Miller CW-200LE User manual

Miller CW-200LE User manual
 Janaury 1976 FORM: OM-418B
Effective with Serial No. HF870501
|]
MODEL
CW-200LE
MODEL/STOCK NO.
SERIAL/STYLE NO.
DATE PURCHASED
OWNER'S MANUAL
CHARGER
) KY HOOK
WELDER
BALDWIN - WARD Mfg. Co.
NTE,
ha
this manual.
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
1, AMENDMENT TO FIGURE 11-1 CIRCUIT DIAGRAM
o];
NOTE | 000"
The circuit diagramis) on this supplement replace any other circuit diagramis} ‘appearing later in this
, Manual. Г
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| CI À Circuit Diagram No. CB-930 004-2K
Na SH í
SEs PRESSURE
item Dia. Part No. Listed Replaced With В
No. Mkgs. In Parts List Part No. Description Quantity
43 005 402 006 672 CIRCUIT CARD ASSEMBLY iia 1
D54 026 202 026 202 DIODE {quantity changes from 2to Tregd)............ i... 1
000 036 Deleted
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-4188 Page A
Hem Dia. Part No, Listed Replaced With
No. 1Mkgs. In Parts List Part No. Description Quantity
28 D8 027 369 Deleted (Eff with S/N HG061707)
29 C4 031 670 Deleted (Eff with S/N HG061707)
43 005 402 006 672 CIRCUIT CARD ASSEMBLY 114402400110 4 000 4 ua una u 00 1
| 054 026 202 026202 DIODE (quantity changes from 2 to 1'reg'd”) ............. 1
000 036 Deleted
73 035 137 Deleted
74 012571 Deleted
75 012 618 Deleted
76 020 779 007 250 BRACKET, mounting - brushhoider {Eff with S/N HG061707) 1
77 018614 Deleted
*003 921 BRUSH, w/spring (Eff with S/N HGO61707! ............_.. 3
005 614 HOLDER, brush - w/tabs (Eff with 5/N HG0D61707) ........ 3
003 923 CAP, holder - brush (Eff with S/N HGO61707) ............ 3
007 249 STRIP, retaining - brushholder (Eff with S/N y HG061707) . 1
82 039 100 **007 239 SIATOR, generator ........ee__..ese. e nereaccrerecerce 1 .
90 SR4 039 123 052 785 RECTIFIER, silicon -diode .. 2..2, к 2. оз кс океан он новое 1
92 VR1 039 122 Deleted (Eff with S/N HHO039082)
142 039 958 035 958 PANEL, front......_..eenaaoneanronaaonondaca nana aan» 1
149 Si 011 622 052 769 SWITCH, toggle 4PDT 15 amp 125volts ................. 1
159 Rb 028 839 052 782 RESISTOR, dual adjustable 180 watt 12chm ............. 1
*Recommended Spare Parts.
**Rotor and Stator are available on an exchange basis. Contact Factory Service Department for Details.
RESISTOR, dual adjustable 180 watt 12 chm .....
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-4188 Page C
mana SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE ==
1-1.
INTRODUCTION
We learn by experience, Leaming safety through personal
experience like a chiid touching a hot stove is harmful, waste-
ful, and unwise. Let the experience of others téach you.
Safe practices developed from experience in the use of weld-
ing and cutting are described in this manual. Research, devel-
opment, and field experience have evolved reliable equ pment
and safe installation, operation, and servicing practices. Acci-
dents occur when equipment is impropery used or main-
tained. The reason for the safe practices may not always be
given. Some are based on common sense, others may require -
technical volumes to explain. It is wiser to follow the rules.
Read and understand these safe practices before attempting
то install, operate, or service the equipment. Comply wi th
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
Failure to observe these safe practices may cause serious in-
jury or death. When safety becomes a habit, the equipment
can be used with confidence.
Responsibilities of installer, user, and serviceman. Ins tail a-
tion, operation, checking, and repair of this equipment must
he done only by a competent person, experienced with such
equipment. |
These safe practices are divided into two Sections: 1 -
General Precautions, common to arc welding and cutting; and
2 - Are Welding (and Cutting) (oniy).
Reference standards: Published Standards on safety are also
Available for additional and more complete procedures than
those given in this manuai. They are listed in the Standards
Index in these safety rules. ANS! 249.1 is the most complete.
The National Electrical Code, Occupation Safety and Health
Administration, tocai industrial codes, and local inspection
requirements also provide a basis for equipment installation,
use, and service.
GENERAL PRECAUTIONS
Burn Prevention
Wear protective ctothing - leather (or asbestos) gauntlet
gloves, hat, and hion safery-toe shoes. Button shirt cotlar and
pocket “aps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear helmet with safety goggles or glasses with side shieids
underneath, appropriate filter lenses or plates {protected by
clear cover glass}. This is a MUST for welding or cutting, (and
chipping) 10 protect the eyes from radiant energy and flying
metal. Replace cover gtass when broken, pitted, or spattered.
See 1-3A.
Avoid oily or greasy cioming. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
Medical first aid and eye treatment, First aid facilities and a
qualified first aid person should be available for each shift
unless medicai facilities are ciose by for immediate treatment
of flash burns of the eyes and skin burns.
Ear plugs should be worn when working on overhead ar in a
confined space. A hard hat should be worn wien others work
overhead.
Flammabie Hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adeauate ventitatuon. Severe discomfort, 1llness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depleton that welding for cutting) may produce. Prevent
them with adequate ventdation as described in ANS] Stan-
dard Z49.1 listed 1 in Standards index. NEVER venrilate
with oxygen.
Lead, cadium, zing, mercury, and beryllium bearing and simi-
lar materiais, whan welded (or cut) may produce harmful
concentrations of toxic fumes. Adequate local exhaust venti-
lation must be used, or each person inthe area as weil as the
operator must wear an air-supplied respirator. For beryilium,
both must be used. a
Metals coated with Or containing materials that emit toxic
furhes shouid not be heated unless coating is removed from
the work surface, the area is weil ventilated, or the operator
wears an air-supplied respirator,
Work in a confined space only while it is being venulated
and, if necessary, while wearing an ai r-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. The
space will then be safe to re-enter, if downstream valves have
been accidently opened or left open.
Vapors from chlorinated solvents can be decomposed by the
heat of the arc tor fame) to forn PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultra
violet (radiant) energy of the arc can also decompose tri-
chioroemylene and perchlorcethylene vapors to forn phos-
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the welding or cutting atmosphere or where the
radiant energy can penetrate to atmospheres containing even
minute amounts of trichlorethylene or perchlorethylene.
Fire and Explosion Prevention
Causes of fire and explosión are: combustibles reached by the
are, flame, flying sparks, hot stag or heated material; misuse
of compressed gases and cylinders; and short circuits.
Be aware that flying sparks or falling slag can pass through
cracks, along pipes, through windows or doars, and through
wall or floor cpenings, out of sight of the goggled operator.
Sparks and siag can fly 35 feet.
To prevent fires and expiosion:
Keep equipment clean and operabie, free of oil, grease, and
lin electrical parts) of metallic particles that can cause short
circuits.
If combustibles are in area, do NOT weld or cut. Move the
work if practicable, to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage areas, ventilators. If the
work can not 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 shouid not be
welded on (or cutl. Wails, 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 welc-
ing or cutting if:
a. appreciable combustibles {including building construc:
tion) are within 35 feet |
5. 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, ar metal
partitions can be ignited by radiant or conducted heat.
Hot work permit should be obtained before operation to
ansure supervisor's approval hat adequate precautions nave
been taken.
After work 15 done, check that area is free of sparks, giowing
embers, ang flames.
An empty container that heid combustibies, or that can oro-
duce flammable or tOXIC vapors when heared, must never be
weideg on or cut, unless container has first Geen cleaned as
described in 4WS Standard A6.0, listed 3 in Standards index.
01-413 Page!
Sage 2
This. includes: a thorough steam or caustic cleaning (ог а
solvent or water washing, depending on the combustibie’s
solubility) followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom-
mended in A6.0. Warerfilling just below working evel may
substitute for inertihg.
A container with unknown contents shouid be cleaned (see
paragraph abovei. Do NOT depend on sense of smell or sight
to determine if it is safe to weld or cut
Hollow castings ar containers must be vented before weiding
or cutting. Thay can explode.
Explosive atmospheres. Never weld or ctt where the air may
contain flammable dust, gas, or liquid vapors (such as gaso-
line),
Compressed Gas Equipment
Siandard 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 reguia
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 reguiator veas designed.
Remove faulty regulator from service immediately for repair
(fist close cylinder valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to nse with
downstream valve closed.
Faulty Gauge - if gauge pointer does not move off stop pin
when pressurized, nor remurns to stop pin after pressure
release. .
Repair. Do NOT attempt repair. Send faulty regulators for
repair to manufacturer's designated reparr 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 to à serious accident. (See
1-3C.)
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder 15 properly handled.
Identifying gas content. Use only cylinders with name of gas
marked on them: do not rely on color ta identify gas con-
tent. Notify supplier if unmarked. NEVER DEFACE or aiter
name, number, or other markings on 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 ar roller.
Secure from falling. Chain or secure cylinders upright when a
reguiator (and hose) are connected toit.
Passageways and work areas. Xeep cylinders clear of areas
where they may be struck.
Transporting cylinders. With a crane, use a secure support
such as a platform or cragle. Do NOT lift cylingers off the
ground by their valves or caps, or by chains, slings, or mag-
nets.
Oo NOT expose cylinders to excessive heat, sparks, slag, and
flame, été. that may cause rupture. Do not allow contents to
exceed 1300F. Cool with water spray where such exposure
exists.
Protect cylinders particuiarly valves from bumps, falls, failing
objects, and weather. Replace caps securely when mowing
cylinders.
Stuck valve. Do NOT use a hammer or metal wrench to open
a cylinder valve that can not be opened by hand. Notify your
supplier.
Mixing gases. Never try to mix any gases in a cylinder,
Never refill any cylinder. |
Cylinder fittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and biack 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 tangtes.
Protect hose from damage by sharp edges, and by sparks,
slag, and open flame.
Examine hose regularly for leaks, wear, and loose connec-
tions. Immerse pressured hose in water; bubbles indicate
leaks. !
Repair leaky or worn hose by cutting area out and splicing
11-203). Do NOT use tape,
4. Proper Connections
Clean cylinder valve outlet of impurities that máv ciog
orifices and damage seats before connecting requiacor. except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint
less cloth.
Match regulator to cylinder. Before connecting, check that
the regulator label and cyiinder marking agree, and that me
regulator inlet and cylinder outlet match. NEVER CON-
NECT a reguiator designed for a particular gas or gases 10 a
cylinder containing any other ass.
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary, Tighten. If connec-
tion leaks, disassembie, clean, and retighten, For metal-to-
metal seating, use correct wrenches, available from your
supplier. For O-ring connections, hand tighten.
Adapters. Use a CGA adapter {available from your supplier)
between cylinder and regulator, if ane is required. Use two
wrenches to tighten adapter marked RIGHT and LEFT
HAND threads.
Regulater 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.
S. Pressurizing Steps:
Drain regularor of residual gas through suitable vent before
opening cylinder (or manifoid valve) by turning adiusting
serew in (clockwisel. Draining prevents excessive compression
heat at high pressure seat by allowing seat to open ON pressur-
ization. Leave adjusting screw engaged siightly on single-stage
regulators. |
Before opening cytinder valve, check that hoses are con-
nected and that downstream valves are closed.
Stand to side of reguiator whiie opening cytinger valve.
Open eviinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge reaches regu-
lator maximurr) leave cviinder valve in following position:
For oxvgen, and inert gases, open fuily to seal stem agarnst
1-3.
possible leak, For fuel gas, open to less than one turn to
Dermit quick emergency shutoff.
Use pressure charts lavailable from Your supplier) for safe
and efficient, recommended pressure settings on regulators. It
will reduce backfiring and chance of flashbacks.
Check for leaks on first pressurization and regulary there-
after. Brush with soap solution (capfui of могу Саш!" ог
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 and: repair them only if recommended in equipment
instruction manual. Send others for repair to manufacturer's
designated repair center where special techniques and tools
are used by trained personnel. Refer ta User Responsibilities
statement in equipment 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: ropé may burn.
ARC WELDING
Comply with précautions in 1-2 and this section. Arc Weid-
ing, properly done, is a safe process, but a careless operator
invites trouble. The equipment carries high currents at signifi-
cant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviciet 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. {ts radiation can
damage eyes, penetrate iightweight clothing, refiect from
lightcolored surfaces, and burn the skin and eyes, Skin burns
resemble acute sunburn, - those from gas-shielded arcs are
more severe and painfui. DON'T GET BURNED; COMPLY
WITH PRECAUTIONS.
1. Protective Clothing -
Wear loncsieeve clothing {particularly for gas-shielded arc) in
addition to oloves, hat, and shoes (1-2A). As necessary, use
additional protective ctothing such as leather jacket or
sleeves, ftame-proof apren, and fire-resistant leggmgs. Avoid
outergarmments of untreated cotton.
gare skin protection. Wear dark, substantial clothing. Button
coliar to protect chest and neck and button pockets 10 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.
Wetding helmet or shield containing a filter plate shade no. 9
or genser must be used when welding. Place over face before
Striking arc,
Protect filter plate with a clear cover plate.
Cracked or Droken heimet or shieid should NOT be worn;
radiatióon can pass through to cause burns.
Cracked, broxen, or loose filter piatées must be replaced IM-
MEDIATELY. Repiace clear cover plate when broken, pitted,
or spatiereg.
Flash googles with side shields MUST be worn under the
. heirmet to give some protection to the eyes should the heimet
nor be towered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particularly a
High intensiry gas-shietded arc; can cause a retinai burn that
may leave a pérmanent dark area in the field of vision.
*Trademark of Proctor & GCampole.
3. Protection of Nearby Personnel
Enclosed welding area, For production welding, a separate
room or enclosed bay is best. In open areas, surround the
operation with low-reflective, non-cornbustible screens or
panels. Allow for free air circulation, ‘particularly at floor
level. +
Viewing the weld. Provide face shields for all persons who
will be looking directly at the weld.
Others working in area, See thar all persons are wearing 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 kiii.
Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipments rated capacity. Do not overload arc weiding
equipment. It may overheat cables and cause a fire,
Loose cable connections may overheat or flash and cause a
fire.
Never strike an arc on a cylinder or other pressure vessel. it
creates a brittle area that can cause a violent rupture or lead
to such a rupture tater under rough handling.
Compressed Gas Equipment
Comply with precautions in 1-20.
Shock Prevention
Exposed hot conductors or other bare metal in the welding
circuit, or in ungrounded, electricaily-HOT equipment can
fatally shock a person whose body becomes a conductor, DC
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH 3 wer sur
face when welding, without suitabie protection,
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insulation against electrical shock. Stay оп а
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or morsture between body
and an eiectricaity HOT part - or grounded metal - reduces
the body surface electrical resistance, enabting dangerous and.
possibly iethat currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such as
welding power source, control, work table, and water circuia-
tar 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 NCT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammabie liquid such as oil or fuel,
Three-phase connection, Check phase requirement of equip-
ment before installing. If only 3-phase power is avaiable,
connect singie-phase equipment ta only two wires of the
3-phase iine. Do NOT connect the equipment ground lead го
the third (ive! wire, ar the equipment will become etectr-
cally HOT - a dangerous condition that can shock, possibty
fatally.
Before welding, check ground for continuity. Be sure ccnaduc-
tors are touching bare metal of equipment frames at connec-
tions.
IF a line cord wir a ground lead is provided with the ecuip-
ment for connection to à switchbox, connect The ground lead
to the grounded switchbox. if a three-prong plug is added for
connection to a grounded mating receptacle, the ground gad
must be connected to the ground prong oniv. tf ne line cord
comes with a three-prong plug, ¢connact to a grounded maung
receptacle. Never remove the ground prong from a plug, or
use apkug with a broken off ground prona.
= 4 a ==
CATE Page 2
Page 4
2. Electrode Molders
Fully insulated electroda holders should be used. De NOT
Use holders with protriding screws.
3. Connectors
Fully insulated lock-type connectors should be used to join
walding cable lengths.
4, Cables
Freguantly inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
damaged insulation to avoid possibly - lethal shock from
bared cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable. Keep cable dry, free of
cil and grease, and protected from hot metal and sparks,
5. Terminals
Terminals and other exposed parts of electrical units should
have insulating covers secured before operation.
6. Electrode Wire
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed. Keep hands and body clear of wire and
other HOT parts.
7. Safety Devices
Safety devices such as interlocks and circuit breakers should
not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turrting ON of power. Discon-
nect all cables from welding power source, and pull all 115
volts line-cord plugs,
14.
Do not open power circuit or change polarity while welding.
If, in an ermergency, 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. ANS! Standard 249.1, SAFETY IN WELDING AND
* CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, Fla, 33125.
2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA -
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y, 10018.
3.‘ American Welding Society Standard AB.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD,
COMBUSTIBLES, obtainable same as item 1,
4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
National Fire Protection Association, 470 Atlantic
Avenue, Boston, Mass. 02210.
5. NFPA Standard 51B, CUTTING AND WELDING PRC-
CESSES, obtainable same as item 4.
6. CGA Pamphiet P-1. SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N. Y. 10036.
7. OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD-
ING, CUTTING AND BRAZING.
2-1.
2-3.
—o SECTION 3 - INSTALLATION
3-1.
Amperes Amperes| Open-
- 200 35-200 {72 Voits
DC DC DC
Battery Weight
Output 100% | Welding | Circuit Charging | Dimensions : {Pounds}
. Duty Cycle Range | Voltage Power Capabilities (inches) Net | Ship
‘ 115 Volts
OC power while ,
welding — 1 kva 12 Volts }Height- 27-1/4
120 Voits single- 36 Voits {Depth - 46-3/4
phase, 60 Hz :
AC - 3.6 kva
24 Volts Width - 22 615 |- 680
Figure 2-1. Specifications
GENERAL
This manual has been prepared especially for use in famitiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment, All informa-
tion presented herein should be given careful consideration TO -
assure optimum performance of this equipment.
RECEIVING-HANDLING
Prior to installing this equipment, clean ail packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. À copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial tor Style) Numbers of the equipment be supplied.
DESCRIPTION
This unit is a gasoline engine-driven welding generator which
produces direct current for welding and battery charging. The
welding output of this welding generator 15 designed to be
used in conjunction with the shieided metal-arc (stick elec-
trode) welding process. The battery charging current ¢an be
used ta charge a 12, 24, or 36 volts battery.
In addition to welding and battery charging capabtlity, this
model 15 equipped with a two-pole, three-wire receptacle
through which 1 kva of 115 volts de etectricat power can be
obtained while weilding. Up to 3.6 kva of 120 volts ac elec-
trical power can be obtained at the 120 МОСТУ АС гесер-
tacie when operating at power rpm.
LOCATION (Figure 3-1)
A proper :nstallation site should be selected for the welding
generator if the unit is to provide dependable service, and
remain relatively maintenance free.
If this unit is to be operated indoors, it shouid 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 bodily injury or {oss af life, 1
A eroper installation site permits freedom of air movement
into and out af the weiding generator, and also least subjects
the unit to dust, dirt, moisture, and corrosive vapors. A mini-
mum of 18 inches of unrestricted space must be maintained
between the weiding generator front and rear panets and the
~agrast obsiruction. Also, the undarside ci the welding
generator must be kept completely free of obstructions, The
installation site should also permit easy removal of the vweld-
ing generator puter enclosure for maintenance functions.
24. SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completely.
This will help avoid possible injury due to misuse or improper
welding applications. -
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Under this heading, installation, operating, and main-
tenance procedures or practices wili be found that if
not carefully followed may create a hazard to per-
I sonnel. ' 3
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
i ment. |
Under this heading, explanatory statements will be
found that need special emphasis 10 obtain the most
efficient operation of the equipment.
=.
|
A \ |
[
= — |
| “E. o a 27-1/4
Do == =x 1/4"
; = 4 ge °F
|
|
=. TB-990 004-7A
Figure 3-1, Dimensional Drawing
OM-418 Page 5
+2.
33.
race ©
IMPORTANT
Do not place any filtering device over the intake air
passages of the weiding generator as this would restrict
the volume of intake air and thereby subject the weld-
Ing generator internal components to an overheating
condition and subsequent failure. Warranty is void if .
| any type of filtering device is used. I
+
Holes are provided in the weiding generator base for mount-
ing purposes. Figure 3-1 gives overall dimensions and the base
mounting hole layout.
On most welding generators a lifting device is provided for
moving the unit. However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under base.
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal compan-
ents to damage shoutd the tips of the lift forks pene-
1 trate the bottom of the unit. 1
GENERATOR CHASSIS GROUND (Figure 3-2)
Normally engine-driven welding generators are not required
to be grounded. However, this machine has auxiliary power
plant capability, therefore, grounding of the frame and case is
recommended. For this reason a convenient grounding ter-
minal is provided. For detailed grounding instructions consult
your local or state codes or the latest issue of the National
Eiectrical Code,
Equipment
Grounding
Terminal
TB-920 004-14
Figure 3.2. Equipment Grounding Terminal
WELDING OUTPUT CONNECTIONS
Welding Cables
It is recommended that the weiding cables be kept as short as
possible, placed close together, and be of adequate current
carrying capacity, The resistance of the welding cables and
connections cause a voltage drop which is added to the volt-
age of the arc, Excessive cable resistance may result in over-
loading as welt as reducing the maximum current output of
which the weiding generator is capable. The proper operation
of any arc weiding generator is tO a great extent dependent
on the use of welding cables and connections that are in good
condition and of adequate size. An insuiated electrode hoider
must be used 10 ensure the operators safety.
Use Table 3-1 as a guide for selecting the correct weiding
cable size far the anticipated maximum weid current that will
be used, Table 3-1 takes into account the total cable length
for tha weid circuit. This means the length of the electrode
cable that connects the electrode hoider to the welding
generator and the work or around cable between the weiding
generator and the work piece, For example: If the etectrods
cable is 75 feet ¡ong and the work or ground cable is 25 feet
long, setecr the size cable from Table 3-1 that is recom-
mended for 100 feet. In a situation where a maximum weld
current of 180 amperes is anticipated, No. 3 weld-cabie 15
recommended for Ecta the eiectrode and work cables.
Table 3-1. Welding Cable Sizes
WELDINGL TOTAL LENGTH OF CABLE { COPPER! IN WELD CIRCUIT
AMPERESÍ *SO_| 100 | 150 | 200 { 250 | 300 | 350 | 400
100 | 4 4 | 4 3 | 2 + | wo fro
150 3 3 2 1 1/0 >
200 2 2, 1 1/0
250 | 1 1 {10
. | А-002 202
NOTE: “A. 50 FEET OR LESS,
"В. CABLE SIZE IS BASED ON DIRECT CURRENT (DCI,
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
. DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP,
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (Ocv) OF THE WELDING GENERATOR MUST BE
USED, WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100
VOLTS, SOME WELDING GENERATORS OF SPECIAL
DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE.
B. Jack Plug Installation
The supplied red jack plugs are to be connected to the weld
cables in order to facilitate connection to the weld output
receptacles. Connect the red jack plugs to the electrode cable
and the work clamp cables as follows:
10.
11.
13.
A GD
5 =
с бе
о БВ o
E 20 7
E
Fi р
Figure 3-3. Jack Plug installation
Remove 3/4 inch of insulation from one end of each
welding cable.
TA-901 024-4
Clamp the welding cable in a vice with the uninsulated
end protruding upward out of the vise approximately
1-3/4 inches.
Place the steel tie wire (See Item A Figure 3-3)
approximately 1/4 inch from the end of the insuia-
tion.
Make a hatf turn around the cable bringing the iooped
ends of the tie wire together.
Insert a. rod of approximately 3/6 inch diameter
through the two looped ends of the tie wire.
Twist the tie wire (8) until the entire tie wire is
twisted and is tight around the insulation of the
welding cable.
Clip off the iooped ends of the tie wire.
Bend the twisted tie wire over and along the side (CI
of the uninsulated portion of the weiding cable.
Wrap the strip of copper fail tightly around the
uninsulated end of the welding cable ang the twisted
tie wire (Dl.
Place the jack plug on the end of the welding cable
and push in onto the welding cable over the copper
foil (D).
Insert the t/4-20 set screws into the center and bot-
tom holes in the {ack plug ana tighten (El,
Remove the weiding cable from the vise and insert the
jack plug into the fiber sleeve. Slide the fiber steeve
over the iack piug and welding cable untii the hole in
the fiber sleeve lines wp with the remaining hole in the
jack piug.
insert the 8-32 self tapping screw (F) through the hole
in the fiber sleeve into the jack piug. Tighter the ecrew
with a screw driver,
34.
41.
SATTERY CABLE CONNECTIONS
This welding génerator comes equipped with cranking battery
terminal studs. Lead wires no smailer than No. 6 copper lor
No. 4 aiuminum) should be run from the terminal studs to —.
the 12 volts vehicle battery. ;
See the Engine Manufacturer's manual for complete
| engine care. ] —
4-2.
- LUBRICATION
This engine vas shipped frem the factory with the crankcase
filled with the correct amount and type of break-in oil unless
otherwise ordered. Check the oil level before attempting to
operate the engine, It should be up to the full mark on the
bayonet type indicator. Add a quality brand of detergent oil
if the oi! level is low. See the oil selection chart (Table 9-1) in
Section 9).
IMPORTANT
New engines have very close clearance between the
moving parts. Thus, it is recommended that loading of
the engine be kept to a minimum during the first 10
hours of operation. Be sure to check the oil level
several times each day during the éngine break-in
period. This engine requires about 10 hours of running
I time before becoming fully broken in. q
KEEP CIL |
AT THIS LEVEL ee ete FULL
|
.
NEVER OPERATE |
ENGINE WITH OIL |i
BELOW THIS LEVEL ——-------- LOW
| TA-900 435-8
Figure 4-1. Oi Level Indicator
Fine Amparage
Selector Receptacles
The 12 volts crane battery may be used for cranking,
but we recommend using the vehicle battery for crank-
| ing.
—— SECTION 4 - ENGINE PREPARATION memes
After about 10 hours of running time, drain the break-in oil.
See the oil selection chart (Table 9-1) in Section 9 for correct
oil type and grade to use after the break-in oii is drained.
FUEL
IMPORTANT
Do not mix cil with the gasoline,
Ler————ssm———
Use a good grade of “regular” gasoline, rated at least at 85
octane, for this engine. Fuels of lower octane ratings may
cause detonations (knocking) which could result in damage
to the engine bearings and head gasket. The fuel capacity of
the fuel tank is 3.8 gallons (U.S, Weasurel,
Never allow the fuel to drain on tke engine, the
generator, or other components, Arrange provisions
for catching the fuel when being drained and if the
tank must be drained frequently, install a valve and
drain line in the tank. When filling the fuel tank, do
not fill completeiy full. The reason being thar che cold
fuei will expand due to engine hear and the outside air
when operating in à warm climate. H the tank is too
full, it wiil overflow causing a potential fire hazard.
Also, do not attempt to НИ the fuel tank with the
L engine running, always shut the engine down first. ]
AIR CLEANER
This engine is equipned with a replaceable dry slement type
air cieaner. The air cleaner requires no initial service.
SECTION 5 - FUNCTION OF GENERATOR CONTROLS msn
Fine Amperage Jack Plug
Coarse
Amperage
Selector - —
: Receptacies
e
Coarse ;
Amperage
Jack Plug
= 120 Volts AC
Duplex
Receptacle
Weld / Power
— Switch
———| 20 Volts AC
Circuit
3reaker
-— A re.
Е 115 мон; OC
rReceptacie
DC Negative Charge
Recentacie
DC Positive Charge
Receptacie
Figure 5-1.
oc Negative weld
Receptacle
Fine Amperage Control
DC Positive Weld
Receptacle
TE-990 004-44
Generator Controi Panel
FAA Aa Las! -
DN rudo -
51.
Page 8
AMPERAGE SELECTOR JACK PLUGS & RECEP-
TACLES (Figure 5-1)
Through use of the three COARSE AMPERAGE selector
receptacles, the five FINE AMPERAGE selector receptacies,
and the coarse and fine amperage jack piugs, fifteen different |
dc amperage settings can be obtained. Amperage range selec-
tion is made by placing the ¢oarse amperage jack plug into
the desired COARSE AMPERAGE selector receptacie and
the fine amperage jack piug into the desired FINE
AMPERAGE selector receptacie.
Amperage range selections can be determined through use of
the amperage scale on the nameplate. The amperage range
desired can be selected by reading the amperage scale
immediately to the right of the COARSE AMPERAGE seiec-
tor receptacle to be used and down from the FINE
AMPERAGE selector recepiacie to be used.
If the unit is to be used for battery charging, it is recom.
mended that the coarse and fine amperage jack plugs be posi-
tioned as follows:
Coarse Plug Fine Plug
12 Volts Battery — LO Receptacle — 55 Receptacle
24 Volts Battery — MED Receptacle — 115 Receptacie
36 Volts Battery — HI Receptacie — 200 Receptacle
FINE AMPERAGE CONTROL {Figure 5-1}
The FINE AMPERAGE control permits selection of the
axact weld current desired within the range being used. As
the FINE AMPERAGE control is rotated in a clockwise
direction, weld current will increase. When the FINE
AMPERAGE contrat is set ar the 100 [full clockwise} posi-
tion, the amperage which is indicated on the паптер!ате for
the range in use will be obtained.
Better weld characteristics are obtained by selecting
the next lower amperage range than desired, and then
rotating the FINE AMPERAGE control clockwise
1 until the desired weld is obtained. y
The scale which surrounds the FINE AMPERAGE control ís
calibrated in increments of ten from 0 to 100 percent. Due to
this percentage calibration, it should be noted that if the
operator is using this scale to select a fine amperage setting,
the operator :5 selecting a percentage of the coarse range In
use and not an actual amperage vaiue.
The FINE AMPERAGE control must Se ser at the 100
| position when utilizing the 120 VOLTS AC receptacle. 1
120 VOLTS AC DUPLEX RECEPTACLE (Figure
The duslex 120 VOLTS AC receptacle, located on thé front
control panet, will provide 15 amperes of 120 volts 60 hertz
power from each haif of the receptacie. Whenever thrs recep-
tacie is to be used, the engine must be operating at power
rom, the WELD/POWER switch must be in the POWER posi-
tion and the FINE AMPERAGE control must be set ar TOO.
120 Voits AC Receptacle Circuit Breaker
The 120 volts ac circuitry is protected from damage due to
axcess.ve overioad by a 30 ampere CIRCUIT BREAKER.
Should an excessive amount of current be drawn from the
120 VOLTS AC receptacie, the circuit breaker will open and
thereby suspend any further output from the 120 VOLTS
AC receptacle. To reset the CIRCUIT BREAKER. manually
dep: 255 the CIRCUIT BREAKER button.
115 VOLTS DC RECEPTACLE (Figure 5-1)
A two-Dole. three-wire receptacie, labeted 115 VOLTS DC. is
provided on the front panei то serve as a junction point for
connecting accessory =quipment which regurres 715 volts de
alectrical gower. The cated cuipul of the 115 VOLTS DC
5-5.
5-6.
Charge/ Weld
receptacle is 1 kva. The engine must be operating, at weid/
charge rpm whenever this receptacie is used.
WELD/POWER SWITCH (Figure 5-1)
A two position switch, labeled WELD/POWER, is provided
on the front panel for selecting weld/charge current output
ог power plant output. In order for the welding generator to
operate, the WELD/POWER switch must be in the WELD
position when the engine 1s operating at weld/charge rpm and
in the POWER position when the engine is operating at
power rpm. If it is desired to change from weid/charge opera-
tion to power plant operation or vice versa while the engine is
operating, observe the following procedures:
From Power Plant Operation To Weld/
peration
Changin
Charge
1. Turn off all equipment connected to the welding genera-
tor.
2. Place the WELD/POWER switch in the WELD position.
3. Place the THROTTLE control in the WELD/CHARGE
position. -
4. Make connections co the weld output receptacles.
Changing From Weld Operation To Power Plant
Operation
1. Break the arc and disconnect the welding cables from the
weiding generator.
2. Place the THROTTLE contrat in the POWER position.
3. Place the WELD/POWER switch in the POWER position.
4, Make connections to the 120 VOLTS AC dupiex recep-
tacie.
BATTERY CHARGE CUT OFF (Figure 5-2)
Automatic battery charge cut off is dusir into the charge
controf of this welding zenerator. Provisions are made for
automatic ‘control of charging current for the standard bat-
tery voltages, namely 12, 24, and 36 volts. Three terminals
anda selector lead are provided for selecting any of the above
ranges.
The selector lead shouid be placed on the proper terminal,
e., the same as the nominal voltage of battery to be charged.
This will permit the automatic charge cut off circuit to func-
tion properly on either 12, 24, or 36 volts battery systems.
Six volts batteries may be charged with this generator but no
automatic charge cut off is provided. For a 6 voir battery use
the same charge connections as for the 12 voit battery: The
generator likewise May be used to charge batteries of voitages
higher than 36 volts burt, if this is done the charge circuit
should be taken directly from the WELD terminals, and the
CHARGE/WELD switch in the WELD position. No auto-
matic charge cut off is provided when the welding generator
is operated in the above mode.
Selector
Switch
1
1
€ 4
АА
ELENA
12 Volts | : |
| Terminal | == a === |
24 Volts E E НИ
ei 726 80 $ g-—= = o
LA ge |
Battery Voltage = - I
Setector Lead
36 Valts Terminal TC-000 704
Figure 5-2. Battery Charging Panel And Charge/Weid
Selector Switch
5-7, CHARGE/WELD SWITCH (Figure 5-2)
On the tower portion of the left side pane! is a selector switch
labeied CHARGE/WELD. When using the generator as a
welding unit, be sure the selector switch is placed in the
WELD position. When the generator is used as a battery
charging generator the selector switch must be placed in the
. CHARGE position. | -
IMPORTANT
£0 not.change the position of CHARGE/WELD selec-
tor switch under lgad. Arcing caused by changing the |
switch when carrying high current wil severely burn’
the contact surfaces of the switch. This buming of the
contact surfaces will decrease the maximum current
carrying capacity of the switch and possibly cause it to
1 become inoperative, J
5-8. VOLT-AMPERE CURVES (Figure 4-3)
The volt-ampere curves show the output voltage and current
of the welding generator available at any point from the mini-
mum to maximum of each coarse current range.
SECTION 6- FUNCTION OF
62.
Throttie
control
a
VILLE -
7
| ME
| Pd
Bee va
EA
Starter swires-—— A. í
Choke Controt — 2
Figure 6-1. Engine Controls
6-3.
>
TB-900 468-10
6-1. CHOKE CONTROL (Figure 6-1}
A CHCKE contro! is provided for varying the fuel-air mixture
to the engine. When the CHOKE controt is pulied futly out,
very little air will be admitted to the engine thru the car-
buretor thereby supplying a richer mixture of fuel. This
position is required if the engine is cold when started. As the
engine warms up it wiil be necessary to push the CHOKE
control inward slowly until it is pushed in as far as it wiil go.
When tha CHOKE control is fully in, the engine should be
ready for operation.
Never operate the unit with the side panels removed.
1 the sides are removed, a hazard exists to personnel
from moving and electrical components. Also, weather
protection to the internal components of the unit will
i be greatly reduced. 1
7-1. STARTING THE ENGINE
IMPORTANT
Make sure al! electrical equipment connected to the
120 VOLTS AC receptacles is turned off before start-
ng the engine. The engine, when starting, has iow
speed which causes low voltage at The output receo-
tacle of the generator, This could result in damage to
] gigerrical equipment. | y
+
Load voltage is predetermined to a large extent by the arc
characteristics. With the use of the voit-ampere curves it is
possible to determine what the weld current will be at a
particular arc voitage. The voit-ampere curves show the mini-
mum and maximum curves of each coarse current range.
80
un
o
DE VOLTS
a
o
>
a
150
200
DC AMPERES
250 306 350 400
B-002 894
Figure 5-3. Volt-Ampere Curves
ENGINE CONTROLS
THROTTLE CONTROL (Figure 6-1)
The selection of weldicharge, power, or idle rpm is made by
adjustment of the THROTTLE control.
To operate the engine at weld/charge rpm, push the
THROTTLE control fully over to the left. Placing the
THROTTLE controf in the notch in the center of the throttle
bracket will provide power rpm. Idie rpm is obtained by
moving the THROTTLE control into the notch on the ex-
treme right.
STARTER SWITCH (Figure 6-1)
The STARTER awitch, iocated on the engine blower housing,
provides the foilowing three funcrions: |
Off Position
The OFF position removes voltage from thé engine electrical
system. The STARTER switch is to be in this position when
the engine is not running or far stopping the engine.
Run Position
Whenever the engine has started and is ¢perating, the
STARTER switch must be in the RUN position. The START.
ER switch is spring-loaded to return to the RUN position
automatically from the START position.
Start Position
The START position will actuate the engine starter and
thereby start the engine.
1. Fill the fuel tank arg check to ensure that oil level is
adequate.
2 Pull the CHOKE control fully our. Lesser degrees of
choking may be required if the engine is warm.
3. Place the THROTTLE control in the IDLE position.
4. Place the WELD/PCWER switch in the POWER position.
5. Place the STARTER switch in the START position.
6. Once the engine has started, release the STARTER switch
to the RUN position and slowly push The CHOKE contro:
inward.
7. Allow the éngine to run for à few minutes Before appiying
a ‘nad. This is necessarv to a2nabig the engine to Droper:y
warm up and ensure droper lubrication.
3. HH ro angina 12 TO be operated at POWER rpm, piace the
THROTTLE control in the POWER position.
OM-4185 Page 9
9. If the engine is to be operated at weld/charge rpm, place
the WELD/POWER switch in the WELD position and
then place the THROTTLE control in the WELD/
CHARGE position. |
7-2. STOPPING THE ENGINE
1. ‘Remove the weld and/or power load from the welding
generator.
2. Place the THROTTLE control in the IDLE position. 7-3.
Operate the engine at this rpm for 2 minutes; this will
allow internal engine temperature 10 equalize.
3. Place the STARTER switch in the OFF position.
7-3. SHIELDED METAL-ARC WELDING (Figure 7-1)
1. Prepare the engine for operation as instructed in
Section 4,
2. Connect the weid cables to the de wetd output recep-
tacies. N
3. Place the coarse and fine amperage jack plugs into the
desired COARSE and FINE AMPERAGE selector
receptacies.
4. Rotate the FINE AMPERAGE control 10 the desired
setting.
5. Place the WELD/POWER switch in the POWER pasi-
tion. -
6. Place the CHARGE/WELD switch in the WELD posi-
tion.
7. Start the engine as instructed in Section 7-1.
8. Place the WELD/POWER switch in the WELD posi-
tion.
9. Place the THROTTLE control in the WEL D/CHARGE
position.
CAUTION: \
Prior to weiding, it is imperative that proper protective
ciothing {welding coat and gloves) and eye protection
{glasses and/or welding helmet) be put on. Failure to
compiy may result in serious and even permanent
{ bodily damage. я 1
10. Connect the work ciamp to the object to be welded,
piace the desired electrode into the electrode halder,
and commence welding. -
The wed output connections shown in Figure 7-1
are for dc reverse nolartty.
T®-920 004-5A
Figure 7-1. DC Welding Connections
7-4. POWER PLANT OPERATION
1. Prepare tha engine for operation as instructed in Section
+.
7 маке cancections ta sme 120 VOLTS AC duplex reced-
Rotate the FINE AMPERAGE control fully clockwise.
Place the WELD/POWER switch in the POWER position.
‘Start the engine as instructed in Section 7-1,
о п ен
Place the THROTTLE control in the POWER position,
7. Turn on the auxiliary equipment and commence opera-
tion.
BATTERY CHARGING CPERATION
1. Prepare the engine for operation as instructed in Section
4.
2. Connect the battery voltage selector lead on the battery
charge panet, Figure 5-2, to the battery voltage selection
terminal which corresponds to the voltage of the battery
to be charged. {See Section 5-6).
3. Connect a copper cable, na less than 2/0 size, between the
DC CHARGE NEGATIVE receptacie and the negative -
side of the hattery to be charged.
4. Connect a copper cable, no less than 2/0 size, between the
OC CHARGE POSITIVE receptacie and the positive sige
of the battery to be charged.
5. Place the coarse and fine amperage jack plugs into the
recommended COARSE and FINE AMPERAGE Seiector
receptacles for the size battery to be charged as shown.
Coarse Plug Fine Plug
12 Volts Battery = LO Receptacle — 55 Receptacie
24 Volts Bartery — MED Receptacie — 115 Recepracie
36 Voits Battery ~ Hl Receptacle — 200 Receptacie
If the charging current begins to puisate on ang off, |
select a lower Current by either piacing the jack plugs
to a-lower range or decrease the setting of the FINE
| AMPERAGE control. 1
If the charging current cycias off and on, while the battery is
under charge and with light or ne load being drawn from the
battery, the charge rate is too high for the battery involved.
This may be due to the battery being retativeiy smalit ta size,
low etectrolyte, sulfation due to iong standing of under-
charge, or poor or imadeguate electrical connections between
load and battery. Shouid such short cycling occur, carefully
check for possible faulty conditions indicated above and take
corrective measures as necessary. If the probtem continues,
the charge rate should be reduced. In general, the charge rate
should never exceed, in amperes, the ampere value of the
ampere/heur rating of the battery. For example, If the bat
tery is rated at 150 ampererhours, do not exceed a charge
rate of 150 amoeres. This generator has adequate capability
to handie heavy Continuous |oads with the battery meralv
anerating as a voltage siabilizer in the circuit. For longer
battery life, it is suggested that charge rates be ‘imiteg to the
lowest value that will give satisfactory operation. -
6. Place the WEL O/POWER switch in the WELD position.
Start the enarne 3s instructad in Section 7-?.
~1
8. Place the CHARGE/WELD
CHARGE position.
lector swtiten Im ne
J. Place the THROTTLE controi in tne WELD/CHARGE
position.
Never ZJisconnect the charging circuit while liie waigd-
:ng Generator 15 operating. SAut down the 2ng'ne das
described :n Section 7-2 before disconnecung the
charging circuit. a
неее SECTION 8 - GENERATOR MAINTENANCE ==
ae NLS | 8-2.. COLLECTOR RING BRUSHES
If any work is to be done on the rotor of the genera-
tor, remove the spark piugs from the engine. This wilt
prevent engine compression from. turning the rotor”
rand catching the repairperson's hand between the -
The brushes should be inspected periodicasily to ensure their
groper function. The brush life is very good under normal
conditions. If the generator has been operating in an
extremely dusty or dirty location, a close check of the
brushes for freedom of movement and cleantiness should be
rotor fan casting and the stationary adapter casting. -
- ' rings will discolor to a dark brown. if it shouid become
battery. 7
Ea; . necessary to clean the slip rings or commutator, use a 3/0 or
finer sandpaper followed by a crocus cloth. Never usé emery
8-1 GENERAL Cloth as part of the emery will embed itself into the exciter
ar collector rings and in turn destroy the carbon brushes,
Economical operation and trouble-free service of this welding Toe .
generator are based upen reqular inspections and reasonable '
attention. 3-3. WELDING CABLES
Qceasional blowing our of the unit with clean, dry com- Check connections periodicaily for tightness. The cabies
pressed air is recommended. This should be performed should be inspected frequently and all breaks in the insula
periodicaily, depending upon the location of the unit and the sion should be repaired with electrical insulating tape or the
amount of dust and dirt in the atmosphere. cables replaced. |
SECTION 9 - ENGINE MAINTENA NCE =eee——————————
9-1. LUBRICATION
IMPORTANT
This engine wiil require at least 10 hours of running time to
become fully broken in. During this period, the load on the
engine should be kept as light as possible. The ait level shouid Do not attempt to clean the spark plug electrode by
he checked a number-of times during an operating day, as sandblasting. Particles of abrasive may stick to the
some engines will use oii during the break-in period. After spark plug ang thereby enter the engine and cause
about 10 hours of running time on the break-in oil, drain the damage to the internal engine components. Also, the
cil. Premium heavy duty oil, manufactured by any one of the | spark piug gap shoufd be kept at 025",
major oil companies, should be used as a repiacement oil. Lara °
Table 9-1 gives a list of recommended grades of oil to use to
keep oil level up during break-in and to use after the break-in
oii is drained. The oil capacity of the engine is 3-1/2 quarts. 9-4, FUEL FILTER
Check the dip stick to make sure Oil level is up to the re- '
quired operating ievel. The fuel filter is located below the fuel tank. Check the
_ . . sedement bowl periodically for water and dirt deposits. How
Table 9-1. Recommended Engine Oil often the filter has to be checked will depend on the grade of
gasoline used and how dusty and dirty the location in which
LOWEST TEMPERATURE AT SAE NO. the angine Is being used,
THE ENGINE Olt |
Above GOOF (320C) for Continuous Duty No. 50 . D RVIC
300F (- 190! to 909F [37200] No. 30 95. PERIODICSE Е
OOF 1-189C! ta SO9F 1- 10C) No. 10W - The efficiency of the engine depends a great deal on the care
Below OOF (18°C) ; | No, ZW and atrention given it. By following a definite scheduie of
inspection and service, engine faliure caused by negtect 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 efren.
in normal operation, oil should be .changed after about 50
hours of operation, The oil shouid be drained after the engine
has been warmed up to normal operating temperature, thus
promoting foreign particle suspension in the oil and thereby
removal! when the oil is drained. Foreign particles tend to
settle at the bottom of the crankease when the oil is allowed
to cool, thereby avoiding removai and thus contaminating the ,
new oi! added.
Table 9-2. Periodic Engine Maintenance Chart
RATIONAL H
9-2. CLEANING THE ENGINE MAINTENANCE [TEMS 50 | 100 | 200
2 . | Plant
This air-cooled engine operates most efficiently when kept
clean. Maintain cleanliness at all times. Wipe oil spills from K via
engine immediately to avoid accumulation of dust. k Oil Level
k Air Cleaner
9.3. SPARK PLUGS Clean mor Lin
, Check rk q
The area around the base of the spark piugs should be ankcase Oil.
cieaned prior to removal of the spark plugs to help avoid dirt нее
getting into the angine. an ran Le
| an Fuel System
Remove the piugs pertodically and clean the electrode with a gttery
wire brush or knife biade. Take care so as not to crack the |
рогсе!аип insulator on the spark pluas, x 1 - Perform more often in extremely dusty conditions.
—l ue — SECTION 10- GENERATOR TROUBLESHOOTING cum
The data coilected nere, discusses some of the common grobiems which may occur in this welding generator,
The assumption of this data is that a proper welding and/or power condition has been achieved and has been used until trouble developed. In ail
cases of 2quioment malfuncrion, the manufacturers recommendations shouid be strictiy aghered to and foltowed.
¡f after performing the fotllavine procedures the trouble is still not remedied, :T 15 recommended that a serviceperson de calied.
ly ig recommended that the circuit diagram be used for reference during the trousleshooting.
OM-418 Page 11
TROUBLE PROBABLE CAUSE : - REMEDY
No 115 volts dc output RC1. page lead in 175 vdc circuitrÿ | Ensure all leads are secure.
Low weld output. Engine speed is iow, Adjust engine speed to 3000 rom (no load speed), If engine
| rom drops below 2600, engine servicing is indicated. Place
THROTTLE controt in WELD position.
Erratic weld current, Damp or detective electrodes. Use new dry electrodes.
Work or electrode connections Secure connections.
loose.
Jack plugs loose in receptacles. Secure ack plugs.
Jack piugs 101 in COrracl racap- Connect jack plugs to correct receptacle.
racle for electrode in use.
No output from the 120 VOLTS CIRCUIT BREAKER CB1 open. | Reset CB1 by depressing CIRCUIT 8REAKER bution on
AC receptacle RC2. front panel.
No battery charging cutoff, Qil pressure switch S3 defective. | Replace 83. {S3 is located behind the panel on the left side of
the engine.)
Low output from 120 VOLTS AC Fuse F1 open. Replace fuse F1. (Fuse F1 is located behind the generator
receptacle RC2. | right side panel.)
—Á E CTION 11- ENGINE TROUBLESHOCTING =============—=——Ñ=ÑÑZsAsa
[FAILURE TO START!
]
CARBURETION [COMPRESSION]
[Mechanical |
Poar grade Restricted air cleaner. Plugs wet Breaker points pitted Cylinders dry
of fuel Fuel pump diaphragm or dirty ar fused Sticking valve
Water Choke Condensation Spark plug insulation bad Loose or broken spark plugs
in fuel Flooded on electrodes Breaker arm sticking Cylinder head gasket teakirig
Gum Dirt or qum holding Weak battery Improper timing Piston rings stuck
in fuel float needle valve Broken ignition cables Warped or broken valves
Dirt Damaged HS needle valve ignition cables .
in fuel Fuel line clogged disconnected
Improper Air vent, filter cap plugged
volatility Manifold gasket leak.
No fuel Muffler ctogged
[MAIN BEARINGS] [BREAKER POINTS|
| J
Clean crankcase
breather valve
Breather valve installed
upside down
{See Engine Manufacturer's
Manual.)
KNOCKING
CARBURETION MECHANICAL | IGNITION
j
Poor grade of fuel Heavy load at siow speed Breaker points
Octane rating to low{ | Carbon or lead deposits in — too far advanced
cylinder head
1 case connecting rod
Loose main bearings
8utned cut connecting rod
Worn ar loose piston pin
Worn ог loose timing gears
improper piston fit :
V'aive lash too great
Valves sticking
8-005 412
Figure 11-1. Engine Troubieshooting Chart
Page 12
CARBURETION.
COMPRESSION
|
==
Weter in fuel
Gum in fuel
improper neadls valve
Improper carburetor
Dirty fuel system
Improper fuel mixture
Inoperative fuel pump
(Dirt or mechanical)
Ar leaks in system
Defective float mechanism
inoperative choke control
Vapor lock
CARBURETION
Scored cylinders
Improper valve lash
Sticking vaives
Piston tings stuck
Sand hole in casting
Loose or broken spark plugs |
Cylinder head gasket leaking
Warped or broken valves
Valve springs weak or broken
Improper heat range in plug
Loose plug
Poor insulation on plug
Spark plug gap incorrect
Worn and leaking ignition cables
Weak spark
Loose electrical connections
Breaker points pitted.or worn
Breaker points sticking
improper tension of breaker point
— spring
. improper breaker point gap
Bad condenser -
Weak cotl
Worn out plugs
Defective ignition switch
Grounding of ignition accessories
Moisture |
Defective distributor cap
OVERHEATING
LUBRICATION
Low grade of fuel
Engine operated while
detonating, due to
low octane fuel or
heavy load
Improper carburetor
setting
Plugged air filter
Leak in intake system
Oii supply low
Dirty or incorrect
grade of oil
Plugged iubrrcating A
system |
Bad oi pump
Worn parts in
lubricating system
SURGING
Engine overioaded Timing
Carbon deposits in incorrect].
engine
Restricted exhaust
Choke control partially
putled out
Valves leaking
Restricted air cleaner
Recirculation of hot air
Improper break in
CARBURETION |
|
GOVERNOR
Carburetor flooding
Improper adjustment
Intake leaks
Sticky contrels
[mproper lubrication
[ELECTRICAL (Under Load) |
|
Dirty or ioose
battery connections
Amperage setting
15 too high
Figure 11.1. Engine Troubleshooting Chart {Cont'd)
B-00S 412
А
BOWER |= =m — — = 3 an
gnFET#_, THMOTTLÉ 1 ATTE € "
BITs STA - __ -
1 HIE
Ava TIC "ra 1
1
{
TOTAL TIME MÜTTERN — ==
CHT ONAL
В ACTUATED Ie § Fu PET
nado POSITION AC ' | Mn
= = == == = == = == = = = = - DC POWER = Ca Y 7
Le I + ;- == 1
TA 1 Y Ix | — +
anse N 1 :
J уе | =
г o amy I | 7 { N
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1 1 Pe PT he | Het
| x
ола A ; 1 ` жа =, ABE
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a 11 | 23
2d ji 1 es
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. mete TA k Ay ACES WMER AECL RED TO
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GENERATOR
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TERMI MALY
Figure 11-1. Circuit Diagram
= = он == == == «=
METER
=
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$ & Бом
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January 1976 FORM: OM-413B
Effective with Serial No. HF870501
- MODEL STOCK NO
. CW-200LE 990 004
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MODEL/STOCK NO, SERIAL/STYLE NO. DATE PURCHASED
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CM-478 Page 1
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
“Figure A Main Assembly
1 035 141 WHRAPPER.........e.crreererera va ndenreoreocerrerverarrenroevecerarereca. 1
2 015670 TANK, fuel (consisting of) ....02242400 2221 464 a 0 ae as ea a 0e 1e 5 00 60 010 aa 000 0 1
3 015 721 .CAP, fuel tank ............—.—..........emsxreedrerecrcranacasa ra rereverro 1
4 014 951 STRAP, mounting - fuel tank 1.220124 4141014 06 0 1 a a a ee ea ee ea ea ea as ee en T6 2
5 602 898 NIPPLE, brass-pipeclose 1/8 MPT ........isenrescareroamadaCerame ner. 1
6 015602 FILTER fuel...........e.eerserrorererrerecreneaaaraernararacaneamoana, 1
7 010 731 NIPPLE, brass - pipe 1/4 hase shank 1/4 MPT LL... iii aa au a a a en aa nan» 1
8 603 124 STRIP, rubber - firewall (4 feet req'd - order by foot) .............. coin но 4 ft.
9 035471 BAFFLE, air ........e.. tt ti te tit tt mate eee a eae ae ее 1
10 015712 GROMMET, rubber 5/8 {Dx 7/8 hole x 1/16 groove ........... cc... 1
11 010610 CONNECTOR, clamp -cabie 1/2... iii ii ii 6 4 ee a 0 ea 0 ee a a ee 0e 0 0 0 1
12 ‘AC-Z 035434 REACTOR oii i te aaa ae 1
13 038 532 ENGINE, gas - electric start (consisting of)... coir на о 1
14 010865 .CLAMP, hose 13/32 to 7/16 clamp dia ......._.o_e-e-esesarerereracerrerermes 2
15 603 106 . HOSE, braided 1/4 ID x 1 (11 inches red'd - order by foot! .......... oot. 1 ft.
16 605 802 .MUFFLER, exhaust .........—.. e .madaraearerenereverotrrrronaraerernes, 2
17 602 945 . NIPPLE, galvanized 1 MPT x 4 inches lg ........ oii, 2
18 019603 . KNOB, ball ......02220010 210022211244 44 44 44 ea a 0 0 ea ee a ea a as ea ea ee eee 0 1
19 016561 COVER, switch - limit ........o_.e.eroearrererero0neeraree ce cancnerenma—. 1
20 82 027 878 SWITCH, limit SPDT .............02x2222eredvarecrvraracaorerene vero. 1
53 011 917 . SWITCH, pressure 2 pole normally open ‚RR 1
005 498 . NIPPLE, galvanized 1/2 NPT x 4 inches (vil draini —.,.......e__—-—_—esreerecorere. 1
005 499 . CAP, galvanized pipe 1/2 NPT (oil drain} ..... . a NR RR RER Le 1.
026 239 .MANIFOLD, intake - engine KA 1
063205 GASKET, manifold ..... ie 4
015 708 SPACER, manifold ........ KRKKEEKEFAEE TEE EH 2
21 601 976 SCREW, cap -steel hex hd 1/2-13 x 1-1/2 1... 22141440 4e 410 14000 0e aa 181 01046 4
22 602 246 WASHER, flat - steel standard 172.1... 2224 04 42 412 14 21 4 ea ea ae eue a ea ae ee 106 5
23 Figure 8 GENERATOR ASSEMBLY {(SeePaged) .. .... iii, 1
24 601 993 SCREW, cap - steel hex hd 1/2-13 x 2-1/2 . oo i ieee 1
25 502 217 WASHER, lock - steel external tooth 1/2 .........eeerecarnerarereanv eri. 1
26 020 359 SHIM endbell - foot 18 ga... «ivi iii i thie te eit tiara eee es ee As Req'd
26 103723 SHIM,endbell- foot 1/8 inch «LL. tee aa eae As Req'd
27 602 216 WASHER, lock - steel split 1/2 Lo i eee eee ео 5
28 D8 027 369 DIODE, 3 amp 600 volts straight polarity ..... iim ea 1
29 Ca 031670 CAPACITOR, ceramic 0.05 uf B00 volts dC... LL Li ii i ee ee ieee eae eas 1
30 601 880 NUT, steel - hex jam 172-13 tt it tet eee erates 5
31 DC-Z 035429 STABILIZER 2.212012 41144 eee ete ee ee ee eee 1
32 601 837 NUT, brass - hex jam 3/8-16 ..............00s000r0rearescereatenenreree ree. 3
602 227 WASHER, iock -steel internal tooth 3/8... Lo. eae 2
010910 WASHER, flat - steel SAE 3/8 ...... 2 ssererererirreeraararereamerrierdare 2
020 326 BUSHING, shoulder 7/16 ID x 1 CD x 1/4 e. .a2serecareredararereem 1
010 291 WASHER, flat - nylafil 5/8 1D x 1-1/4 0D x 1/8... ......earresresare ener. 1
038 937 STUD, brass 3/8-16 x 2 .....,.. RR R RR RR a ae a 0 1
33 54 038 524 SWITCH, weld/change (See Fig. C Page B) ..... iii, 1
24 038573 BASE tt ee aa 1
35 Figure E” PANEL, front - with components (See Page 8) ......... cia, 1
36 039608 PLUG, jack ~red {consisting ofl... ..e.errereee reee creer. 2
37 019833 . STRIP, copper 0.010 x 2-1/2 x 3/4 111111112414 4e a 4 a 4e eee ea ea ee rece. 1
38 010521 YT = i RR KR RK RR RR HK KK RK Er 1
39 B02 178 .SCREW, set - steel socket hd 1/4-20 x 3/8... ia 2
40 101 219 . PLUG, jack era AN DA 1
47 502 814 INSULATOR, jack plug - rad ooo ir oe re ee ee ei meee о 1
42 802160 . SCREW, seif tapping - fillister hd 8-32 x 1/4... 22.22 80r ete ia 1
43 005 402 CIRCUIT CARD ASSEMBLY, voltage sensing (See Fig. D Page B) ................ 1
44 010957 TUBING, steel 1/20D x 17 ga wail x 1-3/4 19... oii ннео о 2
49 035 135 PANEL, side - right hand 20000000 ee ee ]
46 038 571 PANEL.side -iefthand ... KK 7
47 019603 KNOB. Ball (Sa) 1.111011 1 LL LA A 4 4 4 4 44 4 ee LA 44 4e ae ea 4 ee Se a a ee ame 1
| BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-418 Page 2
hd
ТВ-004 509
Figure 8 — Generator Assembly
Fage Z
item Dia. Factory
No: ‘Mkgs. Part No. Description Quantity
Figure B Generator Assembiy (See Fig. A Page 2 [tem 23)
61 014376 QGUARD, fan- rotor ......._e.e.eeememrerare rene: Cee nea iaa 1
62 **035 167 ROTOR ASSEMBLY, generator {consisting of)... .. oo iin. 1
63 024 617 . RING, retaining-- external .. 1.202000 00 004 4e de ea ee a ae aa a ea ae sa ae ee 1
64 024 800 BEARING, ball RAR RK 0. na 4 ee 1 1e 0100 6 1
65 017 624 -. FAN, rotor ti et eee ie ett earnest ieee ia hea 1
602 348 KEY, 1/4x 1/4 x 3/4 1111104 14 2 4 4 4 4 14 414 4 4 4 a 4 4 4 ee ee a a ea a a 8500 Ii... 1
66 017618 ADAPTER, fan - rotor ............, Tae eee eee eae ees 1
67 017 702 ADAPTER, engine .........eceereeaoo. ee eran 1
68 010681 KEY, woodruff 1/4x 1 ..............—.——ressreerore ene. PS 1
69 010601 SCREW ASSEMBLY, adapter - fan (consisting of) .........e.e.eceeereccoraroc.. i
70 602226 . WASHER, flat - steel 7/16 ID x 2-1/4 OD x 3/16 ...12220 0000 a aa aa sas a ae se 00 1
71 502 215 .WASHER, lock : steel split 7/16 oo... titties tite assem ena 1
72 602 018 . SCREW, cap - steel socket hd 7/16-14 x 1-1/2... co iii i i ea a 1
73 . 036 137 BRACKET, mounting- fuse holder .. arca. RAS 1
74 012571 HOLDER, fuse - miniature ..........eceexdrrrrcorien—oeeaereneerecra a. 1
75 F1 *012 618 FUSE, miniature - glass 5 amp ..........oeeeescexereorocanearereve... nia 1
76 | 020779 BRACKET, mounting- brushholder ........._eeeeorecooaran—ecm_ecreovenarare—. 1
77 018614 BRUSH SET {consisting of}... ooo. ee 3
78 018665 CAP Le ee ee PT 1
79 600 270 BRUSHMOLDER ........,............. RS eee 1
80 *020 034 .8RUSH, contact 2.0.0000 e 0 fe eee area ee 1
81 **039100 STATOR ..........0emmeca.s ana noorocaarervarrnrodrra [a 1
82 020 908 ENDBELL, generator 2.00 eat teeta ca ae aaa 1
83 SR1 035 413 RECTIFIER, silicon diode (consistingof) .............. omit, 1
84 035 410 .ANGLE, meunting - rectifier .........eceeeevorrreioeteecana re RD 2
85 037 305 .DIODE, 150 amp 300 volts straight polarity .......—.ereenrresvereereserer. 2
86 (C58 031689 .CAPACITOR, ceramic 0.01 uf .......o_e.eeeerrvoo. aaa iaaoeon idear aro. 4
87 037 306 .DIODE, 150 amp 300 volts reverse polarity ...... _erec-eerrocoorertreacme.. 2
88 R2 030 726 .RESISTOR, WW fixed 5 watt TOCO ohm .........._—-eee0arrerrreraa rra. 1
89 VS1 024 471 .SUPPRESSOR, luf 2.70hM....24000 20000 4 0 a 0 a a a a eee 4 ee ee ae 2 ee 0 000 1,
90 SR4 039 123 RECTIFIER, silicon diode (consisting of) ........20220000 881244 040 a ae aa ee 020 1
91 SR2 035 704 . RECTIFIER, integrated 6 amp 600 voits........2002 000000124211 1 кк о i
92 VR 039122 . VARISTOR, 150 volts, ......22 44144441 12 0 4 a 4 a ea 8 84 a a a ee 1 ea 2 0 111200 8 1
93 D1-3 -037 572 . DIODE, 50 amp 400 volts straight polarity ...1...2204 0442124 4 0e a a ee a as 0 206 3
94 . 020847 .WASHER, shoulder - nylon 5/16 1D x 7/8 0D x 1/16 ............e—.e=.—.. ena 4
“Recommended Spare Parts |
**Rotor and Stator replacements are available on an exchange basis. Contact Factory Service Department for Details,
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN CREDERING REPLACEMENT PARTS.
OM-418 Page 4
item Dia. Factory
No.” Mkgs. Part No. Description Quantity
Figure C 038 524 Switch, Weld/Change (See Fig. A Page 2 [tem 33)
111 010805 HANDLE.......e.eremacare ra reariererearesxervaerrereacerararoranecon e a 1
112 601 849 NUT, steel - self locking - hex 1/4-20........ PA ree ieee 1
113 038 769 CONTACT BOARD ASSEMBLY, movable (consisting of) .........—-— e... E
114 011645 .CONTACT ASSEMBLY, movable - switch (consisting of) ..................ea... 1
115 011074 ..SPRING, pressure - contact .......... PE ee cee - 1
116 011075 .. SPRING, pressure - contact ............ ee rare. 1
117 011953 ..CONTACT, switch...... SES ee Pe 2
118 103 632 .PLATE, toggle - switch .......... A aayredi da oanoaoór aero 1
119 011948 GUIDE, contact - movable..........e.ec_eeerendosconmererenemereracrrara—a . 2
120 011 950 CONTACT, switoh....101 2000 2044 04 ea 4 a 0 8 4 4 4 ea a 0 a 4 4814 0 ааа аа неа неко 2
121 011 951 CONTACT, switch ........ ER eee err ee drena a 2.
122 010569 TUBING, steel 5/8 OD x 5/32 wall x 3/41g............0esmíesereamia ace ea. 2
123 LST 035967 SWITCH, limit 10 amp 125 volts ........... LL a A a a a ea aa a LL a a a aan ee 1
124 ; 3.214 0365680 MOUNTING BOARD .....2222 4400010000 AS 1
125 024 694 !BEARING ......i.. ecomxeonreonaserredarna LL LL LA 2 114 244 4 a 4 a 4 4 4 a 4 a a 1 12 a 2 2 0 7
Includes
Item 115
116
-121
124 2d € $ — 122
— 123
120
Figure C — Switch, Weld/Change
TB-004 511
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REFLACEMENT PARTS.
Page 5
Dia. Factory -
Mkgs.. Part No. Description ; Quantity
Figure D 005 402 Circuit Card Assembiy, Voltage Sensing (See Fig. A Page 2 item 43)
CS0 » 025 288 CAPACITOR, tantalum 15uf 85 voitsdc.......... ea eu 0 à 2 8 14 4 a 1 a 8 ua au au ua 5 -1
СБТ. 031 646 CAPACITOR, ceramic 0.007 uf 500 voitsde ...... on inva cine ее 1
C52 - 1031670 CAPACITOR, ceramic 0.04 uf 500 volts de (5 ва ОР $76 SOM LL an aan» 1
D50,54 026 202 DIODE, 1 amp 400 volts straight polarity .... 7 eee ee 4 a 0e ee a a a ea свое 2
D51 037 203 DIODE, zener 6.8 volts 1 watt .........2200400 004 am aa aa aa 0e aa sa 0 seu 0 aa 000000 1
D52 037 449 DIODE, zener 15 volts 1 watt 2.222000 0 400 480 1 een es 1 0 1 0 80 ea ea ee ee ea na 0200 1
DS3 030 529 DIODE, 12 amp 600 volts reverse polarity ......... LL LL La a aa 1 414 ae a ae es 0 ana. 1
D55 037450 DIODE, zener 10 volts 1 watt .......... Tee a a see a esse 0 PA 1
MCSO - 000042 REGULATOR, voltage - integrated 1S0MA 40 volts ......r__ere-—esressvervarernen.s 1
PC50 000041 TRANSISTOR, 100MA 25 volts ........._.eonrecradenoeatrteooraorererearo reee. 1
050 . 000040 TRANSISTOR, 5 amp 400 volts ........eeeeereveroovorcígerrrdere AAA AE 1
Q51 037278 TRANSISTOR, 4 amp 55 volts ........oeeeeeereoo DAS PS 1
R50,55 000034 RESISTOR, metal film 0.5 watt 2.2K ohm ......20 0000 0e 0e sas 0e nee ee a ae ea ren nee 0 2
R51 000035 RESISTOR, metal film 0.5 watt6.8K ohm... iii 1
R52 000 033 RESISTOR, metai film 0.5 watt 1.78K ohm ........ iii, 1
R53 000.031 RESISTOR, metal film 0.5 watt 866 ohm ....... 2 00800000 10e ee ee see 1 ea 11100000 1
R54,51 000032 RESISTOR, metal fitm 0.5 watt 1.5Kohm 1.222000 000100001000 000 enana. 2
R56 000 038 POTENTIOMETER, trimmer 25 turn 0.5 watt 2K onm .....2020-00000 00000 ee es 1000000 1
R57 . 028282 RESISTOR, carbon 0.5 watt 220 ohm .................... ee eee eas 1
R58 000039 RESISTOR, carbon 2 watt 680 ohm .........—.—eeeremveererecare PA 1
R5E9 000038 RESISTOR, metal film 0.5 watt 14K ohm ........!.eeoeerrsrracsrvervecnereecaroe. 1
R60 030025 RESISTOR, carbon 0.5 watt 100 ohm .....r..eéem_eonenmmenorere PT 1
R62 028 277 RESISTOR, carbon 0.5 watt 10K ohm .. LL. icra cea 1
R83 ‘ 000037 RESISTOR, WW fixed 10 watt 5K ohm ........eeeeesxerverrorreeasrroeresrerertó., 1
R64 030141 RESISTOR, WW fixed 100 watt 250 ohm..........e ces... RAA ana 1
RES 030706 RESISTOR, carbon 1 watt 330hm ... 77 7. AE RIEL eiii 1
— 000045 HARDWARE, mounting - resistor .:.....e-—eeeevereererer errr eae ears ces 1
003240 RAIL, mounting- circuit card o.oo. eet aaa 2
PCSO
| T8-004 510-A
Figure D — Circuit Card Assembly, Voltage Sensing
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Givi-418 Page 6
166 160 158 137 163 158 162 161
TD-004 508-A
Figure E — Panel, Front - With Components
Page 7
*Recommended Spare Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING R EPLACEMENT PARTS.
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure E Panel, Front - With Components (See Fig. A Page 2 ltem 35)
136 032 826 RECEPTACLE, jack plug - black (consistingof) ..................... 3
137 039 796 . NUT, terminal - black ........r-.—e-eerrerecirirerrerenmer A. | 1
138 010291 .WASHER, flat - nylafil 5/8 ID x 1-1/4 OD X 1/8 .. ........ cova... 1
139 604 668 . NUT, steel - self locking hex 1/2-20.. _—ee-.—e——ec_esererecrvoe. i
140 020015 .RECEPTACLE, jack plug ........... RE 1
141 501 881 . NUT, steel - hex jam 1/2-20 1.222020 0000 2e a ee a ea ea a sa a 00 3000000 1
142 035 958 PANEL, front .....02221210000 004 een a ea aa eee ea ee a a aa eee ee 0 . 1
143 039 801 RECEPTACLE, jack plug - black (consisting of) ............rex=aeeaoo 7
144 039 796 . NUT, terminal - DIack ....... iii iii iia mamaria 1
145 010291 .WASHER, flat - nylafii 5/8 1D x 1-1/4 OD x 1/8 ..........—.—e-—esoe—. 1
146 604 668 . NUT, steel - self locking hex 1/2-20..........—e _ec—errenmeorenecrooo 1
147 038198 . RECEPTACLE, jack plug .....22422020000 15004 ee 00 0 sa 0e 00 ee 00000 1
148 601 881 . NUT, steel - hex jam 1/2-20......2220 00050 ee 2 aa ae a ea 0411 5100000 1
149 51 052769 SWITCH, toggle 4PDT 15 amp 125 voits......22042 0001000000 a 0000 1
150 СВ! 012661 CIRCUIT BREAKER, manual reset 30 amp ........_e.eere-sevrrsvreco 1
151 RC2 039864 RECEPTACLE, duplex - grounded 2P3W..........—..—.— _2emeerrcrere 1
152 Ri “000101 RHEOSTAT, WW 50 watt 16 ohm ..... fe eee 1
153 039800 RECEPTACLE, jack plug - red (consisting of} ................... 0 2
154 601881 . NUT, steel - hex jam 1/2-20.......er-_cecesearvoneraneretteveter. 1
155 020015 . RECEPTACLE, jack plug .....eoe.eemmenvenavererereor rene. 1
156 604 668 . NUT, steel - self lockinghex 1/2-20 .. ... iii iii na 1
157 010291 .WASHER, flat - nytafit 5/8 ID x 1-1/4 0D x 1/8 .........er-.ereceoa 1
158 039 768 . NUT, terminal - red ........—_—-—e=erscosrvavesrearrrvorrrererme,. i
159 028839 RESISTOR, WW adj 100 watt 10 ohm La nana sea ee ce ane 0000 1
160 010325 BUSHING, strain reliet 7/8 x .840 hole ee 2
161 NAMEPLATE (order by stock, model, and sertal numbers) ............. 1
162 RC1 034952 RECEPTACLE, straight 3P3W snapin,.....ee_.e_eeoererenoresmeeneo 1
163 024 366 KNOB, pointer (RI) ,.....e.eeeereorcareamrace e. Le a aa eee ee 0 1
164 035 531 CABLE & PLUG, jack {consisting of) .....-..0400000 000000 nana 0006 1
165 602 178 . SCREW, set - steel socket hd 1/4-20x 3/8... inva. 2
166 600 319 .CABLE, weld No. 2 (14 inches req’d- order by foot) ................ | 2 ft.
167 019833 .STRIP, copper 0.010 x 2-1/2 x 3/4 ..........eeseredrvrcernarerne. 1
168 010219 .PLUG, jack ......._._eseosrvrecocerrredemerarerra Arrracae 1
169 602814 ‚INSULATOR, jack plug-red .........000000 00000000 HERREN 1
170 602 160 .SCREW, self tapping - fillister hd B-32X 1/4 21.210001 00000 ea ee 0000 1
171 035 532 CABLE €: PLUG, jack (consisting af) ..........eeeerrercrrrecnrer. 1
172 600 319 . CABLE, weld No. 2 (18 inches req'd - order by foot) ................ 2 ft.
173 019833 .STRIP, copper 0.010x 2-1/2 x 3/4 . iii iii e 000 1
174 101219 PLUG, jack « « «we ee eee ee eee eee ee ee oe eae ee eee ne 1
175 601 178 . SCREW, set - steel socket hd 1/4-20 x 3/8... ....e.rec-sxrerarer. 2
176 602 814 .INSULATOR, jack plug -red........—-—_—-—essescserererrr testar. 1
177 602 160 .SCREW, self tapping - fillister hd 8-32 x 1/74 2.120100 00 eee ee eee a == 1
OM-418 Page 8
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