Miller ROUGHNECK 2E User manual

 March 1895 Form: OM-420L
er Effective With Serial No. KF824571
WNER’S
ANUAL
Roughneck® 2E
@ CC/AC Welding Generator
@ For SMAW Welding
mM 200 Amperes, 25 Volts DC At 100% Duty Cycle (60 Hz)
180 Amperes, 25 Volts DC At 100% Duty Cycle (50 Hz)
Ш 7 kVA/KW AC Auxiliary Power With Overload Protection (See Specifications)
E Tecumseh OH160 Air-Cooled, Gasoline Engine
№ For Options And Accessories, See Rear Cover
E Read and follow these instructions and all = “ар | № Give this manual fo the operator.
safety blocks carefully. Irak
E Have only tramed and qualified persons —
install, operate, or service this unit. — m For help, call your distributor
m Call your distributor if you do not understand mor: MILLER Electric Mfg. Co., P.O. Box 1079,
the directions. POT m Appleton, WI 54912 414-734-9821
cover 5/94 — ST-150 826 © 1995 MILLER Electric Mfg. Co. PRINTED iN USA
_ )
v
MILLER'S TRUE BLUE“ LIMITED WARRANTY
Effective January 1, 1995
(Equipment with a serial number preface of “KD” or newer)
This imited warranty supersedes all previous MILLER warranties and is exclusive with no other quarantees of warranties expressed or implied,
LIMITED WARRANTY — Subject to the terms and conditions below, MILLER Etectric
Mfg. Co., Appleton, Wisconsin, warrants to its original retali purchaser that new
MILLER equipment sold after tha effective date of this limited warranty is free of de-
fects in material and workmanship at the time itis shipped by MILLER. THIS WAR-
RANTY 15 EXPRESELY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted parts or components that fail due to such defects in material or workmanship.
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
followed.
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time perieds. All warranty time pariods
start on the date that the equipment was delivered 0 the original retail purchaser, or
óne year after the equipment is sent to a North American distributor or eighteen
months after the eguipment is sent to an International distributor.
1. 5 Years Parts - 3 Years Labor
* Original main power rectifiers
2. 3Years — Paris and Labor
* Transformer! Rectifier Power Sources
" Plasma Arc Gutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Robots
3. 2 Years — Paris and Labor
* Engme Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
* Air Compressors
4. 7 Year— Parts and Labor
" Meter Driven Guns
* Process Controllers
* Water Coolant Systems
ы HF Units
* Grids
* Spot Welders
* Load Banks
* SDX Transformers
* Running Gear/Trailers
* Plasma Cutting Torches {excapt APT, ZIPCUT & PLAZCUT Models}
" Tecumseh Engines
* Deutz Engines {outside North America}
" Fieid Options
(NOTE: Field options are covered under True Blue ™ for the remaining
warranty period of the product they are installed in, or for a minimum of
ana year — whichever is greater.)
5. 6 Months-- Betteries
6. 90 Days — Parts and Labor
MIG Gung/TIG Torches
APT, ZIPCUT E PLAZCUT Model Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts
MILLER'S True Blue M Limited Warranty shall not apply to:
1. tems fumished by MILLER, but manufactured by others, such as engines or
trade accessories, These items are covered by the manutacturer's warranty, i
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
and relays or parts that fail due to normal wear.
3. Equipment that has bean modified by any party other than MILLER, er equip-
ment that has been improperly installed, improperly operated or misused
based upon industry standards, or equipment which has rot had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-
CIALINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, thé exclusive remedies
shall be, at MILLER'S option: (1) repair; or (2) replacement; or, where authonzed in
writing by MILLER in appropriate cases, (2) the reasonable cost of repair or replace-
ment at an authorized MILLER service station; or {4} payment of or credit for the pur-
chase price (Jess reasonable depreciation based upon actual use) upon retum of tha
goods at customer's risk and expense. MILLER'S option of repair or replacement
will be F.0.B., Factory at Appleton, Wisconsin, or F.O.B. ata MILLER authorized ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. INNO EVENT SHALL MILLER BE
HABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISICN, MIGHT ARISE BY IMPLICATION,
OPERATION CF LAW, CUSTOM OF TRADE OR COURSE CF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER iS EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, spacial or consequential damages, so
the above limitation or exclusion may nat apply to you. This warranty provides spe-
cific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for cartain additional warranties
or remadies other than as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
vary from province to province.
ZN vay on provides specific legal rights, and other rights may be available, but may
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 Model Designation and Serial or Style Number.
Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located onthe rating label
or nameplate.
Model
Serial or Style No.
Date of Purchase
miller 1/95
ARC WELDING SAFETY PRECAUTIONS
4 WARNING
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 complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
terminal in disconnect box or that cord plug is connected Io a
properly grounded receptacle outlet.
circuits.
— or severe burns. The electrode and work circuit is 7. When making input connections, attach proper grounding
— electrically live whenever the outputis on. The input conductor first — double-check connections.
power circuit and machine intemal circuits are also ; ; A
live when power is on. In semiautomatic or automatic 8. Frequently Inspect Input power cord for damage or bare wi ng
wire welding, the wire, wire reel, drive roll housing, replace cord immediately if damaged — bare wiring can kill,
and, all metal parte loucring he weloing wire are 9. Tum off all equipment when not in use.
electrically live. Incorrectly instailed or improperly ;
grounded equipment is a hazard. 10. Do not use worn, damaged, undersized, or poorly spliced
2. Wear dry. hote-free insulating gloves and body protection. 12. Hearth grounding of the workpiece is required, ground it directly
3. Insulate yourself from work and ground using dry insulating with a separate cable — do not use work clamp or work cable.
as or covers big enough to prevent any physical contact with 13. Do not touch electrode if you are in contact with the work,
4 Dis WO ot input [ top engine bef install ground, or another electrode from a different machine.
. Disconnect input power or stop engine before instaling or лай
servicing this equipment. Lockouttagout input power according 14. Use only wel maintained equipment. Repair or replace
to OSHA 29 CFR 1910.147 (see Safety Standards). damaged parts at once. Maintain unit according to manual,
5. Properly install and ground this equipment according to its 15. Wear a safety harness if working above floor level.
Owners Manual and national, state, and local codes. 16. Keep all panels and covers securely in place.
6. Always verify the suppiy ground — check and be sure that input 17. Clamp work cable with good metal-to-metal contact to
power cord ground wire is properly connected to ground workpiece or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin; ARC RAYS
NOISE can damage hearing; FLYING | | |
SLAG OR SPARKS can injure eyes. 2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding orwatching (see ANSI
= fn Arc rays from the welding process produce intense 2749.1 and Z87.1 listed in Safety Standards).
A” visible and invisible (ultraviolet and infrared) rays that 3 W d saf | th side shield
— can bum eyes and skin. Noise from some processes ‚ Wear approved satety glasses with side shields.
can damage hearing. Chipping, grinding, and welds 4, Use protective screens or barriers to protect others from flash
cooling throw off pieces of metal or slag. and glare; warn others not to watch the arc.
NOISE 5. Wear protective clothing made from durable, fiame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material (wool and leather) and foot protection.
+ | 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-supplied respirator. Always have a trained
Welding produces fumes and gases. Breathing watchperson nearby. Welding fumes and gases can displace
these fumes and gases can be hazardous to your air and lower the oxygen level causing injury or death. Be sure
health. the breathing air is safe.
6. Do notweld inlocations near degreasing, cleaning, or spraying
1. Keep your head out of the fumes. Do not breathe the fumes. operations. The heat and rays ofthe arc can react with vapors to
2. If inside, ventilate the area and/or use exhaust at the arc to form highly toxic and irritating gases.
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3. Ifventilation is poor, use an approved air-supplied respirator. cadmium piated steel, unless the coating is removed from the
4. Read the Material Safety Data Sheets (MSDSs) and the weld area, the area is well ventilated, and if necessary, while
manufacturers instruction for metals, consumables, coatings, wearing an air-supplied respirator. The coatings and any metals
| cleaners, and degreasers. containing these elements can give off toxic fumes if welded.
CYLINDERS can explode if damaged. 4, Never drape a welding torch over a gas cylinder.
Shielding gas cylinders contain gas under high 5. Never allow a welding electrode to touch any cylinder.
pressure. I damaged a cylinder can explode. Since 6. Never weld on a pressurized cylinder — explosion will result.
- cylinders ar a art © weldin es
process, be sure to treat hem Carefully. 9 7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
1. Protect compressed gas cylinders from excessive heat, 8. Turn face away from valve outlet when opening cylinder valve,
mechanical shocks, slag, open fiames, sparks, and arcs. 9. Keep protective cap in place over valve except when cylinder is
2. Install cylinders in an upright position by securing to a stationary in use or connected for use.
support or cylinder rack to prevent falling or tipping. 10. Read and follow instructions on compressed gas cylinders,
3. Keep cylinders away from any welding or other electrical associated equipment, and CGA publication P-1 listed in Safety
Standards.
sr1.1.1 2/94
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where fiying sparks can strike flammable material.
3. Remove ali lammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder 10 thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves,
heavy shirt, cuffiess trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or
matches, from your person before doing any welding.
A WARNING
ENGINES can be hazardous. |
ENGINE EXHAUST GASES can kill.
Engines produce hamiul exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed arez, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
la
Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Do not overfill tank — allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
engine,
A 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 place.
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. Keephands, 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 weara face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables,
3. Do not allow tools to cause sparks when working on a battery.
4. 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.
itis best to check coolant level when engine is cold
to avoid scalding.
1. Ifthe engine is warm and checking is needed, follow steps 2
and 3.
2. Wear safely glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly 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 NW, LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
571.1.1 2/94
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 Cutfing, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada MSW 1R3.
Safe Practices For Occupation And Educational Eye And Face Prolec-
fon, ANSI Standard 287.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MÁ 02269.
EMF INFORMATION
NOTE (7
Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields —
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989); “, | | there is now a very
large volume of scientific findings based on experiments at the
celluiartevel and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
To reduce magnetic fields in the workplace, use the following
procedures:
1.
Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3.
4
Do not coil or drape cables around the body.
Keep welding power source and cables as far away as
practical.
Connect work clamp to workpiece as close to the weld as
possible,
About Pacemakers:
The above procedures are among those alse normally
recommended for pacemaker wearers. Consuit your doctor for
compiete information.
mod10.1 4/83
SECTION 1 — SAFETY INFORMATION ...........eeee_nercrreveroroesrednasnmetrenencerevervena. 1
SECTION 2 — SPECIFICATIONS ........22200 04e ea ea ea ee La aa ee ae da ea ea ee aa eee a aa ea eee Le 1
2-1. Volt-Ampere Curves ..........eserdervoeceaooaaarie en zereacosnranDnir racer enanas 2
2-2. Duiy Cycle .............0.0000x0cio reee rsreceecane vo: a rr era c0nmererecmt ra river 2
2-3. Fuel Consumption .........eer-ererorarrriararranrrraerertaernr er erecmooenmecamaraa 3
2-4. AC Auxiliary Power ..........—..oeendcorooriorirraorre o e erearenrerneeonecenmena_ 3
SECTION 3 — INSTALLATION ............—e...e.e0senroerorecacecroaaeonrarecanamoeracaaanrenreDZ 2 4
3-1. Selecting A Location And Moving Welding Generator ..........240 040000102110 s Lau» 4
3-2. EEE 6
3-3. Engine Prestart Checks ............eeceseeeeooamerrcrati at aaceneracaaar ere ene 6
3-4. Grounding The Generator Auxiliary Power System ..............—e—.r-eeee::raesanee,, 7
3-5. $Selecting And Preparing Weld Output Cables ............—.—.—._—.eeerrrrrererreneamene. 7
3-6. O Connecting To Weld Output Terminals .............0e0...e-e---.xreresrerie reee eceaa A 8
SECTION 4 - OPERATING THE WELDING GENERATOR ..........e.eoremereererrrerenen e... 8.
SECTION 5 — OPERATING AUXILIAR Y EQUIPMENT ............_eeeesorec2oreranane rec nene? 11
5-1. 120 And 120/240 Volt Receptacies ............._ e .enrreerereeri renacer read 11
5-2. Wiring Instructions For Optional 120/240 Volt Twistlock Plug ......................... 12
5-3. Field Installation instructions For Optional 240 Volt AC Duplex Receptacie(s) ........... 13
SECTION 6 — MAINTENANCE & TROUBLESHOOTING .............. iia, 15
6-1. Routine Maintenance ........_._.erercoooecsnorrerenronanenedcarrenovrenarcenrrenanaroa 15
6-2. Checking Battery Voltage Or Replacing Battery .......... co iii. 16
6-3. Adjusting Engine Speed coi i eee ea ae da a ee ee ee en 17
6-4. Overload Protection... oi ie ree ко. 19
6-5. Optional Spark Arrestor Inspection And Cleaning .........eee_.e_-e-.e.eserererenea. 19
6-6. Troubleshooting ........._._._e._.eeeeeeeecrsamocororemereererie va reuderermerionenan e 20
SECTION 7 — ELECTRICAL DIAGRAM ..............esesmererercereneererendenrerercan are. 22
OM-420L — 3/95
SECTION 8 - WELDING METHODS & TROUBLESHOOTING .................. ...... os.
8-1. Shielded Metal Arc Welding (SMAW) i ee ies
8-2. Welding Troubleshooting -.... corti ei itera о ,
SECTION 9 — AUXILIARY POWER GUIDELINES ........ ..... i en. .
9-1. How Much Power Does Equipment Require? ........ iii ee RK Es
9-2. Ном Much Power Can Generator Supply? iii i i rire
9-3. Typical Connections To Supply Standby Power .......... iii iii... .
9-4. Selecting Extension Cord 0.0.0000 iii ea eee
SECTION 10 —- PARTS LIST ...............20r00rerierarererererecazarerCranneneecramnenee—
Figure 10-1. Main Assembly oo. i te ea aaa ans
Figure 10-2. Panel, Front w/Components ............——ese-r_eerverrerenre are cr var en ano ne
Figure 10-3. Switch, Selector ..............e_esredoorearacerrreaaareracernererace een
31
31
33
34
35
36
36
39
40
SECTION 1 - SAFETY INFORMATION
mod1.1 #93
@ Read all safety messages throughout this manual,
Ш Obey all safety messages to avoid injury.
M Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
A CAUTION
ELECTRIC SHOCK can kill.“
® Do not touch live electrical parts.
® Disconnect input power before
installing or semnvicing.
or serious injury can happen.
E] A WARNING
MOVING PARTS can injure.
CAUTION means possible minor
injury or equipment damage can
8 Keep away from moving parts. happen.
® Keep all panels and covers closad 3 Statement Of Hazard And
_ when operating. Result
4 Safety instructions To Avoid
Hazard
5 Hazard Symbol {If Available)
Fam?
e SA | Section 3-1 before proceeding.
READ SAFETY BLOCKS at start of
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
7 NOTE _7
Turn Off switch when using high frequency.
Special instructions for best oper-
ation — not related to safety.
Figure 1-1. Safety information
Table 2-1. Welding Generator
SECTION 2 — SPECIFICATIONS
Specification
60 Hz
50 Hz
Type Of Output
Rated Weld Output
Amperage Range
Max. Open-Circuit Voltage
Welding Process
Auxiliary Power Rating
Auxiliary Power When Welding
Engine
Engine Speed {No Load)
Fuel Tank Capacity
Weight
Overall Dimensions
Constant CurrenYAltemating Current (CC/AC)
200 Amperes, 25 Yolts DC At 100% Duty Cycle
(See Section 2-2)
50-225 À
80 Volts AC
Shielded Metal Arc Welding (SMAW)
Single-Phase, 7 kKVA/KW, 120/240 Volts AC,
58/29 Amperes
See Table 5-1
Tecumseh OH160 Air-Cooled, One-Cylinder,
Four-Cycle Gasoline Engine
Weld/Power Speed: 3700 rpm; Idle Speed: 2400
rpm
1.5 gal (5.6 L)
Net: 410 Ib (186 kg); Ship: 456 Ib (208 kg)
See Figure 3-2
Constant Current Altemating Current (CC/AC)
180 Amperes, 25 Volts DC At 100% Duty Cycle
(See Section 2-2)
50-200 А
80 Volts AC
Shielded Metal Arc Welding (SMAW)
Single-Phase, 5.5 kWVA/KW, 115/230 Volts AC,
48/24 Amperes
See Table 5-1
Tecumseh OH160 Air-Cooled, One-Cylinder,
Four-Cycle Gasoline Engine
Weld/Power Speed: 3250 rpm; Idle Speed: 1900
rpm
1.5 gal (5.6 1)
Net: 415 Ib (188 kg); Ship: 463 Ib (210 kg)
See Figure 3-2
OM-420 Page 1
2-1. Volt-Ampere Curves
100
30 E
60 ^
© <
в ово | А
© \\\ S
= 50 Г Wy NN
{3 À ` “``
< 40 | VAN NN NS
1 VAN ` ` `
30 | MENTE EN NON
Noa YAN NY
20 | \ 1141 EY \ \
Arta MAG \
10 } I] 131) da \ \
| IATA \ \
0 [ J I i 1 | Ih 13
Q 50 100 150 200 250 300
AC AMPERES
100
90 +
80 E
"EN
70 ку
NOS
5 60 + A м
5 NENAS
> 1 SAR Ra
O \ VA Na
< 40 | \ \ a % NA `
\ МАММА Ху Хх
30 + \ МАМА NANO
\ 1 LA \ x NN
20 | NON DANOS
NN Hara \ \
D PL Y N т LY La + a
0 50 100 150 200 250 300
AC AMPERES
The voit-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding generator. Curves of
other settings fall between the
curves shown.
A. 60 Hz Models
B. 50 Hz Models
rsb1.1 10/91 — SB-090 296-A / SB-092 691-4
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
4 CAUTION
® Do not weld at rated load longer than shown below.
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
a
Continuous Welding
wam7.1 8/93
9 Definition Chart RATED OUTPUT
200
EN MODEL
10 Duty Cycle is percentage of 10 250
minutes that unit can weld at
. H
rated load without overheating. = о He
. wh
Minutes ha 160
ul
=
100% Duty Cycle At 200 Amperes (60 Hz) € nm
100% Duty Cycle At 180 Amperes (50 Hz) a
E
= 7
50
28 25 X 40 50 86 7 89 90 +0
% DUTY CYCLE 41.1 8/93 — 58-053 025-C
Figure 2-2. Duty Cycle
OM-420 Page 2
TT
2-3. Fuel Consumption
The fuel consumption curve shows
typical fuei use under weld or pow-
e с T er loads.
I 5 3
1
«x
Er о 8
E 2 e
3 = =
7.57 1.70 2.00
6.62 1.46 1.75 F
5.67 1.26 1.50
4.73 1.04 1.25
3.78 0.83 1.00
2.84 0.62 0.75
1.98 0.40 0.50
0.95 0.21 0.25 |
] | | } l | ! ] {
0 25 50 75 100 125 150 175 200 225 250
DC WELD AMPERES AT 100% DUTY CYCLE
O 1 2 3 4 5 6 7
POWER KVA AT 100% DUTY CYCLE
rsb2.1 10/91 — 5B-090 326-8
Figure 2-3. Fuel Consumption Curves
AC Auxiliary Power
The ac power curve shows the
auxiliary power in amperes avail-
140 280 able at the 120 and 240 volt
receptacies.
130 260
© 120 © 240
а 4 60 Hz
=~ > N
O 110 Y 220 |
< < 50 Hz
100 200 }
O 0 | | ] ] À | |
0 5 10 15 20 25 30 35 40
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60 70 80
AC AMPERES IN 120Y MODE
reb3.1 2/92 — 5B-090 297-B
Figure 2-4. AC Power Curve For 120 And 240 Volt Receptacies
OM-420 Page 3
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
A WARNING
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
ENGINE EXHAUST GASES can kill.
e Do not breathe exhaust fumes.
e Keep exhaust and pipe away from flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
® Use lifting eye to lift unit only, 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 property on trailer (if applicable)
according to trailer manual.
9 Useinopen, well-ventilated areas, orvent exhaust
outside and away from building air intakes.
ENGINE EXHAUST SPARKS can cause
fire.
e Use only U.S. Forestry Department approved
spark arrestor and comply with all local, state, and
federal faws.
® A spark arrestor is mandatory in all National
Forests and in grass, brush, orforest covered lands
in California, Oregon, and Washington. Check with
state and local authorities in other areas.
® Properly maintain the spark arrestor.
e Stop engine and allow exhaust system to cool
down before servicing spark arrestor.
® Service spark arrestor away from flammables.
rwami.i 353
Movement 1 Lifting Eye
2 Lifting Forks
! Use lifting eye or lifting forks to
move unit.
OR If using lifting forks, extend forks
DA beyond cpposite side of unit.
3 Trailer
install unit on trailer according to
trailer manual.
Location And Airflow
18 in
(460 mM)
rsb20.1 12/94 — ST-B00 402 / ST-150 826
Figure 3-1. Movement And Location Of Welding Generator
OM-420 Page 4
NOTE |” Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
Inches | Millimeters
A 25 635
B 22-3/4 578
с 37 940
D 36 914
E 24 610
F 15 381
G 4-718 124
H 1-1/2 38
J 19-1/4 489
N K 20-3/8 518
A L | 21-144 540
M 716 11
Engine End
N { 13/32 Dia. 11 Dia.
8 Holes 8 Holes
+ — |
E
те xD — | D
F
o> — | i
? | © {о
лин —— H
М — f= K >
51-150 827
Figure 3-2. Overall Dimensions And Base Mounting Hole Layout
O Li
o Do not exceed operating
O | o angles while running or
30° m PSS AT 30 engine damage will occur.
0 > pa
23°
Da 30°
5-0024-C
Figure 3-3. Maximum Welding Generator Operating Angles
OM-420 Page 5
3-2. Connecting The Battery
A WARNING
e Stop engine before disconnecting or connecting battery cables.
e Always wear a face shield and proper protective clothing when working on a battery.
e Do not allow tools to cause sparks when working on a battery.
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.
mwam2.1 9/97 |
Tools Needed:
= 3/8, 716in
1 Ignition Switch
Place switch in Ignition Off posi-
tion.
4 Positive (+) Battery Terminal
5 Positive (+) Battery Cable
Connect positive cable first.
6 Negative (—) Battery Terminal
7 Negative (-) Battery Cable
Connect negative cable last.
If engine does not crank, check
battery voltage according to Sec-
tion 6-2.
Ref. ST-115 735-B / Ref. ST-800 256 |
Figure 3-4. Connecting The Battery
3-3. Engine Prestart Checks
A WARNING
ENGINE FUEL can cause fire or
explosion.
e Stop engine before fueling.
® Do not fuel while smoking or near sparks or flames.
e 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 until hissing stops
before removing cap.
rwarn3.1 3/93
Check all fluids daily. Engine must
be cold and on a level surface.
Add fresh fuel before starting
engine the first time (see
Figure 6-2).
1 Fuel Cap
2 Fuel Vaive
Open valve.
3 Oil Dipstick
4 Oil Fill Tube
If oil is not up to full mark, add oil
(see Figure 6-2).
rsb4.1 11/92 — Ref. ST-150 820
Figure 3-5. Checking Fluid Levels
OM-420 Page 6
3-4. Grounding The Generator Auxiliary Power System
1 Equipment Grounding
Terminal
E E The generator auxiliary
power neutral is connected
to the machine frame.
7
5-027 657-D
Connect To Earth Ground
If Required By National
Or Local Codes
Tools Needed:
IX 12in
rsb5.1 8/93 — Ref. ST-D90 082-C
Figure 3-6. Equipment Grounding Connection
3-5. Selecting And Preparing Weld Output Cables
1 Weld Output Cable
Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, electrode hold-
er, and weld output terminals.
10 ft (3m)
Tools Needed:
10 ft (3 т)
For Example,
Total Cable
Length In Weld
4 | Circuit = 20 ft (6 m)
3 Insulated Electrode Holder
Install according to manufacturer's
instructions.
4 Work Clamp
Instali onto work cable.
sb6.1 5/94 — 5-0653
Figure 3-7. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length in Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (50 m) Or Less (45m) | (60m) | (om) | (Om) | (105m) | (120m)
Welding 10 To 60% 60 Thru 100% % D |
Amperes | Duty Cycle Duty Cycle 10 Thru 100% Duty Cycle
Le 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 voits or less drop or a current density of at least 300 circular mils per ampere. 5-0007-D
OM-420 Page 7
3-6. Connecting To Weld Output Terminals
A WARNING
= ELECTRIC SHOCK can Kill.
o * Do not touch live electrical parts.
IN e Donot use this unit in damp areas, if movement is confined, or if there is a danger of falling.
e Read Safety Precautions at beginning of this manual.
® Stop engine before making any weld output connections. wam6.1" 4/82
1 Electrode Weld Output
| Terminal
1 e о 2 Work Weld Output Terminal
| e) Connect work cable to Work termi-
2 ——e nal and electrode holder cable to
A Electrode terminal. Use for
e) Shielded Metal Arc Welding
© © (SMAW).
c a
/ a | |
1 я 1 5
A
Left Side
Tools Needed:
ЭРО ВА п
Front Panel
ST-150 829-A / Bef. 5T-115 735-B
Figure 3-8. Weld Output Connections
SECTION 4 — OPERATING THE WELDING GENERATOR
A WARNING
ENGINE EXHAUST GASES can Kill.
€ Do not breathe exhaust fumes.
e Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes,
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
ELECTRIC SHOCK can kill.
== .
<
ENGINE FUEL can cause fire or explo-
SION.
e Stop engine before fueling.
® Do not fuel while smoking or near sparks or flames.
Watch for fire; keep extinguisher nearby. ® Do not overfill tank; clean up any spilled fuel.
Keep all panels and covers securely in place.
WELDING can cause fire or explosion.
Do not weld near flammable material.
“
.
® Do not locate unit over combustible surfaces. —
e MOVING PARTS can cause injury.
Во not weld on closed containers.
Allow work and equipment to cool before handing. . Rach away from moving parts such as fans, belts,
ARC RAYS can burn eyes and skin; e Keep all doors, panels, covers, and guards closed
NOISE can damage hearing. and securely in place.
® Wear welding heimet with correct shade of filter. MAGNETIC FIELDS FROM HIGH CUR-
e Wear correct eye, ear, and body protection. RENTS can affect pacemaker operation.
FUMES AND GASES can be hazardous. e Pacemaker wearers keep away.
e Keep your head out of the fumes. e Wearers should consult their doctor before going
e Ventilate area, or use breathing device. near any welding operations.
® 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. rwam5.1 10/91
OM-420 Page 8
of 1 Amperes Range Switch
| @ @ 2 Range Selector Switch
3 Ignition Switch
1— © @ 4 Choke
LL 3 E
a 5 Start Switch
OF 6 Engine Throttle Control
|
Right Side
ST-150 828-A / SB-090 082-C
Figure 4-1. Operating Controls
1 2 Wear the following while welding:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
249.1)
sb3.1 1/94
Figure 4-2. Safety Equipment
1 Work Clamp
Tools Needed: 1
E Connect work clamp lo a clean,
—— paint-free location on workpiece,
Ut ZA as close to weld area as possible.
Слон пн PU Use wire brush or sandpaper to
-
clean metal at weld joint area, Use
chipping hammer to remove slag
after welding. sb4.1 2/03
Figure 4-3. Work Clamp
ARCING can damage switch.
+ Do not change Amperes Range switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail. rwarme.1 2/93
1 Amperes Range Switch
Use switch to select weld
amperage.
2 Range Selector Switch
Use switch to selectampere range.
Switch may be moved while
welding.
For auxiliary power only, place
switch in the High position. For
weld and auxiliary power, move
switch to meet welding needs (see
Table 5-1).
Hef, ST-115 7353
Figure 4-4. Amperage Controls
OM-420 Page 9
Right Side IN-IDLE OUT-WELD/POWER
el DT
Pe =
S-085 130-B
TT
© IGNITION
O) RardI TION
OFF
1 Throttle Control
Use control to set engine speed
(rpm).
2 Choke Control
Use control to change fuel-air mix-
ture to engine.
3 Ignition Switch
Use switch to supply battery power
to ignition circuit.
4 Start Switch
Use switch to engage starter and
start engine.
To Start: Push throttle control in
(Idle), pull choke control out, move
ignition switch io Ignition On posi-
tion, and push start switch up
(Start). Release switch when en-
gine starts to avoid damaging
starter.
As engine warms up, push choke
in. Pull throttle control out {Weld/
Power) to run.
To Stop: Move ignition switch to
Ignition Off. Keep switch in Ignition
Off position when unit is not run-
ning to prevent battery from
discharging.
ST-150 826-A
Figure 4-5. Engine Controls
install &
Connect
Equipment
Select Put On Turn On
Electrode Personal Safety Set Controls Start Engine Auxiliary
{See Section 8) Equipment Equipment
)
insert
Electrode Begin Welding
Into Holder
rsb8.1* 9/92
OM-420 Fage 10
Figure 4-6. Sequence Of Shielded Metal Arc Welding (SMAW)
SECTION 5 — OPERATING AUXILIARY EQUIPMENT
4 WARNING
ELECTRIC SHOCK can Kill.
® Do not touch live electrical parts.
e Stop engine before making internal inspection or
reconnection.
e Ground generator according to all applicable
national, state, and local codes.
® Connect equipment grounding terminal to a proper
earth ground.
® Do not connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and grounging procedure are
employed (see Section 9).
ELECTRIC SPARKS can cause fire.
e |f using auxiliary power only and not welding,
disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
® 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.
Co
MOVING PARTS can cause serious
injury.
® Keep away from moving parts such as fans, belts,
and rotors.
® Keep all doors, panels, covers, and guards closed
and securely in place.
LOW VOLTAGE AND FREQUENCY can
damage electrical equipment.
® Tum off or unplug all electrical equipment
connected to auxiliary power receptacles before
starting or stopping the engine.
When starting or stopping, the engine has low speed
which causes low voltage and frequency.
wam8.1 10/92
5-1.
120 And 120/240 Volt Receptacles
NOTE (+
For 50 Hz models, each duplex receptacle (Figure 5-1, lfems 1 and 2) supplies 115
volts ac, 30 amperes of single-phase power, and the twistlock receptacle (3)
supplies 230 volts ac, 24 amperes of single-phase power. Maximum auxiliary
power output of 50 Hz models is 5.5 КУА.
1 120Y 15A AC Duplex Re-
ceptacles RC1
2 120V 15 A AC Duplex Re-
ceptacles RC2
Each half of the 120 volt duplex re-
ceptacle has full kVA available and
can supply 1& amperes continu-
ously. Receptacles suppiy 60 Hz,
single-phase power at weld/power
speed.
3 120/240 V 30 A AC Twistlock
Receptacle RC3
This receptacle has full KVA avail-
able and can supply 29 amperes
continuously.
The combined output of all recep-
tacles limited to 7 kVA/kW rating of
the generator.
EXAMPLE: IF 30 Á is drawn from a
120 V receptacle, only 14 À is
available at the 240 V receptacle:
(120 V x 30 A) + (240 V x 14 A) =
7.0 KVAKW
Table 5-1 shows approximate ac
auxiliary power available under
various welding inads.
Ref. ST-115 735-8
Figure 5-1. Auxiliary Power Receptacles
See Section 9 Install á Connect Move Throttle Tum On Auxiliary
Auxiliary Power Auxiliary Amperace Controls Start Engine Control To Weld/ Equipment
Guidelines Equipment (See Figure 4-4) Power Position
) Begin Operation }
rsb11.1" 2/93
Figure 5-2. Sequence Of Auxiliary Equipment Operation
OM-420 Page 11
Table 5-1. Auxiliary Power While Welding
Amperse Range | Power Avateble” o
(KVA/KW) peres)
115 VAC 120 VAC 230 VAC 240 VAC
50 Hz 60 Hz 50 Hz 60 Hz Receptacles Receptacles Receptacles Receptacles
(50 Hz) (60 Hz) (50 Hz) (60 Hz)
200 225 300 500 2.6 4.1 1.3 2.1
180 200 400 1200 3.4 10 1.7 5
165 180 1300 2400 11.4 20 57 10
150 155 1300 2800 11.4 23.4 5.7 11.7
140 140 2200 3600 19.0 30 95 15
125 125 2100 3400 18.2 28.4 9.6 14.2
115 115 3000 4100 26.2 34.2 13.1 17.1
105 105 2500 3900 21.8 32.6 10.9 16.3
95 95 3800 4800 33 40 16.5 20
85 85 3300 4400 28.8 36.6 14.4 18.3
75 75 4300 5800 37.4 48.4 18.7 24.2
70 70 3400 5600 29.6 46.6 14.8 23.3
55 55 4700 6500 40.8 54.2 20.4 271
50 50 4200 6200 36.6 51.6 18.3 25.8
5-2. Wiring Instructions For Optional 120/240 Volt Twistlock Plug
A WARNING
— ELECTRIC SHOCK can kill: INCORRECT CONNECTIONS can cause fatal electric shock.
.
EN ® Do not touch live electrical parts.
e Wire the 120/240 volts twistlock ptug according to Figure 5-3.
* Have only qualified persons make winng connections.
1 The plug for the 120/240 volt twist-
lock receptacle can be wired to
3 supply a 240 volt, 2-wire load or a
4 120/240 volt, 3-wire load. See cir-
2 cuit diagram when wiring plug.
1 Plug Wired For 120/240 Volt,
= 3-Wire Load
120V 2 Plug Wired For 240 Volt,
2-Wire Load
240V, 3 Neutral (Silver) Terminal
4 Load 1 (Brass)Terminal
5 Load 2 (Brass) Terminal
Ч 6 Ground (Green) Terminal
o 7 Outer Shell
—
8 Cord Grip
Strip cord jacket back enough to
separate conductors. Strip con-
ductors enough to make good con-
tact with plug terminals. Make plug
Tools Needed: connections and reinstall outer
shell and cord grip. Tighten assem-
= lnm >= o biy screws onto shell. Do not over-
— tighten.
rsb12.1" 2/92 / 53-085 361-0D
Figure 5-3. 120/240 Volt AC Plug Connections
OM-420 Page 12
5-3. Field Installation Instructions For Optional 240 Volt AC Duplex Receptacle(s)
A WARNING
— ELECTRIC SHOCK can kill.
e ® Do not touch live electrical parts.
x \ ® Stop engine before inspecting or installing.
FILINGS AND TOOLS HITTING INSIDE
PARTS can damage unit.
e Cover parts.
e Clean unit and remove covers before operating.
fwarn 4.1 9/91
Stop engine and remove wrapper.
Drill out rivets to remove 120 vac
receptacle RC1 from front panel.
Mark leads and disconnect from
receptacle.
Lead 3
Connect to 240 vac receptacle.
Lead 4
Tape end of lead and tie into wiring
harness.
Lead 33 (Ground)
Connect to 240 vac receptacle
grounding terminal (green).
Lead 5 (Supplied)
Connect between 240 vac duplex
receptacle and terminal Y of 240
vac twistlock receptacle. Allow
existing lead 5 to remain con-
nected to terminal Ÿ of 240 vac
twistlock receptacle,
Install new 240 vac receptacie in
front panel.
Reinstall wrapper. Apply supplied
label over existing voltage rating
on nameplate.
1 120V 15 A AC Duplex Re-
ceptacle RC2
See Figure 5-1 for description.
à 240V 15 A AC Duplex Re-
ceptacle RCA
Receptacle supplies 60 Hz, single-
phase power at weld/power speed.
Maximum output is 7 KVAÏKW.
The combined output of all recep-
tacles limited to 7 KVA/KW output of
generator. See example in
Figure 5-1.
Lead 5
Lead 3
Lead 33
Lead 4
Tools Needed:
3/16 in
Ref. ST-115 735-B / ST-150 823-C
Figure 5-4. Installing One 240 Volt AC Duplex Receptacie
OM-420 Page 13
Stop unit and remove wrapper. Re-
place first receptacle (see
Figure 5-4). Remove second recep-
tacle. Mark leads and disconnect
from receptacie,
Lead 3
Connect to 240 vac receptacle
Lead 4
Splice both leads 4 together. Tape
splice and tie leads into wiring har-
ness.
Lead 33 (Ground)
Connect to 240 vac receptacie
ground terminal (green).
Lead 5 (Supplied)
Connect lead 5 between the two 240
vac duplex receptacles.
Install new 240 vac receptacle in
front panel.
Reinstall wrapper. Apply supplied la-
bel over existing voltage rating on
nameplate.
1 240V 15 A AC Duplex Recep-
tacle RC4
2 240V 15 A AC Duplex Recep-
tacle RCS
Receptacles supply 60 Hz, single-
phase power at weld/power speed.
Maximum output from either recep-
facle is 7 KVA/KW.
O Me < The combined output of all recep-
Sy tacies limited to 7 KVA/KW output of
E generator. See example in
==
tn
E”
Figure 5-1.
A
-
ий
N
HR (6
Le
E
Lead 5 <
(DS (DS
\
X
\
y en
\ |
Lead 33
Tools Needed:
3/16 in
Ref. ST-115 735-8 / ST-150 824-B
Figure 5-5. Installing Two 240 Volt Duplex Receptacles
OM-420 Page 14
SECTION 6 — MAINTENANCE & TROUBLESHOOTING
А WARNING
ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Always wear dry insulating gloves.
e Insulate yourself from work and ground.
°
e
HOT PARTS can cause severe burns.
® Allow cooling period before servicing.
e Wear protective gloves and clothing when working
on a hot engine.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
ENGINE EXHAUST GASES can kill.
® Do not breathe exhaust fumes.
e Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
ENGINE EXHAUST SPARKS can cause
fire.
e Use only U.S. Forestry Department approved
spark arrestor and comply with all local, state, and
federal laws.
a A spark arrestor is mandatory in all National Fo-
rests and in grass, brush, or forest covered lands in
Catifornia, Oregon, and Washington. Check with
ENGINE FUEL can cause fire or explo- state and local authorities in other areas.
sion. ® Properly maintain the spark arrestor.
® Stop engine before fueling. e Stop engine and allow exhaust system to cool
down before servicing spark arrestor.
® Service spark arrestor away from flammables.
ad
æ
e Do not fuel while smoking or near sparks or flames.
® Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury. Maintenance to be performed only by qualified
. persons.
® Keep away from moving parts such as fans, belts,
and rotors.
e Keep all doors, panels, covers, and guards closed
and securely in place. mwam9.1 10/93
6-1. Routine Maintenance
| o Do not throw away engine
a Stop engine before maintaining. o fluids - take to area recycling
8 Hours center.
nN @) 50 Hours @) 250 Hours
secion Clear Check
3-
3 Tighten — Clean
Weld Spark
Check Terminals 6-5 Arrestor
Fluid
Levels
O 100 Hours O 500 Hours
Clean Check Tape Or
Cooling Spark eplace
System engine Plug 7 Cables
manual 35
Cl And
@) 25 Hours Tighten @ 1000 Hours
Battery
Check
Air 3-2 Connections
Cleaner
engine Paper O
manual Element 200 Hours
E 3
HE. NE Replace During Heavy Service,
cen AS Unreadable Clean Monthly.
: ' Labels
engine 10
manual —
Figure 6-1. Maintenance Schedule
OM-420 Page 15
TECUMSEH OH-160 GAS ENGINE
See Engine Manual for complete engine care.
Give engine Specification and Serial Number
when ordering parts.
Weld/Power
Engine RPM — No Load
... 3700 (60 Hz); 3250 (50 Hz)
2400 (60 Hz); 1900 (50 Hz)
daily.
Recommended Qil ..... API Service
Classification SF or SG
°С A E 12 Volt Battery ...... BCI Group UN
+30 Cranking Performance at 0°F (-18°C) ....
220/ | | | eee 260 Amps
Valve Clearance — Cold
In. ... 0.005 in (0.13 mm)
Ex. .. 0.010 in (0.25 mm)
O | +32
Oil Change ......................... 10
dirty conditions ..... 25 hours or less
normal conditions ... 25 hours 20 0
Oil Capacity .......... 1.62 qt (1.53 L) |-30
Spark Plug Gap
Spark Plug .....
Fuel Capacity ....... 1.5 gal (5.7 L)
Fuel Grade ......... Regular or Unleaded,
87 Octane min.
Gasoline
ne 0.030 in (0.8 mm)
‚... Champion RL-82C
Use only resistor spark plugs and wires.
Air Filter Service ....
25 hours or less — see
Owner's Manual 1148089) ...... 250 operating hours - see Owner's
Air Filter Element .... Miller 061 166, Manual
Tecumseh 32008 Optional 5-093 003-D
Spark Arrestor Inspection And Service ........
Figure 6-2. Maintenance Label
6-2. Checking Battery Voltage Or Replacing Battery
eyes and skin.
battery cables.
4 WARNING
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can burn
® Stop engine before disconnecting or connecting
e Always wear a face shield and proper protective
clothing when working on a battery.
® Do notallow tools to cause sparks when working on
a battery.
® Do not use welder to charge batteries or jump start
vehicles.
* Observe correct polarity (+ and —) on batteries.
wam10,1 9/91
Ss 4
2 >, 6 Tools Needed:
If engine does not crank, check
battery voltage as follows:
1 Ignition Switch
Place switch in the Off position.
2 Battery
3 Negative (>) Battery Cable
4 Positive (+) Battery Cable
5 Voltmeter
If battery voltage is less than 12.4
volts, charge battery following bat-
tery charger's instructions.
If battery tests okay but unit does
not crank, contact Factory Autho-
rized Service Station/Service
Distributor.
To replace battery, proceed as
follows;
Disconnect battery cables, nega-
tive cable first.
6 Hold Down
Remove hold down and battery. In-
stall new battery and secure with
hold down. Reconnect cables,
negative (—} cable last.
xk 38, 7/16 in
Ref. ST-800 256 / Ref. ST-115 7355
Figure 6-3. Checking And Replacing Battery
OM-420 Page 16
6-3. Adjusting Engine Speed
á WARNING WE
A. Governed Idle Speed Adjustment
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Clean and gap spark plug and ad-
just carburetor (see engine manu-
al) before adjusting engine speed.
Engine speeds are factory set and
do not require frequent readjust-
ment.
1 Govemor Springs
If disconnected, reattach as
shown. Have governor adjustment
done by a Factory Authorized Ser-
vice Station/Service Distributor.
2 Throttle Control
3 Throttle Mounting Bracket
Push throttle control in and lock in
bracket notch.
4 Carburetor
5 Governor Am
Pull and hold governor arm toward
carburetor.
6 Weld Speed Spring
If spring has tension, see item 7.
Otherwise, release govemor arm
and see item 8.
7 Throttle Lever Stop
Adjustment
Adjust throttle lever stop adjust-
ment until weld speed spring ten-
sion is gone. Be sure spring does
not fall off governor arm.
If spring still has tension, remove
throttle mounting bracket cover
and loosen bracket mounting Бой
and nut. Slide bracket forward until
spring tension is gone. Retighten
bolts and nut and replace cover.
Release governor arm.
8 Govemed idle Speed Adiust-
ment Nut
Rotate nut until engine runs at
2400 rpm (60 HZ) or 1900 rpm (50
Hz).
Tools Needed:
===
€ 38 5/6in
ST-181 575 / ST-150 820
Figure 6-4. Governed Idle Speed Adjustment
OM-420 Page 17
B. Carburetor idle Speed Adjustment
1 Throttle Control
2 Throttle Mounting Bracket
Push throttle control in and lock in
bracket notch.
3 Carburetor
4 Govemor Am
Hold arm towards carburetor to
make engine idle.
5 Carburetor Idie Speed Ad-
justment Screw
Rotate screw until engine runs at
2100 rpm {60 Hz) or 1700 rpm (50
Hz).
Tools Needed:
ef
ST-150 820 / ST-151 575
Figure 6-5. Carburetor Idie Speed Adjustment
C. Weld/Power Speed Adjustment
1 Throttle Control
2 Throttle Mounting Bracket
Full throttle control out and lock in
bracket notch.
3 Throttle Lever
4 Weld/Power Speed Adjust-
meni Screw
If throttle [ever is not against screw,
remove throttle mounting bracket
cover and loosen mounting bolts
and nut.
Slide bracket forward until throttle
lever hits screw. Tighten hardware
and replace cover.
Rotate screw until engine runs at
3700 mm (60 Hz) or 3250 mm (50
Hz).
Recheck govemed idle speed (see
Figure 6-4). 1f speed is incorrect,
remove throttle mounting bracket
cover and loosen bracket mount-
ing bolts and nut. Slide bracket for-
ward until weld speed spring does
not apply tension to governor arm.
Check governed idie and weld
speeds. Slide bracket forward or
е=== в backward until rpm and spring ten-
sion are Correct.
I——< 3/8,5/16in
Tools Needed:
ST-156 820 / ST-151 846-A
Figure 6-6. Weld/Power Speed Adjustment
OM-420 Page 18
6-4. Overload Protection
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
4 WARNING
Stop engine.
1 Fuse F1 In Fuse Holder (See
= 4 Parts List For Rating)
© 2 Wrapper
3 Range Switch Mounting
Bracket
3 4 Integrated Rectifier
If F1 opens, there is no weld or aux-
iliary power output.
PD
Remove wrapper and replace F1.
Reinstall wrapper before operating
unit. If F1 opens again, have Facto-
ry Authorized Service Station/Ser-
vice Distributor check rectifier,
Tools Needed:
Te
——
Coal авы
ST-150 909-A
Figure 6-7. Fuse F1 Replacement
6-5. Optional Spark Arrestor Inspection And Cleaning
READ SAFETY BLOCKS at start of
4 WARNING Section 6 before proceeding.
Stop engine and allow to cool.
1 Spark Arrestor
2 Cieanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine, and run at idle speed
to blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe.
Stop engine and allow to cool.
Reinstall cleanout plug.
Tools Needed:
aC E6in
ST-800 206
Figure 6-8. Spark Arrestor Inspection And Cleaning
OM-420 Page 19
6-6. Troubleshooting
4 WARNING
ELECTRIC SHOCK can kill. ENGINE FUEL can cause fire or explo- ee”
— e Do not touch live electrical parts. sion.
Always wear dry insulating gloves. ® Stop engine before fueling.
Insulate yourself from work and ground. ® Do not fuel while 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.
ENGINE EXHAUST GASES can kill.
® Do not breathe exhaust fumes.
® Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
с
MOVING PARTS can cause injury.
e Keep away from moving parts such as fans, belts,
and rotors.
® Keep all doors, panels, covers, and guards closed
and securely in place.
HOT PARTS can cause severe burns.
e
Allow cooling period before servicing. Troubleshooting to be performed only by qualified
® Wear protective gloves and clothing when working persons.
ona hot engine.
wam1i.1 11/91
Table 6-1. Welding Trouble
Trouble Remedy Section
No weld output. I~ — -| Check position of Amperes Range switch. ———| Figure 4-4
Check fuse F1 and replace if open. — — = 6-4
Have Factory Authorized Service Station/Service Distributor |— — -= -— |!
check brushes, slip rings, and integrated rectifier.
Erratic weld output. = -=! Check and tighten connections inside and outside unit. ——. ——
Use dry, properly-stored electrodes. — — ——
Be sure connection to work piece is ciean and tight. — — >| Figure 4-3
Have Factory Authorized Service Station/Service Distributor — — -# ——
check brushes and slip rings.
Low weld output. Г — -=| Check and adjust engine speed. —— 6-3
Check position of Amperes Range switch. — —-m| Figure 4-4
Tune up engine according to engine manual. — — ——
High weld output. Г — + Check and adjust engine speed. — — = es |
OM-420 Page 20
Table 6-2. Auxiliary Power Trouble
Remedy
Check fuse F1 and replace if open.
Check receptacle wiring and connections.
Have Factory Authorized Service Station/Service Distributor
check brushes, slip rings, and integrated rectifier.
Place Amperes Range switch in High position.
Reduce weld output.
Check and adjust engine speed.
Tune up engine according to engine manual.
Trouble
No output at auxiliary power — —-—e
receptacies.
Low output at auxiliary power ———
receptacies.
High output at auxiliary power ———
receptacles.
Check and adjust engine speed.
--- — - —
Section
6-4
Figure 4-4
5-1
6-3
6-3
Table 6-3. Engine Trouble
Trouble
Engine does not start.
Battery discharges between uses. ро
Remedy
Check fuel level. Open fuel shutoff valve.
Check battery and replace if necessary.
Check connections to ignition switch.
Have Factory Authorized Service Station/Service Distributor
check engine charging system.
Make sure ignition switch isin Ignition Off position when unit is shut
down.
Cleanbatiery, terminals, and posts with baking soda and water so-
lution; rinse with clear water.
— — —
Periodically recharge battery (approximately every 3 months),
— — -№
Replace battery.
Unstable or sluggish engine speeds. I~ = e
Check and adjust engine speed.
Tune up engine according to engine manual.
Figure 4-5
3-2
6-2
OM-420 Page 21
SECTION 7 — ELECTRICAL DIAGRAM
CONNECT #27 70 #8 & #10 FOR NORMAL EXCITATION
X
CONNECT #27 TO #10 & #8 ТО #9 FUR BOOST EXCITATION RES
#9 & #8 TO #10 FOR BUCK EXCITATION
CONNECT #27 TO
— — — "== HE ces ны | ны ны ше” | — | кн | кн | = —
ENE
Z7 |2Y BATT START
ao
| ON si 37 |
ENG
| IGN 7 Zea TO REGULATOR
Lo == o BEER __
Pa a o, ELECTRIC | START-BATTERY IGNITION
EI] —| —= TO STARTER
| |2\ ВАТТ | CRY START
—a 0
| NA © OCFF 53 37 |
| ENG — 52
IGN [£2 2 a TO REGULATOR
RECTIFIER
OM-420 Page 22
TO STARTER
Figure 7-1. Circuit Diagram For Welding Generator
ELECTRODE
Y X W 5 Y
уу RES \/ > Y
RCA A
Y Y Y
IT
| AAA
7 RES |g 5
ALTERNATE
POWER CONNECTION
CONE OR BOTH RECEPTACLES)
RC6
3
F RC7 5
7
ALTERNATE
POWER CONNECTION
230/240 VOLT ONLY
ЗА-089 109-А
SECTION 8 — WELDING METHODS & TROUBLESHOOTING
! "Va
ELECTRIC SHOCK can kill.
e Always wear dry insulating gloves.
e Insulaie yourself from work and ground,
® Do not touch live electrical parts.
e Keep all panels and covers securely in place.
mods.1 9/92
MOVING PARTS can cause injury.
® Keep away from moving parts such as fans, belts,
and rotors,
® Keep all doors, panels, covers, and guards closed
and securely in place.
FUMES AND GASES can be hazardous
to your heaith.
e Keep your head out of the fumes.
e Ventilate area, or use breathing device.
9 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.
e Wear protective gloves and clothing.
WELDING can cause fire or explosion.
Do not weld near flammable material,
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.
® Disconnect both battery cables before welding on a
vehicle.
e Place work clamp as close to the weld as possible.
See Safety Rules at beginning of manual for basic
welding safety information.
8-1. Shielded Metal Arc Welding (SMAW)
NOTE _7
Welding current starts as soon as electrode touches the workpiece.
Tools Needed: Со ке
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 8-2).
4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Are length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will 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.
37-151 553
Figure 8-1. Shielded Metal Arc Welding (SMAW) Procedure
OM-420 Page 23
ELECTRODE
DIAMETER
©
Le
100
150
200
AMPERAGE
RANGE
250
300
350
=
с = Q
o y Q < C5
El 6128/| Е | & =
О а | < n = o
Ш O =
— & TA]
e
6010 | EP ALL | DEEP | MIN. PREP, ROUGH
6011 | EP | / | ALL | DEEP | HIGH SPATTER
6013 | EPEN| / | ALL | LOW GENERAL
SMOOTH, EASY,
7014 | EPEN| y | ALL | MED FAST
LOW HYDROGEN,
7018 | EP | Y | ALL | LOW STRONG
/ Ar SMOOTH, EASY
7024 | EPEN| V | HORIZ | LOW ETE"
NI-CL | EP | y | ALE | LOW CAST IRON
308. | EP | Y | ALL | LOW STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) |
400
450
Ref. 5-087 985-A
OM-420 Page 24
Figure 8-2. Electrode And Amperage Selection Chart
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece
like striking à match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work-
piece, use à quick twist to free it.
5-0049
Figure 8-3. Striking An Arc — Scratch Start Technique
— — — —
\
1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free
the electrode.
L
5-0050
Figure 8-4. Striking An Arc — Tapping Technique
| 105-307 \ | 10°-30° er
\ | \
90° 90°
\ \
End View Of Work Angle Side View Of Electrode Angle End View Of Work Angie Side View Of Electrode Angle
GROOVE WELDS
FILLET WELDS
S-0660
Figure 8-5. Positioning Electrode Holder
OM-420 Page 25
1 Large Spatter Deposits
POOR WELD BEAD 2 Hough, uneven bead
Slight Crater During
Welding
Bad Overlap
5 Poor Penetration
S-0053-A
Fine Spatter
GOOD WELD BEAD 2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
5 1/8 in (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 (Good Penetration Into Base
= Metal
5-0052-B
Figure 8-6. Weld Bead Characteristics
NOTE C7 |
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Correct Angle
Angle Too Small bf 10° - 30° Angle Too Large
| {1
LEE
< e < 5 < >
——=—* Drag
ELECTRODE ANGLE
|| ps
< ¢ 5
Too Short Normal Too Long
ARC LENGTH
< 5 < 5
Slow Normal Fast
TRAVEL SPEED
S-0661
OM-420 Page 26
Fiqure 8-7. Conditions That Affect Weld Bead Shape
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 Pattems
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.
S-0054-A
Figure 8-8. Electrode Movement During Welding
1 Tack Welds
Prevent edges of joint from draw-
ing together ahead of electrode by
tack welding the matenals in posi-
tion before final weld.
1/16 in
2 Square Groove Weld
(1.6 mm)
Good for materials up to 3/16 in
(5 mm) thick.
3 Single V-Groove Weld
Good for materials 316 through
3/4 in {5-19 mm) thick. Cut bevel
with oxyacetylene or plasma cut-
ting equipment. Remove scale
from material after cutting. A grind-
er can also be used to prepare bev-
els.
4
Create 30 degree angle of bevel on
materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than
3/16 in (5 mm).
5-0662
Figure 8-9. Butt Joints
2 To3in
(51-76 mm) =
1 Vise
2 Weld Joint
3 Hammer
o
Strike weld joint in direction shown,
A good weld bends over but does
not break.
2To3in |
(51-76 mm)
2
Pure
ma
==
S-0057-B
Fiqure 8-10. Weld Test
OM-420 Page 27
1 Electrode
2 Fillet Weld
Keep arc short and move at defi-
nite rate of speed. Hold electrode
as shown to provide fusion into the
comer. Square edge of the weld
surface.
For maximum strength weid both
sides of upright section.
3 Multi-Layer Deposits
Weld a second layer whena heavi-
er fillet is needed. Use any of the
weaving pattems shown tn
Figure 8-8. Remove slag before
making another weld pass.
5-0060 / S-G058-A / 5-0061
Figure 8-11. Tee Joint
30” Or Less
30° Or Less
EZ
Single-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-
er fillet is needed. Remove siag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
S-0063 / 35-0064
Figure 8-12. Lap Joint
8-2. Welding Troubleshooting
Table 8-1. 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, paini, coatings, slag, and dirt from work surface before
welding.
OM-420 Page 28
Table 8-2. 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 8-3. Incomplete Fusion
«À
1
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 puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Table 8-4. Lack Of Penetration
Lack Of Penetration — shallow fusion be-
tween weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
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-420 Page 29
Table 8-5. 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 [ower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Table 8-6. Burn-Through
Bum-Through — weid metal melting com-
pletely through base metal resulting in
holes where no metal remains.
Possible Causes Corrective Actions
Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Table 8-7. Waviness Of Bead
Waviness Of Bead — weld metal that is not
paraliel and does not cover joint formed
by base metal.
Possible Causes Corrective Actions
Unsteady hand. Use two hands. Practice technique.
Table 8-8. 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.
OM-420 Page 30
SECTION 9 — AUXILIARY POWER GUIDELINES
mod 3.1 9/92
A WARNING
ELECTRIC SHOCK can kill.
Install and ground generator according to all 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.
® Have only qualified persons make electrical connections.
9-1. How Much Power Does Equipment Require?
1 Resistive Load
A light bulb is a resistive load and
1 2 So || VOLTS 115 requires a constant amount of
N AMPS 45 power.
Hz 60 ist
à Non-Resistive Load
66W
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 9-3).
3 3 Rating Data
Volts and amperes, or watts re-
quired to run equipment. Deter-
— mine power required as shown in
Figure 9-2.
5-0623
Figure 9-1. 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.
115 V x 4.5 À = 520 W
Therefore, the individual load applied by the drill is 520 watts.
EXAMPLE 2: If a flood lamp is rated at 200 watts, the individual load 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.
(200 W + 200 W + 200 W) + 520 W = 1120 W
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.
Figure 9-2. Calculating Power Required To Run Equipment
OM-420 Page 31
Table 9-1. Approximate Power Requirements For Typical Equipment*
industrial Motors Rating Starting Running Farm Equipment Rating Sparing Ama
Split Phase 1/8 HP 800 300 Stock Tank De-lcer 1000 1000
1/6 HF 1225 500 Grain Cleaner 1/4 HP 1650 650
1/4 HP 1600 500 Portable Conveyor 1/2 HP 3400 1000
1/3 HP 2100 700 Gran Elevator 3/4 HP 2400 1400
1/2 HP 3175 875 Milk Cooler 2500 1100
Milker (Vacuum Pump) 2 HP 19500 2800
Capacitor Start- 1/3 НР 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 975
ЗА НР 4500 1400 Feed Augers, Air 3/4 HP 4500 1400
1 НР 6100 1600 Compressors) 1 HP 6100 1600
1-1/2 НР 8200 2200 1-1/2 HP 8200 2200
2 HP 10550 2850 2 HP 10550 2850
3 HP 15900 3900 3 HP 15900 3900
5 HP 23300 6800 5 HP 23300 6800
Capacitor Start- 1-1/2 HP 8100 2000 High Torque (e.g. Bam 1-1/2 HP 8100 2000
Capacitor Run 5 HP 23300 6000 Cleaners, Silo Unloaders, 5 HP 23300 5000
7-1/2 HP 35000 8000 Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 45700 10700 10 HP 45700 10700
Fan Duty 1/8 HP 1000 400 3-1/2 Cu. Ft. Mixer 1/2 HP 3300 1500
1/6 HP 1400 550 High Pressure 1.8 GaYMin 500 PSI 3150 950
14 HP 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 Starting Ring Residential Rating Searing Rng
Hand Drill 1/4" 350 350 Coffee Maker 1750 1750 Typ.
3/8" 400 400 Elec. Range 6” Element 1500 1500
1/2" 600 600 8” Element 2100 2100
Circular Saw 6-1/2" 500 500 Oven 6000 6000
7-1/4” 500 900 Microwave 625 W 2800 2000
8-1/4" 1400 1400 Television (Solid-State) B&W 100 100
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
e 3900 1400 1/2 HP 3100 1000
10 5200 1600 Sump Pump 1/3 HP 2100 800
Air Compressor 1/2 HP 3000 1006 1/2 HP 3200 1050
1HP 6000 1500 Dishwasher (Cool Dry) 2100 700
1-1/2 HP 8200 2200 (Hot Dry) 2850 1450
2 HP 10500 2800 Clothes 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 Tnmmer Standard 9 350 350 Gas Or Fuel Gil 1/8 HP 800 300
Heavy Duty 12” 500 500 Fumace Blower 1/6 HP 1250 509
Electric Cultivator 1/3 HP 2100 700 1/4 HP 1600 600
Elec. Hedge Trimmer 18” 400 400 1/3 HP 2100 700
Ficod Lights RID 125 100 1/2 HP 3225 875
Metal Halide 313 250 Central Air Conditioner 16,000 ETU 3700 1500
Mercury 1006 20,000 BTU 5800 2500
Sodium 1400 24.000 BTU 8750 3800
Vapor 1250 1005 32,000 BTU 11500 2000
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
Floor Polisher 3/4 HP, 16" 4500 1400 13 HP 2125 725
1 KP, 20" 5190 1600 Electric Blanket Portable 400 400
High Pressure Washer 1/2 HP 3150 950 Dehumidrfier 1450 650
3/4 HP 4500 1400 Vacuum Cleaner Standard 800 800
1 EP 5100 7500 Deluxe 1100 1100
55 Gal. Drum Mixer 1/4 HP 1900 700 Lights As indicated On Bulb
Wet & Dry Vac 1.7 HP 900 900 Toaster 2 Slice 1050 1050
2-1/2 HP 1300 1300 4 Slce 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-420 Page 32
Table 9-2. Single-Phase Induction Motor Starting Requirements
Motor Start Code I G H J K L M N Р
KVA/HP I 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0
1 Motor Rating Label
2 Motor Start Code
2 AC MOTOR 3 Determine power required to start
> VOLTS 230 AMPS pga motor using Table 8-2. Determine
1 “CODE M Hz 50 starting amperage required as
shown in Figure 9-4.
HP 1/4 PHASE 1
3 Running Amperage Require-
ment
If code is not present, multiply
running requirement by six. Gener-
ator amperage output must be at
least twice the motor's running
amperage requirement.
5-0824
Figure 9-3. Power Required To Start Motor
KVA/HP x HP x 1000
= STARTING AMPERAGE
VOLTS
EXAMPLE 3: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volis=230 HP=1/4 Using Table 9-2, Code M results in kKVA/HP = 11.2
11.2 x 1/4 x 1000
= 122A
230
Therefore, starting the motor requires 12.2 amperes.
Figure 9-4. Calculating Amperage Required To Start A Motor
9-2. How Much Power Can Generator Supply?
7 == IN 1 Limit Load To 90% Of Gener-
ator Output
? 1 Always start non-resistive (motor)
(> o |” loads in order from largest to
7 smallest, 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.
Ref. SB-140 092-A / S-0625
Figure 9-5. Limits Of Generator
OM-420 Page 33
9-3. Typical Connections To Supply Standby Power
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
á WARNING
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 9-6, ltem 1), and main and branch overcurrent protection (2),
and install equipment as shown in Figure 9-6.
1
240 Y
120/240 Volt ; X
60 Hz ООО y 120V Neutral
Three-Wire mm A
Service 120 V
— A
2
240 Y \
A — y >
г > Load
| y 120 V _
OO J 7
7
CB
Don
д — — = or
- MF]
5
6 Defoe
\ 240 V
— Y
120/240 Volt Y 120 V
Single-Phase X
Three-Wire — 120 V
Generator Output X
Connection Ground
—
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 applicable codes and safety practices.
Obtain and install correct switch. Tum off or unplug all equipment connected
3 Double-Pole, Double-Throw Transfer ; .
Switch 5 Extension Cord to generator before starting or stopping
wa ens engine. When starting or stopping, the
Obtain and install correct switch. Select as shown in Section 9-4. cola nas fr pass which causes low
Switch rating must be same as or greater
than the branch overcurrent protection. 6 Connections To Generator 7 Connections To Load
5-0405-A
Figure 9-6. Standby Power Equipment And Connections
OM-420 Page 34
9-4. Selecting Extension Cord
Use Table 9-3 and Table 9-4 to select extension cords. Use shortest cords possible because long cords may reduce
output er cause unit overload.
Table 9-3. Cord Lengths For 120 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
in Amberes Load In Watts 4 6 8 10 12 14
5 600 350 (106) 225 (68) 137 (42) 100 (30)
7 840 400 (122) 250 (76) 150 (46) 100 (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 9-4. Cord Lengths For 240 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
In Amperes Load In Watts 4 6 8 10 12 14
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) 60 (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-420 Page 35
SECTION 10 - PARTS LIST
<
=
т
+
QI
=
12
10- Fig 10-3 of
и . У p
| = N
57-089 990-F
Figure 10-1. Main Assembly
OM-420 Page 36
Quantity
Item Dia. Part
No. Mkgs. No. Description
Figure 10-1. Main Assembly
CT O 092247... WRAPPER .......... ie.
C2 a 134 792 ... LABEL, warning general precautionary
C3 eue 070921... SHAFT, extension switch .................
AA к... 106 398 .. . PIN, spring .156 x.625 ..................
‚5 ..... C1 ..... 156 289 ... CAPACITOR, elctlt 240uf 250VDC
не. 6 2.....,....... 087 111... CLAMP, capacitor 1.375dia .............—..
Anna, F1 .... *083596... FUSE, mintr cer 124 250V ...............
C8 TT 912571... HOLDER, fusemintr ....................
Oder 070 171 ... BRACKET, mtg switch range .
.10..... 51... 005 563 ... SWITCH, selector (Fig 10-3)
CT ве екеккк к вк 092249... PANEL, rear............. cian.
Dessen 093 003... LABEL, engine maintenance
13... ... 005005... CONNECTOR, termbody ................
I 2110 089 411 ... ENGINE, electric (consisting of)
PS 085 130 ..... LABEL, throttleconirol .................
CAS RK CONNECTOR, (included w/engine - see engine parts list)
I I 072 005 ..... LABEL, Starting instructions
17 ce. 080 514 ..... SPRING, extension .326 OD x .049 wire
‚18 .............. 086150.....CHAIN, throttle .......................
C19 0 aa 0e 602355 ..... PIN, cotter .093x.500 .................
Dessen 0e 086147 .....ROD, throttle .........................
SA кк... о. 019603.....KNOB, ball ...........................
DELL LL eau uen 086151 ..... BRACKET, migswiich .................
Dee 086 148 ..... COVER, switch .......................
CA LL. 044 453 .....STUD, 10-24 -10-32x2 ...............
Bee 085 963 .....SPRING, extension .375 OD x .041 wire
26. 010907 ..... NUT, locking1.000 ....................
CBT LL 032867 ..... FITTING, pipe elb st 1 in NPT
1: . 008 937 ..... FITTING, pipe nipple L1 in NPT x6
‚29 .............. 015621 ..... MUFFLER, exhaust engine
BO a 039508 ..... CLAMP, pipe 1.000 ....................
Sy 082 173 ..... BRACKET, muffler support
CB eee 605 181... NUT, sti sifikg hex hvy .375-16
C33 010 954... WASHER, flat stl .406 ID x 1.250 OD
‚34 2ккклу вк, 602 213... WASHER, lock split. 375 .................
Be 601 965... SCREW, cap sti hexhd .375-16 x 1.000
‚96 anna 108277... BRACKET, migengine ..................
BT 108 177... MOUNT, engine .375-16 .................
ie ee. 111 781... BRACKET, mtg capturing ................
39. 108 289 ... BASE ..... e 0
‚. 40 .............. 605 232... WASHER, spring .413 1D x .709 OD x 1/32
LA ....кннк.., 005 943 ... SCREW, cap stl hexhd .375-16 x 2.000
EC E 090 427 ... BOLT, crg stl .312-18 x 7.500 |
.-43.... BAT ....003426... BATTERY, 12V .........................
RF PEE 052 553... COVER, cable battery post red
45 083 179... CABLE, battery positive . .................
Bee. 017222... HOLD DOWN, battery ...................
AT eine 003 893... CABLE, battery negative .................
2. 48 .............. 108 178 ... MOUNT, generatoradapter ..............
‚ 49 .............. 070218 ... RETAINER, enginemount ...............
‚. 50 .............. 070 037 ... ADAPTER, engine (consisting of)
lesen 010837 .....PIN, spring CS .093 x .625
..52............. 089238... ROTOR, (consistingof) ..................
‚ 58 .............. 031 240.....FAN, rotor ........... —..eecosmarerera0
Br к., 053 390 ..... BEARING, ball rdi sgl row 1.370 x 2.830 x .6
Des 070821... STUD, .312-18 — .312-24 x 15.500
‚ 56 .............. 070 837 ... WASHER, shoulder stl .610 OD x .343 10
B87 a na ee 604 433... NUT, slilkghex 312-18 ..................
.58.............. 088264... BAFFLE, stator .........................
TEE RRRKRKKRREM 1
OM-420 Page 37
Quantity
Item Dia. Part
No. Mkgs. No. Description
Figure 10-1. Main Assembly (Continued)
BO 035 501 ... CLAMP, stl cush .250dia x .281mtg hole
...60.............. 013 367 ... LABEL, warning moving parts
..61............ 4089237... STATOR, 60Hz ..................
CB +092 458 .. . STATOR, 50Hz ..................
RE 168 385 .. . LABEL, warning battery explosion can blind
‚62 .............. 010 116... GROMMET, .375 ID x .500mtg hole
63... reco. 007 251 ... BRACKET, mtg brushholder
7 1 Lean aan» 047 879... BAR, retaining brushholder ........
65 .............. 047 885... CAP, brushholder ................
66............. *126 984 ... BRUSH, w/spring ................
BT 00000 005614... HOLDER, brush .................
‚ 68 .............. 119 148...
‚ 69 .............. 153 298... ENDBELL, (consisting of) .........
TO 143 220 ..... O-RING, 2.859 ID x .138CS
«711.1. a ae eee eee 031 281... GUARD, endcap barrel ...........
AT 006 927... HANDLE, range switch ...........
CTS a 010647... PIN, spring CS .156 x 1.250
74. LL. Fig 10-2 ... PANEL, front w/components
A aaanan 070839... STUD, stl .312-18x16.000........
TG 030 170... BUSHING, snap-in .750 1D x 1.000mtg hole
CTT nananaoannaa 010 014... CLAMP, stl cush .750dia ..........
We PE 116667 ... GUARD, choke cable .............
...79.... SR1 ....035 704... RECTIFIER, integ 40A 800V
‚ 80.... CR1 .... 119722... CONTACTOR, solenoid 12VDC 400A SPNO
81...... Z...... 089 228... REACTOR, 60Hz ................
81...... Z...... 092 528... REACTOR, 50HZ ................
Cerra 010915... WASHER, flat .257 1D brs .........
eerie ieee 097168 .. . KiT,label .......................
*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-420 Page 38
4 m = + à BB HE HE HE NE F&F ® EK 4 FB NF FN FN 4 8 4 N FN 4 FB EN
E. EN ® = % ®» = 4 & a, ин в E NE няни °F 5 3 ыы 4 4 § & & ни ви ни ©®
* § EF 4 4 ss = mm = » mw df BN Ww mE F x § § B Ts ss ss ss HE RF 2 FF NHN
г.п я 4 m = à & & EN NE F & & & F¥ §I = 5 § 4 4 нивы B® 4 = =: ®
#17 à 1 4 EEE Em = a. = = Rh om
+ 5 4 » ® BE E HE BE E E E HE ныне ки ни ни ни ни вы
BUSHING, snap-in nyl 1.968 ID x 2.500mig hole .....................
m= m= =m m mm ¥ @ & HE 5H & EE ¥F FN 4 4 4 4 NH BE BE нина нения
no = = % m= = ® = § = § ®§ §B § & & & & BF ни чин F F Ff 1 ¥ WW x =»
Item Dia. Part
+ OPTIONAL
Figure 10-2. Panel, Front w/Components
No. Mkgs. No. Description Quantity
Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 74)
AA RAS 070 170... BRACKET, mtg term assembly .............orsrenroecerirecec_—r;steoeoo 1
I~ c sua u nue 039 047 ... TERMINAL, pwr output (consistingof) .................. co... 2
TU: 220 601 879..... NUT, hex full .500-13 ................ sm. remrereoe arenero. 1
не. 111111 ae 00e 039044 ..... BUS BAR oe eee eee 1
eB 601880..... NUT, hex jam .500-13.........—esececeroerraarerresrorarciaaeoa ado 1
E - 039 049..... TERMINAL BOARD, red .............. e... .eresvirereer rentado. 1
TU AE о. 601 976 ..... SCREW, cap stl hexhd .500-13 x 1.500 ........................... 1
…. 8... S4 ..... 011 609... SWITCH, tgl SPDT 15A 125VAC ..........eeecesaerererererensenen¡ 1
.. 9... RC1,2 ...604 176... RECEPTACLE, str dx grd 2P3W 15A 125V 1222204 ea aa aa eau ae 000 2
Ce renee 073 690... PLUG, str grd armd 2P3W 15A 125V P&S 5266DF
... 9... RC4,56 . #604103... RECEPTACLE, strdx grd 2P3W 15A250V .......................... 2
ea 025 234... PLUG, str grd 2P3W 15A 250V Arrow Hart 5666
…. 10.... RC3 ....129 067... RECEPTACLE, twlk grd 3P4W 30A 125/250V ....................... 1
eee 088 898 ... PLUG, twik grd 3P4W 30A 125/250V Arrow Нап 6512 ................ 1
e Teee. S2 ..... 011611... SWITCH, tg! DPDT 15À 125V LL. 111044 ae aa ee ea ea a ea aa ea a a 0 1
..12..... S3 ..... 021 467... SWITCH, tgl SPST 3A 250V .........reseesxenevrecanmverorecarevrerevr. 1
LAB 087 245... PANEL, front «ee ia 00 1
Are eau 082329... CONTROL, push pull... i i ee eee eee nn 1
E aa ea aa aa senc ee 0 NAMEPLATE, (order by model and serial number) ................... 1
5D-085 291-A
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-420 Page 39
Item Part |
No. No. Description Quantity
Figure 10-3. Switch, Selector {Fig 10-1 Item 10)
Cee 1 ........ 005562... BRACKET, mig switch ........._eeeeeeeeeeereresao:enrerre re reses |
a 9 ........ O05561... SHAFT, rotor ...........ee ee reecarearacarerenanemenarrerecamenaa |
Cee 3 ........ 005564... INSULATOR, screw switCh ...........eo.nacoerronoranarartin.caaaaren |
na 4 ........ 605276... SCREW, cap stl hexhd .250-20 x 1.250 ......... ccna 1
ee 0 5 ,....... 005 559 ... CONTACT BOARD, movableswitch ........... ccc iii iia 1d
aa 6 ........ 005560... CONTACT, switch movable ...........—.__ 1
nad 7 ........ 008485... SPACER, contact switch .........._.ereeoracereaasnveamearrereesmeam. 1
eno. 8 ........ 005566 ... CONTACT BOARD, stationary switch ...................... ooo 1
aaa. Q .........011644 ... CONTACT, stationary SWitch .........ee.eeecrrireeare rea en 7
aa 10........ 052405... SPRING, pressure contact switeh ...........ece.eeomceriresor eran Ù
aa 11 ........ 052404... CONTACT, movable switch ...........eee_e1resexncerrrrra are 000 Ù
aaa 12........ 005557... BUS BAR, switch range ..............e e. iirc |
ea. 13........ 005558... SPRING, selector switch ..........——.—eeerereccnveorrerere car rameca. 1
13
SC-097 264-A
Figure 10-3. Switch, Selector
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-420 Page 40
NOTES
OPTIONS AND ACCESSORIES
SPARK ARRESTOR MUFFLER
(Field Kit)
(#041 263)
Mandatory when operating on
California grasslands, brush or
forest covered land and all National
Forests. For other areas, check
your state and local laws.
NO. 2WA WELDING
ACCESSORIES
(#040 039)
35’ (10.6 m) No. 2 electrode cable
with insulated electrode holder, 30°
(9 m} No. 2 ground cable with
ground clamp, welding helmet and
wire scratch brush.
240 VOLT DUPLEX
RECEPTACLE
(#041 624 Field)
Replaces one standard 120 volt
duplex receptacle. To convert
completely to 240 volis, two Kits
are required.
TWISTLOCK PLUG FOR 240
VOLT RECEPTACLE
(#088 898)
Three pole, 4 wire, 30 ampere
(NEMA L-14-30P).
CANADIAN CSA KIT
(#041 891)
NO. 4-R2 HAND RUNNING GEAR
(#040 615)
Wheelbarrow type. Includes two
wheels with 4.80-4.00/8 pneumatic
tires, axles and lifting handles.
EDT 1000-2B TWO WHEEL
TRAILER
(4042 878)
Rugged 1000 Ib. capacity trailer
designed to transport welders and
equipment. Features adjustable
bed for easy mounting of Miller and
competitive welders and other
similar construction equipment.
Permits user to achieve desired
tongue weight. Torsional axle,
leveling jack, improved fenders
with skirt and safety chains.
Optional easy-to-install fender and
light kit (#042 897) required for
highway operation. Meets or
exceeds DOT standards.
Note: Hitches must be ordered
separately.
Specifications
GAWR: 1300 ibs. (590 kg)
GVWR: 1300 Ibs. (590 kg)
Net Payload: 1000 Ibs. (454 kg)
Road Clearance:
8-1/2 in. (216 mm)
Track: 47-1/2 in. (1.2 m)
Tire Size: 4.80-12
Net Wt. 250 Ibs. (113 kg)
Ship Wt. 370 Ibs. (168 kg)
When equipped with fender and light kit
and 2” (50 mm) ball hitch this trailer
conforms to all applicable U.S. Federal
motor vehicle safety standards in effect
on date of manufacture.
When ordering trailers without fender
and light kit and bail hitch, the purchase
order must include the statement, “For
off-the-road use only.”
FENDER AND LIGHT KIT 10B
(#042 897)
Includes fenders, lights, wiring
harness and mounting hardware.
Shipping weight: 37 Ibs. (17 kg)
HITCHES
2” (51 mm) BALL
(#042 705)
Shipping weight: 5 Ibs. (2 kg)
CLEVIS
{Not for highway use)
(#042 707)
Shipping weight: 11 Ibs. (5 kg)
2-1/2” (64 mm) LUNNETTE EYE
(#042 706)
Shipping weight: 9 Ibs. (4 kg)
CC-1R1 CANVAS COVER
(#040 495)