to its
Touching live electrical parts can cause fatal shocks Owner's Manual and national. state. and local codes.
or severe burns. The electrode and work circuit is 6. Turn off all equipment when not in use.
— electrically live whenever the output is on. The input ; |
EN power circuit and machine internal circuits are also 7. Do oot use worn. damaged. undersized, or poorly spliced
live when power is on. In semiautomatic or automatic cables.
wire welding, the wire, wire reel. drive roll housing, 8. Do not wrap cables around your body.
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly 9. Ground the workpiece to a good electrical (earth) ground.
grounded equipment is a hazard. 10. Do not touch electrode while in contact with the work (ground)
Do not touch live electrical parts. circuit. a |
Wear dry, hole-free insulating gloves and body protection. 11. Use only well-maintained equipment. Repair or replace
Insulate yourself from work and ground using dry insulating damaged parts at once.
mats or covers. 12. Wear a safety harness to prevent falling if working above floor
Disconnect input power or stop engine before installing or level.
servicing this equipment. 13. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin; 1. Wear a welding helmet fitted with a proper shade of filter (see
NOISE can damage hearing. ANSI 249.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
Arc rays from the welding process produce intense 2. Wear approved safety glasses. Side shields recormmended.
Le | heat and strong ultraviolet rays that can burn eyes 3. Use protective screens or barriers to protect others from flash
“A and skin. Noise from some processes can damage and glare; warn others not to watch the arc.
a earing. |
9 4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
а, FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
to your health. wearing an air-suppliied respirator. Shielding gases used for
Welding produces fumes and gases. Breathing these welding can displace air causing injury or death. Be sure the
fumes and gases can be hazardous to your health. breathing air is safe.
6. Do notweldin locations near degreasing, cleaning, or spraying
ions. fth |
Keep your head out of the fumes. Do not breath the fumes. ith phe nea and rays Soar can react with vapors to
If inside, ventilate the area and/or use exhaust at the arc to 209 99
remove welding fumes and gases. 7. Do not weid on coated metals, such as galvanized, lead, or
if ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, uniess the coating is removed from the
Read the' Material Safety Data Sheets (MSDSs) and the weld area, the area is well ventilated, and if necessary, while
manufacturer's instruction for metals, consumables, coatings, wearing an air-supplied respirator. The coatings and any metals
and cleaners, containing these elements can give off toxic fumes if welded,
~ = WELDING can cause fire or explosion. 5. Watch for fire. and keep a fire extinguisher nearby.
(DS = Sparks and spatter fly off from the welding arc. The 6. Be aware that welding on a ceiling, floor, buikhead. or partition
flying sparks and hot metal, weld spatter, hot can cause fire on the hidden side.
workpiece, and hot equipment can cause fires and |
burns. Accidental contact of electrode or welding wire 7. Do not weld on closed contamers such as tanks or drums.
to metal objects can cause sparks, overheating, or 8. Connect work cable to the work as close to the welding area as
fire. practical to prevent welding current from traveling long. possibly
Protect yourself and others from flying sparks and hot metal. unknown paths and causing electric shock and fire hazards.
Do not weld where flying sparks can strike flammable material. 9. Do not use welder to thaw frozen pipes.
Remove ali flammables within 35 ft {10.7 m) of the welding arc. If 10. Remove stick electrode frem holder or cut off welding wire at
this is not possible, tightly cover them with approved covers. contact tip when not in use.
Be alert that welding sparks and hot materials from welding can 11. Wear oil-free protective garments such as leather gloves, heavy
easily go through small cracks and openings to adjacent areas. shirt, cuffless trousers, high shoes, and a cap.
в. FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles. Side shields
cause injury. recommended.
Chipping and grinding cause flying metal. As welds 2. Wear proper body protection to protect skin.
cool, they can throw off slag.
CYLINDERS can explode if damaged.
|| Shielding gas cylinders contain gas under high
"| pressure. If damaged, a cylinder can explode. Since
"| gas cylinders are normally part of the welding
° | process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Instat and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any weiding or other electrica!
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Useonly correct shielding gas cylinders, regulators. hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder vaive.
7. Keep protective cap in place over vaive except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
A WARNING
ENGINES can be hazardous.
| ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1, Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel ts highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. if possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. И fuel is spitied, clean up before starting
engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
~~ cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in piace.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative {—) battery cable from battery.
5, Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
| burn eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Donot allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
5, Observe correct polarity (+ and —) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiater cap when engine is hot. Allow engine
to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard 249.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
sr1 9/91
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard 287.1, from American National Standards Insti-
tue, 1430 Broadway, New York, NY 10018,
Cutting And Welding Processes, NFPA Standard 518, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
TABLE OF CONTENTS
SN — — — — —_— — —_— — _— "_ _ _—_—_—_— " _ " " _ _ _ _—_—_ ____——m—-—-—- - - "_ -" "_"_" "_ " "_"_ "=
SECTION 1 — SAFETY SIGNAL WORDS . . ee ee 4 a 4 AAA SA LA aa 1126 1
SECTION 2 — SPECIFICATIONS
2-1. Volt-Ampere CUIVES «oo eee н вен 2
2-2. Duty Cycle o.oo ee 2
2-3. Fuel Consumption ooo erre ere. 3
2-4. AC Auxiliary Power Curve eee 3
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding Generator ............................ 4
3-2. Connecting The Battery .................... SE 5
3-3. Engine Prestart Checks ....... e 6
3-4. Grounding The Welding Generator ...... ee 6
3-5. Selecting And Preparing Weld Output Cables ............... aL. 7
3-6. Connecting ToWeld Output Terminals ............. iii 8
SECTION 4 — OPERATING THE WELDING GENERATOR ...... ....... .. ... . ... .... 8
SECTION 5 — OPERATING AUXILIARY EQUIPMENT
5-1. 120 Volt Duplex Receptacles And Circuit Breakers ............ oo. 11
5-2. Optional 240 Volt Duplex Receptacle ......... iii. 12
5-3. Optional 240 Voit Twistlock Receptacle (FUlFKVA) ........ iio. 12
5-4. Wiring Instructions For 120/240 Voit AC Twistlock Plug... ..... cc. oii. 13
SECTION 6 — MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance RR eee е 14
6-1. Changing Engine OE And Filter .... Le 15
6-2. Replacing Fuel Filter oe ea ea sen 6 16
6-3. Overload Protection eee e 16
6-4. Adjusting Engine Speed ........ ee 17
6-5. Replacing Battery Or Checking Battery Voltage .. ........... iL. 18
6-6. Troubleshooting . .. o.oo eee econ, 19
SECTION 7 — ELECTRICAL DIAGRAMS RR ie ae 21
SECTION 8 — AUXILIARY POWER GUIDELINES
8-1. How Much Power Does Equipment Require? ‚eK 23
8-2. How Much Power Can Generator Supply? «oo. oc i a 4 eee eee 0 25
8-3. Typical Connections To Supply Standby Power ..........._e_emrerrererore ve. 26
8-4. Selecting Extension Cord . . RR RR 27
SECTION 9 — WELDING METHODS & TROUBLESHOOTING
9-1. Shielded Metal Arc Welding (SMAW) «ee 28
9-2. Welding Troubleshooting ........ ec 33
SECTION 10 — PARTS LIST
Figure 10-1. Main Assembly ................0000smrireerereríreneecedevena recado 36
Figure 10-2. Panel, Front w/Components ............_e_._eerereoorsrrec. PA 38
Риге 10-3. Сепега{ог/бАгон@ ............. 2..5... к кк 4 A 4 4 a 4 0 ee 0 a 4 0 a eee a ea sa ae» 40
Figure 10-4. Controi Box ............ eee eee aa 41
Optional Equipment .........2022 0200404444 44e 4e 44 a 4e 4 4 a 4 4 a a ee ee ea aa a a a a a a ae» 42
OM-4364 - 3.97
SECTION 1 — SAFETY SIGNAL WORDS
modt.i 9/91
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions. |
Á WARNING
WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.
à CAUTION
| CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.
—
» IMPORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2 — SPECIFICATIONS
Table 2-1. Welding Generator
Specification Description
Type Of Output Constant Current (CC), DC
Duty Cycle See Section 2-2
Rated Weld Output At 60% Duty Cycle 180 Amperes At 25 Volts DC
Rated Weld Output At 100% Duty Cycle 140 Amperes At 25 Volts DC
Amperage Range 50-1804 DC
Maximum Open-Circuit Voltage 75 Volts DC
Weiding Process Shielded Metal Arc Welding (SMAW)
Engine Kehler CH 12.5 Air-Cooled, One-Cylinder, Gasoline Engine (See Engine
Manual)
Engine Speed 3750 rpm Weld/Power Speed; 2400 rpm ldie Speed
Fuel Tank Capacity 3.8 Gal. (14.4 L}
Maximum Auxiliary Power Single-Phase, 5 KVA/kW, 120 Volts AC, 42 Amperes, 60 Hz
Overal! Dimensions See Figure 3-2
Weight Net: 346 ibs. (157 kg); Ship: 360 Ibs. (164 kg)
Options See Rear Cover
OM-436 Page 1
2-1. Volt-Ampere Curves
100
80 |
80 |
DC VOLTS
О 50 190 150 200 250 300
DC AMPERES
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
ofthe weiding generator. Curves of
other settings fall between the
curves shown.
rsb1.1 10/91 — SE-145 168
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
4 CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
e Do not exceed indicated duty cycles.
warn7.1 2/92
RATED OUTPUT =
300
250
200
150
100
WELD AMPERES
75
50
10 15 20 2530 40 50 607080 100
% DUTY CYCLE
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 60% duty cycle
when operated at 180 amperes, al-
lowing welding 6 minutes out of ev-
ery 10 minutes. If the welding am-
peres decrease, the duty cycle in-
creases.
This unit is rated at 100% duty
cycle when operated at 140 am-
peres, allowing continuous weld-
ing.
sb1.4 2/82 - 58-129 658
Figure 2-2. Duty Cycle Chart
OM-436 Page 2
2-3. Fuel Consumption
I
0) LITERS /HR.
6.62
5.68
4.73
3.79
2.84
1.89
0.95
9 IMP. GAL./HR.
1.04
0.83
0.62
0.42
0.21
o US.GAL./HR.
0.50
0.25
The fuel consumption curve shows
typical fue? use under weld or pow-
er loads.
- AUX POWER
| ——— == ово
— IDLE
0 25 50 75 100 125
150
DC WELD AMPERES AT 100% DUTY CYCLE (25 VOLTS)
0 1.0
2.0 3.0 4.0 5.0
POWER KVA AT 100% DUTY CYCLE
6.0
rsb2.1 10/91 - 56-145 107
Figure 2-3. Fuel Consumption Curve
2-4. AC Auxiliary Power Curve
AC VOLTS
300
250
200
150
100
50
The ac power curve shows the aux-
itiary power in amperes available at
the 120 or 240 volt receptacles.
Г 240 У
— 120V
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE
rsb3.1* 10/91 - SB-145 169
Figure 2-4. AC Power Curve For 120 And 240 Voit Receptacles
OM-436 Page 3
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
- A WARNING
ENGINE EXHAUST GASES can Kill.
® [o not breathe exhaust fumes.
¢ Usein open, well-ventilated areas, or vent exhaust
outside and away from building air intakes.
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
e Keep exhaust and pipe away from flammables.
ENGINE EXHAUST SPARKS can cause
fire.
* Useonly U.S. Forestry Departmentapproved spark
arrestor and comply with all local, state, and federal
laws.
A spark arrestoris mandatory in all National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in cther areas.
Properly maintain the spark arrestor.
Stop engine and atiow exhaust system to coot down
before servicing spark arrestor.
Service spark arrestor away from flammabies.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
e Uselifting eye tolift unitonly, NOT running gear, gas
cylinders, trailer, or any other heavy options,
accessories, or devices.
® Use equipment of adequate capacity to lift the unit.
TILTING OF TRAILER can result in
personal injury or equipment damage.
e Install unit properly on trailer (if applicable)
according to trailer manual.
warm 1.1 1291
1 18 in. (457 mm} Open Space
On All Sides For Good Air-
flow
2 Lifting Eve
Use lifting eye to move unit.
3 Exhaust Muffler
4 Lifting Forks
5 Mounting Skid
If using lifting forks, mount unit on
skid. Extend forks out opposite
side of skid.
ST-153 707
Figure 3-1. Location And Movement Of Welding Generator
inches Millimeters
A 24 610
B 25 635
C 31-1/2 800
OM-436 Page 4
Figure 3-2. Overall Dimensions
1 Trailer Hitch
install unit onto trailer according to
© — Engine trailer manual.
о © Bu End Maximum tilt angles also apply to
Ps 25° 1 units not mounted on trailers.
o Le"?
© ~~ eo и
!
! 55°
5-0024-B
Figure 3-3. Maximum Welding Generator Tilt Angles And Trailer Mounting
3-2. Connecting The Battery
A WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.
e Stop engine before disconnecting or connecting battery cables.
e Always wear a face shield and proper protective clothing when working on a battery.
# Do not allow tools to cause sparks when working on a battery.
rwarn2.1 9/91
1 Engine On-Off Switch
1 Place switch in the QEF position.
N
| on 2 Negative (-) Battery Terminal
And Cable
f © Connect cable to terminal on bat-
tery.
START If engine will not crank, check bat-
FF . i
tery voltage according to Section
6-5.
Tools Needed:
I 3/8 in., 7/16 in.
ST-153 469 / 5-132 278-5
Figure 3-4. Connecting The Battery
OM-436 Page 5
3-3.
A WARNING
Engine Prestart Checks
ENGINE FUEL can cause fire or
explosion.
e Stop engine before fueling.
® [Do not fuel while smoking or near sparks or flames.
® Do not overfill tank; clean up any spilled fuel,
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
e Rotate fuel cap slowly and wait unti hissing stops
before removing cap.
wama.1 991
a
Sn
E
SN
o
A
их
O,
ade
чй
o
9.0.0
‚ 0%
NS
1 O! Dipstick
Check oil level at each fueling with
unit on level surface. If oil is not up
to full mark on dipstick, add oil (see
Figure 6-1).
Engine stops if oil pressure gets
too low.
2 Fuel Tank Cap
Add fresh fuel before starting en-
gine the first time (see Figure 6-1).
Fill fuel tank up to 1 in. (25 mm)
from top to aliow room for expan-
sion. Check fuel level! on a cold
engine before use each day.
r554,1* 4/92 — 58-144 336-A
Figure 3-5. Fuel And Oil Checks
Grounding The Welding Generator
Tools Needed:
Эт 1/2in.
1 Equipment Grounding Termi-
nal
Generator neutral connected to
frame. Connect equipment
grounding terminal to proper earth
ground. Meet National Electrical
Code and all other code require-
ments.
repS.1 10/91 / Ref. 5T-141 050-A
Figure 3-6. Equipment Grounding Connection
OM-436 Page 6
3-5. Selecting And Preparing Weld Output Cables
1 Weld Output Cable
Determine total cable length in
weld circuit and maximum weiding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cabies possible.
C | Do not use damaged cables.
2 Terminal Lug
\\
| Use lugs of proper amperage ca-
pacity and hole size for connecting
to work clamp, electrode holder, or
wire feeder.
1
3 insulated Electrode Holder
For Example install according te manufacturer's
— Total Cable instructions.
Length In Weld 4 Work Cl
Circuit = 20 ft. (6 m) ork Glamp
Y en om
Ss
SU
Install onto work cable.
5 Dinse-Type Connector
6 Weld Qutput Cable
7 Insulator
slide cable through insulator and
remove 1 in. (25 mm) insulation
from end of cabie.
8 Sleeve
10 7 9 Connector
= Insert cable with sleeve into con-
9 8 6
VÁ nector body so cable is snug
against bottom.
| SE o DS | 10 Setscrew
Tighten setscrew and push insula-
tor fully over connector.
If job requires cable larger than 3/0
AWG, use 2 ft. (610 mm) or shorter
piece of 3/0 AWG cable for Dinse-
Type connecter installation. Con-
nect other end of short cable to the
4/0 or larger weid cable.
Tools Needed:
> Fm" ay
sbé.2 12/91 —- $-0656 / 5-0289-B
Figure 3-7. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cabie Size*
Totai Cable (Copper) Length In Weld Circuit Not Exceeding*
150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
100 ft. (30 m) Or Less (45 m) (60 m) (70 m) (90m) | (105m) | (120 т)
Welding 10 To 60% 60 Thru 100% o
Amperes | Duty Cycle Duty Cycle 10 Thru 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
*Weld cable size (AWG) is based on either a 4 volts oriess drop or a current density of not more than 300 circular mils per ampere. Use weld cable with
insulation rating equal to or greater than the open-circuit voltage of the unit. S-0007-B
OM-436 Page 7
3-6. Connecting To Weld Output Terminals
A WARNING
ELECTRIC SHOCK can Kill.
e Always wear dry insulating gloves.
e Do not touch live electrical parts.
i |
y
* Stop engine before making any weld output connections.
* Read Safety Precautions at beginning of this manual.
rwarn13 1 2/92
1 Positive (+) Weld Quiput Re-
ceptacie
UN 2 Negative (-) Weld Qutput Re-
Е ceptacie
For Direct Current Electrode Posi-
+ ‘| tive (DCEP), connect work cable to
3 — receptacle and electrode holder
cable to + receptacle.
\
For Direct Current Electrode Nega-
tive (DCEN), reverse cable con-
> nections.
3 Weld Qutput Receptacle
4 Connector
Align keyways on connector and
receptacle. Insert connector and
turn clockwise until tight.
Ref, 57-141 050-A / 57-151 653
Figure 3-8. Weld Output Connections
SECTION 4 - OPERATING THE WELDING GENERATOR
! AR
ELECTRIC SHOCK can kill. 2 9 ENGINE EXHAUST GASES can kill.
— e ® Do not touch live electrical parts. e A ® Do not breathe exhaust fumes.
* Use in open, well-ventilated areas, or vent exhaust
® Insulate yourself from work and ground. outside and away from any building air intakes.
® Stop engine before installing or servicing.
¢ Keep all panels and covers securely in place. ENGINE FUEL can cause fire or explo-
sion.
s Stop engine before fueling.
® Do not fuel while smoking or near sparks or flames.
+ Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
e Keep away from moving parts such as fans, belts,
and rotors.
® Keep all doors, panels, covers, and quards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
¢ Pacemaker wearers keep away.
À e Always wear dry insulating gloves. 5
WELDING can cause fire or explosion.
e Do not weld near flammable material.
e Watch for fire; keep extinguisher nearby.
e Do not locate unit over combustible surfaces.
e Do not weld on closed containers.
e Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
A NOISE can damage hearing.
/ 7 e Wear welding helmet with correct shade of filter.
* Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous.
* Keep your head out of the fumes.
e Ventilate area, or use breathing device.
e Wearers should consult their doctor before going
near any welding operations.
e Read Material Safety Data Sheets (MSDSs) and See Safety Precautions at beginning of manual for ba-
manufacturer's instructions for material used. sic welding safety information. mwams 1 10/01
OM-436 Page 8
Amperage Control
Engine Hour Meter (Optional}
Run/idie Switch
Choke Lever
Engine Start Button
Engine On-Off Switch
<
à N bh WN À
Right Side
ST-153 470 / ST-153 646
Figure 4-1. Controis
1 2 3 1 Insulating Gloves
/ 2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANS! 249.1).
sb3.1 10/91 |
Figure 4-2. Safety Equipment
1 Work Clamp
Use wire brush or sandpaper to clean
metal at weld joint area.
Connect work clamp to a clean,
paint-free location on workpiece, as
Tools Needed: close to weld area as possible.
_—— А
554.1 10/91
Figure 4-3. Work Clamp
1 Amperage Control
в Use control to adjust weld amper-
age. The scale surrounding the
control is marked in amperes.
Amperage control may be adjusted
while welding.
—
1 Ref. ST-141 050-A
Figure 4-4. Amperage Control
OM-436 Page 9
о ВВ ©
ю ВВ °
©
TA
RUNADLE
©
=
1 Choke Lever
Use control to change air-fuel mix-
ture to engine. Move lever to right
(full-choke) before starting engine.
Move lever to left if starting warm
engine.
2 Engine On-Off Switch
Use switch to start and stop en-
gine.
3 Engine Start Button
Push button to energize starter.
To start, turn On-Off switch to ON
position and push Start button. Re-
lease Start switch when engine
starts. Do not engage starter while
flywheel is rotating.
As engine warms up, move choke
lever slowly to left.
4 Optional Recoil Starter (Not
Shown)
Pull starter handle with quick,
smooth motion to start engine.
5 Run/ldle Switch
In RUNADLE position, engine runs
at idle speed with no load applied,
and weld or power speed with load
applied.
In RUN position, engine runs at
weld or power speed all the time.
Stop engine by moving On-Off
switch to OFF position. Keep
switch in OFF position when unitis
not in use.
51-153 470 / 57-153 646 / 5-132 276-8
Figure 4-5. Engine Controls
8 (ee
Y
1 Engine Hour Meter
Use meter to check total operating
hours (see Section 6-1). This meter
operates oniy when engine is run-
ning.
rsb6.1 2/92
Figure 4-6. Engine Hour Meter (Optional)
Install & Select Put On | Turn On
Connect Electrode Personal Safety Set Controls Start Engine Auxiliary
Equipment Equipment Equipment
)
insert
Electrode
Into Holder
) | Begin vers)
rsh8.1 4/92
OM-436 Page 10
Figure 4-7. Sequence Of Shielded Metal Arc Welding (SMAW)
SECTION 5 — OPERATING AUXILIARY EQUIPMENT
A WARNING
ELECTRIC SHOCK can kill. ELECTRIC SPARKS can cause fire.
® Do not touch live electrical parts. e If using auxiliary power only and not welding,
: на 5 . : disconnect both welding cables to prevent live
* Stop tic before making interna! inspection or electrode from causing electric shock and fire
a ° reconnection. hazards.
* Ground generator according to all applicable
: N national, state, and local codes.
¢ Connect equipment grounding termina! to a proper
earth ground.
e Do not connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and greunding procedure are
employed (see Section 8).
MOVING PARTS can cause serious
injury.
e Watch for fire.
+» Keep a fire extinguisher nearby, and know how to
use it.
The weld output terminals are electrically energized
when the engine is running and the contactor, if
applicable, is energized.
LOW VOLTAGE AND FREQUENCY can
damage electrical equipment.
® Turn off or unplug all electrical equipment
e Keep away from moving parts such as fans, belts, connected to auxiliary power receptacies before
a and rotors. starting or stopping the engine.
à) # Keep all doors, panels, covers, and guards closed When starting or stopping, the engine has low speed
and securely in place. which causes low voltage and frequency. oo,
PIMPORTANT: Limited auxiliary power is available while welding to run lights and heaters. If equipment does not run
properly, disconnect auxiliary power load or wait until welding is stopped.
5-1. 120 Volt Duplex Receptacles And Circuit Breakers
2 1 120V 154 AC Duplex Recep-
tacie
/ These receptacies supply 60 Hz
f = A A single-phase power at weld/power
— NEUTRAL BONDED ТО FRAME т speed. Maximum output from half
cel “NIZA NEUTRE RACOORDE AU BAN NA CB? of each duplex receptacle is 1.8
KVA/KW.
SEE OWNERS MANUAL FOR 2 Circuit Breakers CB1
POWER USE EXPLANATION.
DA A Through CB4
1 Circuit breakers protect each half
| | of duplex receptacle from over-
load. if a circuit breaker opens, the
receptacle half does not work.
\ à” Press button to reset breaker.
3 Total Auxiliary Power Qutput
120V Av AC Combined output of receptacles
limited to 5 KVA/kW output of the
| | generator.
EXAMPLE: If 21A is drawn from
one duplex receptacle, only 20A is
uz available at the other duplex recep-
tacle:
A SoA a SA (120V x 21A) + (120V x 20A) = 5.0
| | KVA/KW
— (A A XY = WATTS NY —
« ces TOTAL ALL LOADS 5000 WATTS ca
Ref. ST-141 050-A
Figure 5-1. Auxiliary Power Receptacies And Circuit Breakers
OM-436 Page 11
5-2. Optional 240 Volt Duplex Receptacle
> |
Z
3
a“ = A
LAN NEUTRAL BONDED TO FRAME | /7ANY un
cet NEUTRE RACCORDÉ AU BÂTI ca2
SEE OWNERS MANUAL FOR
POWER USE EXPLANATION.
15A 15A
al | 1 — —
120Y ”v AC
15A 30A
TOTAL
|
— PA A x Y = WTS 7=N —
= © TOTAL ALL LOADS 5000 WATTS cna
= = > A
DA |
2 4
3
1 240V 15A AC Duplex Recep-
tacle
This receptacle supplies 60 Hz
single-phase power at weld/power
speed. Maximum output is 3.6 kVA/
KW,
2 Circuit Breakers CB1 And
CB3
CB1 and CB3 protect the 120V du-
plex receptacle from overload.
3 Circuit Breakers CB2 And
CB4
CB2 and CB4 protect the 240V du-
plex receptacle from overload. If
СВ2 ог CB4 open, output to both
halves of receptacle stops. Press
button to reset breaker.
4 Total Auxiliary Power Output
Combined output of receptacles
limited to 5 KVA/KW output of the
generator.
EXAMPLE: If 21A is drawn from
the 120V duplex receptacle, cnly
10A is available at the 240V duplex
receptacle:
(120V x 21A) + (240V x 10A} = 5.0
KVA/KW
Ref. 5T-148 693
Figure 5-2. Optional 240 Volt Duplex Receptacle And Circuit Breakers
5-3. Optional 240 Volt Twistlock Receptacle (Full kVA)
\ 1 /
a Om © = |
ont \ = A ly BAT] Los > À CB
PUE ro
15A °
fi | | N 240V As AC
120Y7vv AC
15A 304 21 À
TOTAL
| | |
—— Y y A x V = WATTS f \ a
ens TOTAL ALL LOADS 5000 WATTS cad
Q = A
7 | \
2 4 3
1 240V 21A AC Twistlock Re-
ceptacle
This receptacle supplies 60 Hz
single-phase power at weld/power
speed. Maximum output from re-
ceptacle is 5.0 kVA/kKW. See Sec-
tion 5-4 for matching plug wiring in-
structions.
2 Circuit Breakers CB1 And
CB3.
CB1 and CB3 protect the 120V du-
piex receptacle from overload.
3 Circuit Breakers CB2 And
CB4
CB2 and CB4 protectthe 120V and
240V receptacles from overicad. If
CB2 or CB4 opens, output to the
240V receptacle and ane halfofihe
120V duplex receptacle stops.
Press button to reset breaker.
4 Total Auxiliary Power Qutput
Combined output of receptacles
hmited to 5 kVA/kW output of the
generator.
EXAMPLE: If 15A is drawn from
the 120V duplex receptacie, only
13A is available atthe 240Y recep-
tacle:
(120V x 15A) + (240V x 13A) = 5.0
KVA/KW
Ref. ST-151 013
Figure 5-3. Optional Twistlock Receptacle And Circuit Breakers
OM-436 Page 12
5-4. Wiring Instructions For 120/240 Volt AC Twistlock Plug
A WARNING
— ELECTRIC SHOCK can kill; INCORRECT CONNECTIONS can cause fatal electric shock.
e [Do not touch live electrical parts.
e Wire the 120/240 volts twistlock plug according to Figure 5-4.
¢ Have only qualified persons make wiring connections.
«
The NEMA L14-30P plug for the
120/240 volt twistlock receptacie
can be wired to supply a 240 voit,
2-wire load or a 120/240 volt,
3-wire load. See circuit diagram
when wiring plug.
1 Plug Wired For 120/240 Voit,
3-Wire Load
2 Plug Wired For 240 Volt,
2-Wire Load
Neutral (Silver) Terminal
Load 1 (Brass) Termina!
Load 2 (Brass) Terminal
Ground (Green) Termina!
Outer Sheli with Cord Grip
Strip cord jacket back enough to
separate conductors. Strip con-
ductors enough to make good con-
tact with plug terminals. Make piug
connections and reinstall outer
shell. Tighten cord grip screws.
~ (лов (о
Tools Needed:
ЕЕ В
Figure 5-4. 120/240 Volt AC Twistlock Plug Connections
See Section 8 Connect Place Engine Turn On
Auxiliary Power Equipment Start Engine Run/idle Switch In On Auxiliary Begin Operation
Guidelines RUNADLE Positio Equipment
rsb11.1" 2/92
rsb12.1* 2/92 — 58-085 361.0
Figure 5-5. Sequence Of Auxiliary Equipment Operation
SECTION 6 — MAINTENANCE & TROUBLESHOOTING
NINO
ELECTRIC SHOCK can kill. ENGINE FUEL can cause fire or explo-
— e Do not touch live electrical parts. sion,
— Always wear dry insulating gloves. e Stop engine before fueling.
<
Insulate yourself from work and ground. * Donotfuetwhile smoking or near sparks or flames.
Stop engine before installing or servicing. * Do not overfill tank; clean up any spilled fuel.
Keep all panels and covers securely in place. MOVING PARTS can cause injury
e Keep away from moving parts such as fans, beits,
ENGINE EXHAUST GASES can kill. and rotors.
® Do not breathe exhaust fumes. ¢ Keep all doors, panels, covers, and guards closed
e Use in open, well-ventilated areas, or vent exhaust and securely in place.
outside and away from any building air intakes.
а + = &
HOT PARTS can cause severe burns.
e Allow cooling period before servicing.
e Wear protective gloves and clothing when working
on a hot engine.
Maintenance to be performed only by qualified
persons. rwarn9.1 10/91
OM-436 Page 13
6-1. Routine Maintenance
IMPORTANT
KOHLER CH12.5
Recommended Oil-API Service Classification SF-SG/CC-CD
Below 32°F Above 32°F
(0°C) (0°C)
SAE 5W-20, SAE 5W-30 SAE 10W-30, SAE 10W-40
U
Check oil level daily (10 oz. “Add” to “Full” on dipstick)
|
+
Oil Capacity - - - - - - - - 62 oz. (1.81) with filter change
56 oz. (1.6L) without filter change
Oil Change- - -- --- - Normal conditions 100 hours
Oil Filter Element Change- Normal conditions 200 hours
Oil Filter Element - - - - - Kohler 1205001
Miller 066698
Fuel Capacity
3.8 U.S. Gals (14.38 liters)
Vented tank cap
Fuel grade
“Regular”, “unleaded”
— at least 87 octane
octane (RON + MON) 2
Fuel Filter —
Kohler 2505002
Miller 066699
12 Volt Battery
BCI Group Size U1
Cranking performance @
0°F (-18°C) 260 Amps
Minimum
Air Filter Service ©
100 hours or less-See
Owner's Manual ноте НМ
Air filter element е —
Kohler 4708301 Weld & Power — 3750
Miller 066700
Spark plug gap, Resistor and Std .040 (1.02 mm)
Spark Plug Champion: RC-12YC*
*Resistor Spark Plugs Mandatory in Canada
®
+
№
If equipped with a spark arrestor supplied by the welding
generator manufacturer, inspect and/or service weekly or
every 20 operating hours, whichever occurs first.
See Owner's Manual.
If equipped with spark arrestor supplied by others, refer to
that manufacturer's instructions for service and inspection
procedures.
S-141 972-8
Fiqure 6-1. Maintenance Label
Table 6-1. Maintenance Schedule
Check spark plug condition and gap.
Inspect weld output cable insulation. Repair or replace weld
cables if necessary. Clean and tighten cable connections.
Operating Hours Maintenance Section
After first 5 hours Change break-in oil. 6-1
Every 8 hours Check fuel and oil 3-3
Check air cleaner for dirty, loose, or damaged parts. Clean air *
intake and cooling areas if dirty.
Every 20 hours Service spark arrestor according to instructions.
Every 25 hours Service air cleaner foam element (precleaner). *
Every 100 hours Service air cleaner paper element. *
Change oil. 6-1
OM-436 Page 14
Operating Hours Maintenance Section
Check battery and cables. Replace if damaged. Clean and
tighten connections.
Units in heavy service environments: check and clean unit (see
1000 hour entry).
Every 200 hours Change oil and filter. 6-1
Check all labels (see 1000 hour entry).
Replace fuel filter.
Annually or every 500 hours Have Factory Authorized Service Station service starter motor.
Every 1000 hours Mave Factory Authorized Service Station inspect generator
brushes and slip rings.
Check labels: replace any labels that are unreadable or dam- 10
aged.
Clean unit: blow out or vacuum dust and dirt from inside unit with
clean, dry airstream or vacuum suction. Wipe up oil and fuel spills.
Clean and tighten oil and fuel connections.
*See engine manual.
6-1. Changing Engine Oil And Filter
Stop engine.
Change oil while engine is still
warm.
1 O Filter
Remove battery to replace oil filter
(see Section 6-5). See engine
manual for filter replacement pro-
cedure.
2 Oil Fill Cap/Dipstick
3 Oil Drain Plug
Remove oil fill cap/dipstick and
drain plug.
Wait for oii to drain completely. Re-
install plug. Filt crankcase with new
cil to full mark on dipstick. See
Figure 6-1 for specifications.
Reinstall cil fill cap/dipstick.
Tools Needed:
I——— 3/8 in., 7/16 in. Ret ST-153 471
Figure 6-2. Changing Engine Oil
OM-436 Page 15
6-2. Replacing Fuel Filter
4 WARNING |
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Tools Needed:
Stop engine, and allow to cool.
1 Fuel Line
Clamp fuel line between filter and
fuel tank to prevent fuel from leak-
ing while changing filter.
2 Fuel Filter
3 Hose Clamp
Remove clamps and filter.
Inspect fuel line; replace if cracked.
Reinstall new filter with hose
clamps. Remove clamp from fuel
line. Wipe up any spilled fuet.
Start engine, and check for fue!
teaks.
Stop engine, tighten connections
as necessary, and wipe up fuel.
Left Side
> ST-153 472
Figure 6-3. Replacing Fuel Filter
6-3. Overload Protection
READ SAFETY BLOCKS at start of
4 WARNING À Section 6 before proceeding.
Stop engine.
1 Fuse F1 {see Parts List for
size)
Tools Needed:
Ie 3/8in.
2 Rectifier SR1
F1 protects the exciter excitation
winding from overioad. [fthereis no
weld and auxiliary power output,
F1 may be open.
Remove top panel, check and re-
place F1, and reinstall panel before
operating unit.
if fuse continues to open, have
Factory Authorized Service Station
check SR1.
ST-153 473
OM-436 Page 16
Figure 6-4. Fuse F1 Replacement
6-4. Adjusting Engine Speed
| READ SAFETY BLOCKS at start of
x Section 6 before proceeding.
Á WARNING
Table 6-2. Engine Speed Settings (No Load)
Engine Speed RPM
Weld/Power 3750
Idle 2400
©
Stop engine. .
Engine speeds have been factory set and
should not require adjustment. After tuning
engine, check engine speeds with a tachom-
eter, See Table 6-2 for proper no load
speeds. If necessary, adjust speeds as fol-
lows:
1 Speed Adjustment Bracket
2 Securing Screws
Loosen securing screws 1-1/4 turns.
Start engine and move Run/ldie switch to
RUN position.
Slide adjustment bracket forward or back-
ward until engine runs at weld/power speed.
Tighten securing screws.
Move Rur/ldle switch to RUNADLE position.
After engine idles down, return switch to
RUN and recheck weld/pawer speed. Read-
just bracket if necessary.
Rear Of Unit
Stop engine,
3 Governor Arm
4 Carburetor
5 idle Paddle
6 Idle Solenoid Post
7 die Solenoid Bracket
Push governor arm towards carburetor as
far as possible,
Check gap between paddle and solenoid
post. Gap should be approximately 1/16 in.
(2 mm) and paddle should align squarely
with solenoid bracket. Reiease governor
arm. If necessary, adjust gap as follows:
8 Securing Screw
[Loosen screws securing paddle to governor
arm.
Tools Needed: NV
es
Se 10 mm, 1/4 in.
SC-144 235-B
Adjust paddie so gap between paddle and
solenoid bracket is 1/4 in. (6 mm) attop and
5/16 in. (8 mm) at bottom. Tighten screws.
Push governor arm towards carburetor and
recheck gap between paddle and solenoid
post. Readjust if necessary.
9 Air Cleaner Cover
Remove air cleaner cover. Do not remove air
cleaner base.
Start engine and move Run/die switch to
RUN/IDLE position. |
10 Idle Speed Adjusting Screw
Turn screw until engine runs at idle speed.
If engine will not run at idle speed, stop en-
gine and recheck idle paddie/idle solenoid
bracket gap and alignment. Repeat idle
speed screw adjustment if necessary.
Reinstall air cleaner cover.
Figure 6-5. Engine Speed Adjustment
OM-436 Page 17
6-5. Replacing Battery Or Checking Battery Voltage
A WARNING
SPARKS can cause BATTERY GASES e Always wear a face shieid and proper protective
TO EXPLODE; BATTERY ACID can burn clothing when working on a battery.
eyes and skin. ¢ Do not spill acid.
* Stop engine before disconnecting or connecting | e Observe correct polarity (+ and —) on batteries.
battery cables. = ® Do not use welder to charge batteries or jump start
‚ vehicles.
® Donctallowtocis to cause sparks when working on
a battery. rwarnt0.1* 9/91
If engine will not crank, check bat-
tery voltage as follows:
1 Engine On-Off Switch
Place switch in the OFF position.
2 Battery
3 Negative (-) Battery Cable
4 Positive (+) Battery Cable
5 Voltmeter
Remove terminal cover from bat-
tery.
If battery voltage is less than 12.4
volts, charge battery following bat-
tery charger’s instructions.
To replace battery, proceed as fol-
lows:
Disconnect battery cables, nega-
tive cable first.
6 Hold Down
Remove hold down and battery.
When reconnecting battery, con-
nect negative (-) cable last. Rein-
stall terminal cover.
Tools Needed:
e———C 3/8 in, 716 in,
9/16 in.
57-153 465 / 5-132 278-B / Ref. 5-0679-A
Figure 6-6. Replacing Battery And Checking Battery Voltage
OM-436 Page 18
6-6. Troubleshooting
A WARNING |
ELECTRIC SHOCK can kill. ENGINE FUEL can cause fire or explo-
e Do not touch live electrical parts. sion.
e Always wear dry insulating gloves. * Stop engine before fueling.
e Insulate yourself from work and ground.
e Stop engine before installing or servicing.
e Keep all panels and covers securely in place.
e Do not fuel while smoking or near sparks or flames.
e Do not overfill tank; clean up any spilled fuel,
ENGINE EXHAUST GASES can kill.
* Do not breathe exhaust fumes.
e Useinopen, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
MOVING PARTS can cause injury.
* Keep away from moving parts such as fans, belts,
ang rotors.
* Keep all doors, panels, covers, and guards closed
and securely in piace.
HOT PARTS can cause severe burns.
e Allow cooling period before servicing.
* Wear protective gloves and clothing when working Troubteshooting to be performed only by qualified
on a hot engine. persons.
mvamit1,1 11/91
Table 6-3. Welding Trouble
Trouble Remedy Section
No weld output. — — ~| Check fuse F1; replace if open. | —-
Low weld output. = — -#| Check and adjust engine speed. 6-4
Tune-up engine according to engine manual. —. ——
Erratic Weld Output. -- — == Tighten and/or clean connections to electrode and workpiece. — — > ——
Be sure electrode is dry and proper type for SMAW. — — -= ——
Check and adjust engine speed. — — > 6-4
Check internal and external weid cutput connections. — > ——
Have Factory Authorized Service Station check brushes and — — = ——
slip rings, and Field Current Regulator Board PCT.
Table 6-4. Auxiliary Power Trouble
Trouble Remedy Section
No power output. — — -=! Reset circuit breakers CB1 through CB4. — — ->-— 5-1
Check Fuse F1; replace if open. —— -= 6-3
Check connections at receptacles. —_——— ——
Erratic power output. — — | Have Factory Authorized Service Station check brushes and — — -> ——
slip rings.
Low power output. - — -=| Check and adjust engine speed. —— 6-4
Tune-up engine according to engine manual. ——. ——
Have Factory Authorized Service Station check Field Current — — » ——
Regulator Board PC1.
OM-436 Page 19
Table 6-5. Engine Trouble
Trouble
Engine will not start.
|---
Battery discharges between uses.
— le
Unstable or sluggish engine speeds.
|---
Engine stopped during normal opera-
tion.
Engine idles but does not reach weld/
power speed.
Remedy
Check battery and engine charging system.
Check engine On-Off switch S2 and replace if necessary.
Check engine Start button PB1 and replace if necessary.
Check oil level. Check Low Qil Pressure Shutdown switch S54
(see parts list for location).
Check fuel level.
Check fuel filter and replace if necessary.
See engine manual.
Clean battery terminals and posts with baking soda solution;
rinse with clear water.
Periodically recharge battery (approximately every three
months).
Check voltage regulator according to engine manual.
Repiace battery.
Adjust idle solenoid linkage, if necessary.
Adjust idle solenoid paddie.
Tune-up engine according to engine manual.
—
Check oil level. Check Low Oil Pressure Shutdown switch S4
(see parts list for location).
Adjust engine weld/power speed.
Have Factory Authorized Service Station check Auto Idle Module
РС2.
Section
6-5
3-3
3-3
6-2
6-4
6-4
3-3
6-4
OM-436 Page 20
SECTION 7 — ELECTRICAL DIAGRAMS
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OM-436 Page 21
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OM-436 Page 22
SECTION 8 — AUXILIARY POWER GUIDELINES
mod 3.1 10/91
=—au J
A WARNING
¡ ELECTRIC SHOCK can kill.
mt * Install and ground generator according to af! applicable codes, such as OSHA and National Electrical Code.
> * Disconnect both welding cables when using auxiliary power,
* Use all code-required methods for shock and overcurrent protection.
e Have only qualified persons make electrical connections,
8-1. How Much Power Does Equipment Require?
1 Fesistive Load
À light bulb is a resistive load and
2 3 VOLTS 115 requires a constant amount of
AMPS 4,5 power.
1
6 ON R
Equipment with a motor, such as
) a drill, is a non-resistive load and
requires more power while start-
ing the motor than when running
(see Figure 8-3),
3
3 Rating Data
Volts and amperes, or watts re-
quired to run equipment. Deter
EF mine power required as shown in
Figure 8-2.
5-0623
Figure 8-1. Power Required By Different Types Of Equipment (Loads)
VOLTS x AMPERES = WATTS
This equation provides an actual power requirement for resistive loads, or an approximate running requirement for non-
resistive loads.
EXAMPLE 1: If a drill requires 4.5 amperes at 115 volts, calculate its running power requirement in watts.
115V x 4.5A = 520W
Therefore, the individual load applied by the drill is 520 watts.
EXAMPLE 2: fa flood ¡amp is rated at 200 watts, the individual [oad applied by the lamp is 200 watts. If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to calculate total load.
(200W + 200W + 200W) + 520W = 1120W
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.
Figure 8-2. Calculating Power Required To Run Equipment
OM-436 Page 23
Table 8-1. Approximate Power Requirements For Typical Equipment*
| . : | : :
Industrial Motors Rating Starting Rain Farm Equipment Rating Starting ans
Split Phase 1/8 HP 800 300 Stack Tank De-lcer 1000 1000
1/6 HP 1225 500 Grain Cleaner 1/4 HP 1650 550
1/4 HP 1600 600 Portable Conveyor 1/2 HP 3400 1000
1/3 HP 2100 700 Grain Eievator 3/4 HP 4400 1400
12 HP 3175 875 Milk Cooler 2900 1100
Milker Vacuum Pump) 2 HP 10500 2800
Capacitor Start- 1/3 HP 2020 720 FARM DUTY MOTORS 1/3 HP 1720 720
Induction Run 1/2 HP 3075 975 Std. (e.g. Conveyors, 1/2 HP 2575 97s
3/4 HP 4500 1400 Feed Augers, Air 3/4 HP 4500 1400
1 HP 6100 1600 Compressors) 1 HP 6100 1600
1-1/2 HP B200 2200 1-1/2 HP 5200 2200
2 HP 10550 2850 2 HP 10550 2850
3 HP 15900 3800 3 HP 15900 3900
5 HP 23300 6800 5 НР 23300 6800
Capacitor Start- 1-1/2 HP 8100 2000 High Torque (e.g. gar 1-1/2 HP 8100 2000
Capacitor Run 5 HP 23300 6000 Cleaners. Silo Unloaders, 5 HP 23300 6000
7-12 HP 35000 8000 Silo Hoists. Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 45700 10700 10 НР 46700 10700
Fan Duty 1/8 HP 1000 400 3.172 Cu, Fi. Mixer 1/2 HP 3300 1600
1/6 НР 1400 550 High Pressure 1.8 Gal/Min 500 PSI 3150 950
1/4 НР 1850 650 Washer 2 Gal/Min 550 PSI 4500 1400
1/3 HP 2400 800 2 Gal/Min 700 PSI 6100 1600
1/2 HP 3500 1100
Contractor Rating | “Wan | “Watts Residential Rating | “Wars | "Watts
Hand Drill 1/47 350 350 Coffee Maker 1750 1750 Typ.
3/8” 400 400 Elec. Range 6" Element 1500 1500
1/27 600 600 8" Element 2100 2100
Circular Saw 6-1/2" 500 500 Oven 6000 6000
7-1/4" 200 900 Microwave 625W 2800 2000
8-114" 1400 1400 Television (Solid-State) BAW 109 100
Table Saw 9” 4500 1500 Color 300 300
10* 6300 1800 Radio 50-200 50-200
Band Saw 14° 2500 1100 Refrig. Or Freezer 3100 800
Bench Grinder 6” 1720 720 Shallow Well Pump 1/3 HP 2150 750
ar 3500 1400 1/2 HP 3100 1000
10" 5200 1600 Sump Pump 1/3 HP 2100 200
Air Compressor 1/2 HP 3000 1000 1/2 HP 3200 1050
1 НР 6000 1500 Dishwasher {Cool Dry) 2100 700
1-1/2 HP 8200 2200 (Hot Dry) 2850 1450
2 HP 10500 2800 Ciothes Dryer Gas 2500 700
Electric Chain Saw 1-1/2 HP, 12" 1100 1100 Electric 7550 5750
2 HP, 14" 1100 1100 Automatic Washer 3450 1150
Electric Trimmer Standard 9" 350 350 Gas Or Fuel Oil 1/8 HP 800 300
Heavy Duty 12" 500 500 Furnace Blower 1/6 HP 1250 500
Electric Cultivator 1/3 HP 2100 700 1/4 HP 1600 600
Elec. Hedge Trimmer 48° 400 400 1/3 HP 2100 700
Figod Lights HID 125 100 1/2 HP 3225 875
Meta! Halide 313 250 Central Air Conditioner 10,000 BTU 3700 1500
Mercury +000 20.000 BTU 5800 2500
Sodium 1400 24,000 BTU 8750 3800
Vapor 1250 1000 32.000 BTU 11500 5000
Submersible Pump 400 GPH 600 200 40.000 BTU 13800 6000
Centrifugal Pump 900 GPH 900 500 Garage Door Opener 1/4 HP 1650 550
Figor Polisher 3/4 HP, 16" 4500 1400 1/3 HP 2125 725
1 HP, 20" 6100 1500 Electric Blanket Portable 400 400
High Pressure Washer 1/2 HP 3150 950 Dehumidifier 1450 650
34 HP 4500 1400 Vacuum Cleaner Standard 809 800
1 HP 6100 1600 Deluxe 1100 1100
55 Gal. Drum Mixer 1/4 HP 1900 700 Lights As indicated On Bulb
Wet & Dry Vac 1.7 HP 900 800 Toaster 2 Slice 1050 1050
2-1/2 HP 1300 1300 4 Slice 1650 1650
Hair Dryer 300-1200 300-1200
Iron 1200 1200
*Motors require up to two or three times their starting wattage when starting under load.
OM-436 Page 24
Table 8-2. Single-Phase induction Motor Starting Requirements
Motor Start Code | G H J K L M N P
KVA/HP | 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0
1 Motor Rating Label
2 ÑMotor Start Code
2 AC MOTOR | 3 Determine power required to start
> VOLTS 230 AMPS ma motor using Table 8-2. Determine
Ч starting amperage required as
CODE M Hz 60 shown in Figure 8-4.
HP 1/4 PHASE 1
3 Running Amperage Require-
ment
If code is not present, muitiply
running requirement by six. Gener-
ator amperage output must be at
least twice the motor's running
amperage requirement.
5-0624
Figure 8-3. Power Required To Start Motor
KVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE 3: Calculate the starting amperage required for a 230V, 1/4 HP motor with a motor start code of M.
Volts = 230 HP =1/4
11.2 x 1/4 x 1000
Therefore, starting the motor requires 12.2 amperes.
230
= 12.2A
Using Table 8-2, Code M results in kYA/HP = 11,2
Figure 8-4. Calculating Amperage Required To Start A Motor
8-2. How Much Power Can Generator Supply?
Y
© $
18
5
Figure 8-5. Limits Of Generator
1 Limit Load To 90% Of Gener-
ator Qutput
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Het, SB-140 092-A / 5-0625
OM-436 Page 25
8-3. Typical Connections To Supply Standby Power
FIR e E ELECTRIC SHOCK HAZARD. Read safety information at beginning of Section 8 before
proceeding.
Customer-supplied equipment is required if generator is to supply standby power during emergencies or power out-
ages. Locate the power company service meter (Figure 8-6, Item 1), and main and branch overcurrent protection (2),
and install equipment as shown in Figure 8-6.
\ 240
— NV | +
120/240 Volt
1,80 Hz 000 | у 120V Neutral
ree-Wire MI |
Service Y
ми \
Y >
y + —120V
y 120 * 7 |T Load
OO i | 7
3 —
7
CB
OO
43——| or
- de
5
5 Dif
\ 240V
— Y
120/240 Voit y 120V
Singie-Phase X
Three-Wire — y t20v |
Generator Output
Connection Ground _
a ——
S-0405-A
1 Power Company Service Meter 4 Circuit Breakers Or Fused Disconnect Connect terminals or plug of adequate
Switch amperage capacity onto cord. Follow all
2 Main And Branch Overcurrent Protec- applicable codes and safety practices.
tion ; . ‚
Obtain and install correct switch. Turn off or unplug all equipment connected
3 Double-Pole, Double-Throw Transfer to generator before stating ог ЗОО,
Switch 5 Extension Cord g g ppIng
engine. When starting or stopping, the
engine has low speed which causes low
voltage and frequency.
Obtain and install correct switch. Select as shown in Section 8-4.
Switch rating must be same as or greater
than the branch overcurrent protection. 6 Connections To Generator 7 Connections To Load
Figure 8-6. Standby Power Equipment And Connections
‚ ОМ-436 Раде 26
8-4. Selecting Extension Cord
Use Table 8-3 and Table 8-4 to select extension cords. Use shortest cords possible because long cords may reduce
output or cause unit overload.
Table 8-3. Cord Lengths For 120 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
Current Load In Watts 4 6 8 10 12 14
In Amperes
5 609 350 (106) 225 {68) 137 (42) 100 (30)
7 840 400 (122) 250 (76) 150 (46) 190 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)
25 3000 175 (53) 112 (34) 62 (19) 37 (11)
30 3600 150 (46) 87 (26) 50 (15) 37 (11)
35 4200 125 (38) 75 (23) 50 (15)
40 4800 112 (34) 62 (19) 37 (11)
45 5400 100 (30) 62 (19)
50 6000 87 (26) 50 (15)
*Conductor size is based on maximum 2% voltage drop
Table 8-4. Cord Lengths For 240 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
Current | Load in Watts a 6 8 10 12 14
In Amperes
5 1200 700 (213) 450 (137 225 (84) 200 (61)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 50 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
25 6000 350 (107) 225 (69) 125 (38) 75 (23)
30 7000 300 (91) 175 (53) 100 (31) 75 (23)
35 8400 250 (76) 150 (46) 100 (31)
40 9600 225 (69) 125 (38) 75 (23)
45 10,800 200 (61) 125 (38)
50 12,000 175 (53) 100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-436 Page 27
SECTION 9 — WELDING METHODS & TROUBLESHOOTING
à WARNING
ELECTRIC SHOCK can Kill.
e Always wear dry insulating gloves.
e Insulate yourself from work and ground.
¢ Do not touch live electrical parts.
® Keep all panels and covers securely in place.
mod5.1 1/92
MOVING PARTS can cause injury.
* Keep away from moving parts such as fans, belts,
and rotors.
e Keep all doors, panels, covers, and guards closed
and securely in place.
FUMES AND GASES can be hazardous
to your health.
e Keen your head out of the fumes.
e Ventilate area, or use breathing device.
e Read Material Safety Data Sheets (MSDSs) and
manufacturer's instructions for material used.
HOT PARTS can cause severe burns.
e Allow cooling period before touching welded metal.
¢ Wear protective gloves and clothing.
WELDING can cause fire or explosion.
« Do not weld near flammable material.
e Watch for fire; keep extinguisher nearby.
® Do not locate unit over combustible surfaces.
® Do not weld on closed containers.
Allow work and equipment to cool before handling.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
¢ Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
e Wear welding helmet with correct shade of filter.
e Wear correct eye, ear, and body protection.
WELDING CURRENT can damage elec-
tronic parts in vehicles.
e Disconnectboth battery cables before welding ona
vehicie.
e Place work clamp as close to the weld as possible.
See Safety Rules at beginning of manual for basic
welding safety information.
9-1.
Shielded Metal Arc Welding (SMAW)
PIMPORTANT: Welding current starts as soon as electrode touches the workpiece.
Tools Needed: Cr п
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
Place as close to the weld as possi-
ble.
3 Electrode
A small diameter electrode re-
quires less current than a large
one. Follow recommendations of
electrode manufacturer when set-
ting weld amperage (see
Figure 9-2).
4 Insulated Electrode Helder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. Ashort
arc with correct amperage wilt give
a sharp, crackling sound.
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
ST-151 593
Figure 9-1. Shielded Metal Arc Welding (SMAW) Procedure
OM-436 Page 28
ELECTRODE
DIAMETER
-
<
150
200
AMPERAGE
RANGE
250
300
350
4 > À
3 3 | 2 u
| ble| E | € o
a e =
т © us 3
: E
&
6010 | EP ALL | DEEP lyin. PREP ROUGH
6011 | EP |/ | ALL | DEEP | HIGH SPATTER
6013 | EPEN| И | ALL LOW GENERAL
SMOOTH, EASY,
7014 |EP.EN| Y | ALL | MED CAST
LOW HYDROGEN,
7018 | EP | Y | ALL | LOW STRONG
| FLAT
7024 | EPEN| Y | HORIZ | LOW | SMOOTH EASY.
FILLET FASTER
NI-CL] EP |/ | ALL | Low CAST IRON
308L | EP |/ | ALL | LOW STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
LEN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) |
400
450
Ref, 35-087 985-4
Figure 9-2. Electrode And Amperage Selection Chart
OM-436 Page 29
1 Electrode
2 Workpiece
1 3 Arc
Drag electrode across workpiece
>
> < "ак 2 . “os .
7 like striking a match; lift electrode
> 7, | slightly after touching work. If arc
К ! | goes out electrode was lifted to
К high. if eiectrode sticks to work-
7 piece, use a quick twist to free it.
{J
H =
To 3
38-0048
Figure 9-3. Striking An Arc — Scratch Start Technique
1 Electrode
2 Workpiece
3 Arc
я 2 Bring electrode straight down to
workpiece; then lift slightly to start
|| Кр! Г НН lightly
| arc. If arc goes out, electrode was
lifted too high. if electrode sticks to
a workpiece, use a quick twist to free |
; the electrode. |
ЗА
3 |
E
|
8-0050 |
Figure 9-4. Striking An Arc — Tapping Technique
|
| | vas
| 10°-30° \ | 10%-30% y yl
| \ A
\ \ /
o ©
90 90 \ \
-— -— -
¿ L )
End View Of Work Angle
GROOVE WELDS
OM-436 Page 30
S
End View Of Work Angle
о 5
Side View Of Electrode Angle Side View Of Electrode Angle
FILLET WELDS
5.0662
Figure 9-5. Positioning Electrode Holder
1 Large Spatter Deposits
POOR WELD BEAD 2 Rough, uneven bead
3 Slight Crater During Weld-
ing
4 Bad Overlan
Focr Penetration
| S-0053-A
1. Fine Spatter
GOOD WELD BEAD 2 Uniform Bead
Moderate Crater During Weld-
ing
Weld a new bead cr layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 (Good Penetration Into Base
Metal
S-0052-B
Figure 9-6. Weld Bead Characteristics
» IMPORTANT: Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base
metal.
Correct Angle
Angle Too Small by 10° - 30° Angle Too Large
Ну!
< 5 < > < >
Drag
ELECTRODE ANGLE
| _ rene
< y
Too Short Normal Too Long
ARC LENGTH
ETE ,
< >
Slow
TRAVEL SPEED
S-0661
Figure 9-7. Conditions That Affect Weld Bead Shape
OM-436 Page 31
» IMPORTANT: Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide
groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.
1 Stringer Bead — Steady
Movement Along Seam
2 Weave Bead - Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a
wide area in one pass of the elec-
trode. Do not let weave width ex-
ceed 2-1/2 times diameter of
electrode.
AGE DD
Figure 9-8. Electrode Movement During Welding
5-0054-A
1 Tack Weids
Prevent edges of joint from draw-
ing together ahead of electrode by
tack welding the materials in posi-
tion before final weld.
Oo
1/16 in. 30
; / (1.6 mm)
+
2 Square Groove Weld
Good for materials up to 3/16 in. (5
mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 through
3/4 in, (5-19 mm) thick. Cut bevel
with oxyacetyiene or plasma cut-
ting equipment, Remove scale
from material after cutting. A grind-
er can also be used to prepare bev-
els.
Create 30 degree angle of bevel on
materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than
3/18 in. (5 mm}.
55-0662
Figure 9-9. Butt Joints
1 Vise
2 weld Joint
L —3 3 Hammer
Strike weld joint in direction shown,
A good weld bends over but does
not break.
Ww
2To3i |
(51-76 mm) «= Г
| 2 То 3 п. | |
|
(51-76 mm)
S-0057-8
Figure 9-10. Weld Test
OM-436 Page 32
wd :
45° - E O =
Or Less
1 Electrode
2 Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section,
3 Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in
Figure 9-8. Remove slag before
making another weld pass.
S-0060 / S-0058-A / 5-0061
Figure 9-11. Tee Joint
30° Or Less
30° Or Less <
| ›
Singie-Layer Fillet Weld Multi-Layer Fillet Weld
1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-
erfilletis needed. Remove siag be-
fore making ancther weld pass.
Weld both sides of joint for maxi-
mum strength.
35-0063 / 5-0064
Figure 9-12, Lap Joint
9-2. Welding Troubleshooting
Table 9-1. Porosity
Porosity — small cavities or holes resulting
from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long. Reduce arc length.
Damp electrode. Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt
from work surface before welding.
OM-436 Page 33
Table 9-2. Excessive Spatter
Excessive Spatter — scattering of molten
metal particles that cool to solid form near
weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high
Reduce arc length or voltage.
Table 9-3. Incomplete Fusion
a
Incomplete Fusion — failure of weld metal
to fuse completely with base metal or a
preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddie.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt
from work surface before welding.
Table 9-4. Lack Of Penetration
Lack of Penetration
Lack Of Penetration - shallow fusion be-
tween weld metal and base metal.
ma
Good Penetration
Possible Causes
Corrective Áctions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to
bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed. |
OM-436 Page 34
Table 9-5. Excessive Penetration
Excessive Penetration — weld metal meit-
ing through base metal and hanging un-
derneath weld.
Excessive Penetration Good Penetration
Possible Causes Corrective Actions
Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Table 9-6. Burn-Through
Burn-Through — weld metal melting com-
pletely through base metal resulting in
holes where no meta! remains.
Possibte Causes Corrective Actions
Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Table 9-7. Waviness Of Bead
Waviness Of Bead — weid metal thatis not
parallel and does not cover joint formed by
base metal.
Possible Causes Corrective Actions
Unsteady hand. Use two hands. Practice technique.
Table 9-8. Distortion
Distortion — contraction of weld metal dur-
ing welding that forces base metal to
move,
Base metal moves
in the direction of
the weld bead.
Possible Causes Corrective Actions
Excessive heat input. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds. |
1
J
OM-436 Page 35
SECTION 10 — PARTS LIST
>
L2
Е
D
0
0
<L
£
=
т
o
т
©
>=
3
©
LL
OM-436 Page 36
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly
1 еаееклок о +141 036 .. СОМЕН, Юр ............. 5..5. лк. rea enrecene den. 1
C2 о 108 487 .. LABEL, warning failing equipment ................ oo... 1
NB aaa 141209 .. UPRIGHT, base RR 16 1
LS Fig 10-4.. CONTROLBOX .......... 2er. 1
‚бек, 148 418 .. KIT, fuel tank replacement (consistingof} ........................ 1
C6 ............. 147 896 .... TANK, fuei 3.8gal (consisting of) .......... i... 1
A 126239 ...... SCREEN, fuel line pick-up 5/18tbg . . . .. . .. LL 1
‚ОВ .ненннк..... 127 405 .. .... TUBING, urethane ester .250 ID x .3120Dx5000 ............ 1
‚ ® 1.222112 04 400 124253 ..... BUSHING, tank fuel .......... 4 ea 44 4 14 a a 0e 40 1
10 ............. 124252 ..... FITTING, hose stielb1/dthbg ........... 200... 1
CM 084173 .... CLAMP, hose .460-.545¢ip diaslfttng .............. ooo oon 2
12... 107816 .... HOSE, SAE .250 ID x .500 OD (order by ft) ................... 2ft
RAA 148332 .... STRIP, rbradh back .125x1.000x1.000 ...................... 2
13... +146 981 .. BASE ee 1
14 ............. Fig 10-3.. СЕМЕВАТОВ/УНВОМНЮ .......... 2... 5. к.с квн квн канаве 1
15 ............. 010809 .. NUT, stislflkghexreg 375-16 ... iii. 1
16 ............. 142 155 .. DUCT, air engine .......... 2.22. anreac a 1
A 141 453 .. ENGINE, Kohler gas eleC i, 1
18.....54..... 142095 .. SWITCH, pressure oit APSI a. 1
19 ............. 125 802 .. MOUNT, engnprn .312-18dualstud ............... .. ........ 2
1 141 033... BRACKET, mtg engine ...............merereresrerecrerercene. 1
QA a 141029 .. TUBING, stl .625 OD x 12ga wall x 1.625 Ig ....... eee 2
‚ 22 a a aa aa +6 HOUSING w/SOCKETS, (see engine parts list) ................... 1
23 PLG2..... 114 063 .. HOUSING, term plugnyldcontirow ..... cilia... 1
ee 113633 .. TERMINAL male 1pin20-14wire ............................. 4
C24 LL. 141559 .. PADDLE, solenoid ........ 2... 2... eerererererecererCare. 1
25.... TS1 142291 .. SOLENQID, idle ..... een aaren naa, 1
26 ............. 601 965 .. SCREW, cap sti hexhd .375-16 x 1.000 .......... es. 0... 1
"A 602213 .. WASHER, lock stl split .375 ..... iii, 2
28 recorrer 010910.. WASHER, flat stl SAE 375 ........ 2... 000000rareenera. 2
29.... PB1 . 046433... SWITCH, PBMC NO 36VDC ... 22200000, ee. 1
30 ............. 021 385 .. BOOT, tgl Switch lever .. .. ..... . . iii, 1
31.....52...... 011611... SWITCH, tal DPDT 15A 125V i ieee 1
CARS 146 985 .. CABLE, batpos .......10010 101040404444 4 44 a a ea 1 aa Va Le 1
e 052 553 .. COVER, cable bat post red No. 4-10 wire 22. mar... 1
BA 2............ 141205 .. BRACKET, hold down battery ..........._——em-eevrevrerrare ee. 1
35... 142102 .. CABLE batneg ......... a, 1
Ce 142 103 .. CABLE, grd ......... eee |
36... BATT 003 426 .. BATTERY, stor 12V 230crk 32RSV ............................ 1
7 2.2... ккккв ко. 604 311 .. GROMMET, rbr .2501D x .375mtghole ................ ......... 2
‚ 38 ............. 604 538 .. WASHER, flat stl SAE 312 122211010440 444 ea 4 ee ea a a 0 2
‚ 39 ............. 604 433 .. NUT, sti siflkg hex hvy .312-18 1.100114 0204044 a a ae eee sa a ea 00 2
.40....CR5 ..... 119722 .. CONTACTOR, solenoid 12VDC 400A SPNO . .................... 1
CA .............. 114 923 .. BOOT, insulator term postred iii... 1
AD a 604 435... BOLT, crg sti .312-18 x 7.000 ....... ci A eee aa a as 2
AB 009 043 .. SCREW, cap stl hexhd .375-16 x 3.000 ......................... 2
‚ 44 ee 010955 .. WASHER, flat st! 406 ID x 2.000 OD х .125thk ................... 2
‚ 45 ............. 010047 .. TUBING, stl .6250D x 12gawallx 1.000 ....................... 1
AB ............. 010 954.. WASHER, flat sti .406 ID x 1.250 OD x .125thk ................... 1
LG LLLL 11111020 127 595 .. SCREW, cap stl hexhd .375-16 x2.500 ......................... 1
AB ............. 127 593 .. MOUNT, gen nprn adapter .........102204 4440041 ea a ea 111200 1
49 eran. 011 198.. LABEL, warning fan ......... ... ae V4 a ea ae aa 0 1
BO. 013367 .. LABEL, warning moving parts etC .............. e... rerír.s 1
BA 126738 .. STRAP holddownfueltank ............... i... 1
B82 2. енкек.., +141 037 .. PANEL, front lower ............... 2... 00... .erreerarenae0. 1
‚ 58 ............. 132709 .. LABEL, engine fuel can cause fire orexplosion ................... 1
‚ 54 ena. 126 723 .. WASHER, necktank fuel ............ . nereeaerara 1
OM-436 Page 37
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly (Continued)
2. 55 ............. 126994 .. CAP fueltank screw on ....... вкл rara. 1
BO ............. 134 792 .. LABEL, warning депега! ргесациопагу ......................... 1
BT еек екек 128 333 .. BAFFLE airintake ...... 44 AN a 4 4 ee Lea a 46 1
BBL Fig 10-2 .. PANEL, frontw/components . ................. .. .... .... ...... 1
eee 147 713... KIT label .... ee À
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
16 15 9 $” \
13
|
18 1
SB-144 338-A
Figure 10-2. Panel, Front w/ Components
OM-436 Page 38
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-2. Panel, Front w/Components (Fig 10-1 item 58)
1 кк, 602 221 .. WASHER, lock stlintltooth .375.... .. a sa ee sa ee 6 4
2 CB1-4 +125 524 .. CIRCUIT BREAKER, manreset 1P15A250V .......... .......... 4
aa CB2,4 .. +144 474 .. CIRCUIT BREAKER, man reset 1P 25A 250V ...............o e... 2
3 RC1,2 . ++039684.. RECEPTACLE, sir dx grd 2P3W 15A 125V ........... 22.2... 2
ee Le 073 690 .. PLUG, strgrd armd 2P3W 15A 125V
naaa RC2 ... e129067.. RECEPTACLE, twlk grd 3P4W 30A 125/250V .................... ]
aaa 088 898 .. PLUG, twik grd 3P4W 30A 125/250V
aaa RC2 .. 44604 103... RECEPTACLE, strdx grd 2P3W 15A250V ......................1
Ce 025 234 .. PLUG, str grd 2P3W 15A 250V
4 . C3,4 131 646 .. CAPACITOR ASSEMBLY riera rear n ene. 1
5 Neg, Pos 129 525 .. RECEPTACLE, jack 400A ........ i 6 2
CE 042 418 .. CONNECTORKIT, Dinsemale80series ........................ 2
CB ............. 147 898 .. СТАМО-ОРЕ ЗУРРОВТ, РС сага Мо. 6$сг ...................... 4
7 . PC1 142 010 .. CIRCUIT CARD, field currentregulator ............ ............. 1
Cee PLG1 130203 .. HOUSING PLUG & SOCKETS, (consistingof} ................... 1
ee 113746 .... TERMINAL, female 1skt24-18wire ......................... 12
. 8 .....R1..... 072 462 .. POTENTIOMETER, w/shaft lock (consistingof) ................... 1
‚ 9 aa 072590 .... LOCK, shaft pot .375-32 x .250diashaft ....................... 1
10.....53..... 089 085 .. SWITCH, tg! SPST 20A 125VAC i a 440 1
11... CR3,4 090 104 .. RELAY, encl12VDC SPST 330A i. 2
12 ............. 141038 .. PANEL, front . кн кн квн кн венно. 1
e Be aaayereerrenc. NAMEPLATE, (order by model and serial number) ................ 1
Ce € 6 4042 367 .. HOUR METER, (consisting of) ............ 1
14 . HM 032936 .... METER, hour 4-40VDC ...... RR ae a 00 1
RAA AS 604 784 .... SCREW, mach brs rdh 6-32 x .500 ........................... 2
adan 601 829.... NUT, brs hex 6-32reg ......... 2
15... 097 924 .. KNOB£B, poinier ........... eee eee 1
16 ............. 083 030 .. STUD, brs grd .250-20 x 1.750 ....... 22200000 1 Le ae» 1
y AO 010915 .. WASHER, flat brs .250 iD x .625 OD x 031thk Cee, 2
18 ............. 601 836 .. NUT, brs hex .250-20 jam hvy .............. 5... 5. к.кв вне... 3
+Circuit Breaker (CB1,3) (CB1
++Receptacle (RC1) remains the same for Option 042 625 and 042 627 Receptacle Kits.
+ Part of Option 042 625 240V Twistlock Receptacle Kit.
+ + Part of Option 042 627 240V Duplex Receptacle Kit.
+ + + OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-436 Page 39
-4) remains the same for Option 042 625 and 042 627 Receptacle Kits respectively.
item Part ВЕ |
No. No. Description Quantity
Figure 10-3. Generator/Shroud (Fig 10-1 item 14)
. 1 .... 125548 .. HOLDER, brush eleCt . eeocaooere rara. 1
‚ 2 .... 005614 .. HOLDER, brush RK RK 1 LA ee 2
. 8... *126984 .. BRUSH W/SPRING 122010101444 4 A 4 LA A кк кк 4 4 4 44 A NL 4 a a a ee 2
. 4 .... 047885 .. CAP, brushholder ........2044 44 41 LL LL LL LL A 4 4 4 4 4 LL 4 4e A A A A 4 4 4 4 a a 4 6 2
. 5 .... 047 879 .. BAR, retaining brushhoider 2 brushes .. 112001444444 4 44404 a 4 14 4 неее. 1
‚ 6 .... 143220 .. O-RING, 2.859 1D x . A39CS ... aaa nacen averno era. 1
. 7 .... 013367 .. LABEL, warning moving parts etC .......... eo ceerererere enero ae 1
. 8 ....142153 .. ROTOR, generator (consisting Of) ..............,0. 0... 1
.. 9.... 024617 .... RING, retaining ext 1.272 shaft x .050thk ....... .... 0... La 2 1
‚. 10.... 053390 .... ВЕАНМЫ, Ба! г! 501 гоу 1.370 х 2.830 х.6 ................. 25...00... 1
Cee 147 551 .. TOOL, puller rotor ............. eee 1
o11 0.127786 .. KEY, st! .250 x 250 x 1.000 ......111 11111414 14444 4 A A A Aa A ee ea ea ee 1
2. 12.... 142 156 .. SCREW, cap sti hexhd .375-16 x 1.750 ......... eee 4
.. 13.... 602213 .. WASHER, lock sti split .375 ......... 2.2.2.0. eareren 0. 4
..14.... 010910 .. WASHER, flat stl SAE .375 ee 4
..15.... 141129 .. ADAPTER, engine .........244 224444444444 44 4 4e a 44 a a a es a A 4 4 aa 6 1
.16....141 042 .. STUD, sti .312-18 x 10.625... ee 4
.. 17.... 020279 .. CLAMP, stl cush .750dia x .281mtg hole ............ 0.000, 2 4440 3
‚. 18... +142 216 .. STATOR, gen (consisting of) ............ RR a AL aa 4 aa 41 220 1
RS 004 214 .... BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole ......................... À
.. 19....142980 .. ENDBELL,gen..........4421000 04044 AL 44 4 44 44 ee 4 4 ee a 4 a ee aa 4 1
.. 20.... 128154 .. FÁN, rotor ............eseredrererererererer<erenrerecarereroeererdererer 1
21 ....127596 .. WASHER, flat stl .344 ID x 1.500 ОО х 125thk . ........ e... 1
‚. 22.... 128341 .. CLAMP, hose 1.880-2.060cip dia ............. 2... tie eee ee ieee, 1
‚ 23 .... 126 582 .. SHROUD, fan ......... NR RR RR ne 1
SD-144 337
Figure 10-3. Generator/Shroud
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-436 Page 40
item Dia, Part
No. Mkgs. No. Description Quantity
Figure 10-4. Control Box (Fig 10-1 Item 4)
1 ‚. ОС7 .... 128183... STABILIZER ... te eee 1
2 ....CT1 .... 105370... TRANSFORMER, current . .. ... i eee. 1
3... SR1-3 ... 035704 .. RECTIFIER, integ40A 800V ....... iii. 3
‚2. 4...R3VR1... 046818. SUPPRESSOR N 1
05 1111111000. 127 783... BRACKET, mtg rect ........22044 42144141 414 4 a 4 a a 4 4 eee ee 0 1
6....SR4 .... 142502... RECTIFIER, si 3ph 200A 400PIV ...... 2... 2... 0.0. iin, 1
7 012571 .. HOLDER, fuse mintr .250 x 1.250 clip .......................... 1
8 ..... Fi .....*027 419 .. FUSE, mintrcer 15A 250V . . ieee. 1
1. 9 111111111140 087 111 .. CLAMP, capacitor 1.375dia clip ....... ci iia... 3
.. 10....C12..... 087 110... CAPACITOR, elctit 240uf 200VDC ....... Ce AA 3
SA 141035 .. ENCLOSURE, mtgcomponents ......... iin... 1
.. 12..... R2..... 142277 .. RESISTOR, WW fxd 100W 250 ohm . oo... 1
E . 129524... TERMINAL, frict male 250 x .032 3 pair ........................ 1
..14.....T1..... 141 210 .. TRANSFORMER, controlisolation ............................. 1
15.... P02.... 142724 .. MODULE, pullto idle B pin .................0 0. a 1
.. 16... PLG3.... 135556 .. HOUSING PLUG 8 SOCKETS, {consistingof) ................... 1
Ce eee 114 066 .... TERMINAL, female 1skt20-14wire .......................... 6
aaa 004 214 .. BUSHING, snap-in nyl 1.6251D x2.000mtg hole . ................. 1
.. 18.... RC3 .....116045.. HOUSING PLUG & PINS, (consisting of) ..................... 1
PA RR 113633 .... TERMINAL, male 1 pin .084dia20-14wire ..................... 6
.19.... CT2 .... 126 296 .. TRANSFORMER, CUrrent . 0000 i ii 1
SC-135 073
Figure 10-4. Control Box
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-436 Page 41
Dia. Part
Mkgs. No. Description Quantity
Optional Equipment
. HM ...042367 .. HOURMETER, (see Fig 10-2) . . LL. ieee 1
as 042 625 .. RECEPTACLE KIT, twlk 240V (see Fig 10-2) .......... ine... 1
RE 042 627 .. RECEPTACLE KIT, duplex 240V (see Fig 10-2) ................. 0001
ana 042 618 .. RECOIL STARTER KIT ..... 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-436 Page 42
OPTIONS AND ACCESSORIES
EDT 1000-2 TWO-WHEEL TRAILER
(#041 777)
A 1000 ibs. (453 kg) capacity trailer
with welded structural steel frame,
heavy-duty axle with roller bearing hubs
and leaf spring suspension. Mounting
holes for all small Miller engine driven
generators are prepunched. Also
included are a jack stand for raising
and lowering the tongue, and safety
chains and universal tongue mounting for
optional hitches. An optional fender and
light kit is required when trailer is used
on highway.
NOTE: Hitch must be ordered separately.
When equipped with fender and light kit
and 2 in. {51 mm) ball hitch, this trailer
conforms to all applicable U.S. Federal
motor vehicle safety standards in effect
on date of manufacture.
SPECIFICATIONS
GVWR: 1200 165. (544 Ка)
Trailer weight: 186 ibs. (84 kg)
Trailer capacity: 1000 Ibs. (453 kg)
Total width {without optional fender
kit): 55 in. (1.4 m)
Total length {without optional hitch):
72 in. (1.8 m)
Width of bed: 36 in. (914 mm)
Track Width: 49-172 in. (1257 mm)
Height of bed: 18 in, (457 mm)
Tire size: 4.80-12
Shipping weight: 186 Ibs. (84 kg)
FENDER AND LIGHT KIT
(#041 778)
Includes fenders, lights, wiring harness,
and mounting hardware. Shipping
weight 37 ibs. (17 kg).
HITCHES
2 in. (51 mm) BALL
(#041 724)
Shipping weight 5 Ibs. (2 kg).
CLEVIS (not for highway use)
(#041 726)
Shipping weight 11 №5. (5 kg).
2-1/2 in. (64 mm) LUNNETTE EYE
(#041 725)
Shipping weight 9 Ibs. (4 kg).
NOTE: When ordering trailers without
the fender and fight kit and ball hitch, the
purchase order must include the
statement, “For off-the-road use only.”
TRAILER MOUNTING KIT
(4042 373)
Required when mounting units to EDT
series trailers. Consists of four steel
mounting straps and hardware for easy
trailer mounting.
NO. 24 HAND RUNNING GEAR
(#042 615)
Compact, lightweight, hand running
gear with 8 in. (20.3 cm) pneumatic
tires, providing maximum maneuver-
ability. Designed so that cables can be
wrapped around handles, and canvas
cover can be used.
SPARK ARRESTOR KIT
(#042 617)
Mandatory when operating on
California grasslands, brush or forest
covered land, and all Natienal Forests.
Consists of screen and hardware which
attaches to the standard muffler.
NO. 2DWA WELDING ACCESSORY
KIT
(#042 370)
Consists of 35 ft. (10.7 m) No. 3
electrode cable with insulated electrode
holder, 30 ft. (9.1 m) No. 3 ground cable
with work clamp, welding helmet, and
wire brush. Cable terminals are
International style brass twistlock,
matching the receptacles on the welder.
RECOIL START KIT
(#042 618 Factory)
(4042 619 Field)
CC-7 CANVAS COVER
(4042 536) CC-7B Blue
(4042 372) CC-7 Gray
Attractive waterproof canvas covers.
Resists stains and mildew, and protects
the finish of your welder.
GROUND FAULT CIRCUIT
INTERRUPTORS
Handy, convenient add-on devices
reduce shock hazard.
OUTDOOR MOISTURE PROOF GFIC
PLUG
(#042 602)
User attachable GF Cl plug rated 15A at
120 Volts AC. Permanently attaches to
power tool cords. Can connect cords
from 18 AWG to 12 AWG.
OUTDOOR RAINPROOF ADAPTER
(#042 600)
8 in. Outdoor GFCI rated 15A at 120
Volts. Handy plug and receptacle
adapter is rugged, compact, and low
cost. For 14/3 SJTW electrical cords.
RUNNING HOUR METER
(#042 367 Factory)
(#042 368 Field)
Furnishes an accurate record of engine
running time. Recommended for
efficient service.
INTERNATIONAL TYPE
CONNECTOR KIT
(#042 418) 50 mm
Kit includes one International style male
plug which attaches to the work and/or
weld cables and plugs into the
International style receptacles on the
power source.
Accepts #1 or #2 AWG size cable.
EXTENSION KIT FOR
INTERNATIONAL STYLE
CABLE CONNECTORS
(#042 419)
Used to adapt or extend weld and/or
work cables. Kit includes one male
International style plug and one in-line
female International style receptacle.
Accepts #1 or #2 AWG size cable.
INTERNATIONAL/TWECO ”
ADAPTER
(4042 465)
A one-piece adapter which has an
International style male plug (to power
source) on one end and a female
Tweco receptacle (for weld cable
connection) on other end.
INTERNATIONAL/CAM-LOK
ADAPTER
(#042 466)
A one-piece adapter which has an
International style male plug (to power
source) on one end and a Cam-Lok
receptacie (for weld cable connection)
on other end.
240V DUPLEX RECEPTACLE
(#042 627 Factory)
(#042 628 Field)
Provides one 240V duplex receptacle.
When installed, the welder will have
one 120V and one 240V duplex
receptacle.
FULL KVA TWISTLOCK
RECEPTACLE
(#042 625 Factory)
(#042 626 Field)
NEMA L14-30R receptacis provides full
5000 Watt power output through one
twistlock receptacle.
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