Miller BIG 30 DIESEL Owner's Manual

Nov. 1987
Effective With Serial No. JG098154
MODEL
BIG 30 DIESEL™
OWNER'S MANUAL
EU IE Read and understand the entire contents of this manual,
with special emphasis on the safety material throughout the manual,
before installing, operating, or maintaining this equipment. This unit and
these instructions are for use only by persons trained and experienced in
the safe operation of welding equipment. Do not allow untrained persons
to install, operate, or maintain this unit. Contact your distributor if you
do not fully understand these instructions,
Miller Electric Mfg. Co.
A Miller Group Lid, Company
PO. Box 1079
Appleton, Wi 54912 USA
Tel. 414-734-9821
PRINTED IN U.S.A,
FORM: OM-473A
« This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied,
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FERIA RIA IE IZ IZ ROSE SE STE SL ON
EFFECTIVE: OCTOBER 1, 1986
LIMITED WARRANTY - Subject to the terms and condi-
tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new and unused
Equipment furnished by Miller is free from defect in workman-
ship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any . All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
have a two year warranty.
Except as specified below, Miller's warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material,
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
ment to the original user:
1. Arc welders, power sources, robots, and components . 1 year
2. Loadbanks ........... ea a eee» 1 year
3. Original main power rectifiers ................. 3 years
(labor - 1 year only)
4. All welding guns, feeder/guns and plasma torches .. . 30 days
5. Alt other MillermaticFeeders . .................. 1 year
6. Replacement or repair parts, exclusive of labor .. 60 days
7. Batteries ............_eexevreereroroecen e. 6 months
provided that Miller is notified in writing within thirty (30) days
of the date of such failure. |
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Miller's option (1) repair. or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price {less reasonable depreciation based upon actual use) upon
return of the goods at Customer's risk and expense. MILLER’s
option of repair or replacement will be F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authonzed service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NO7 FOR CONSUMERS OR
CONSUMER USE. MILLER'S WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER.
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Section No.
Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
1-2.
1-3.
1-4.
Introduction RR KR RR +
General Precautions . . .. ott aaa
Arc Welding.............. eee
Standards Booklet Index ..............eoeoePorcesvan vere rene.
SECTION 2 - INTRODUCTION
М Ро Кю ю
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Volt-Ampere CumVveS RR KK
Оиту Сус! «oe eee eae
General Information And Safety ........... cia,
Receiving-Handling .......... iii 5
Description «eee
SECTION 3 - INSTALLATION
+ 1
62 62 60 OU Y Www
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Location ......... 122201000000 eee ea
Connecting The Battery . icin
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Lubrication. ee eee a ee
Equipment Grounding Terminal .................. oc een eee
Weld Quiput Connections... ...... ie aaa
Remote Control Receptacle Information And Connection (Optional)
SECTION 4 - AUXILIARY POWER
4 -
4 -
4 -
1
2
3
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5-14.
5-15.
120 Volts 26 Amperes AC Duplex Receptacle And Circuit Breakers .
240 Volts 13 Amperes AC Duplex Receptacle And Circuit Breakers .
7.5 KVAACPowerPlant(Optional). . ............... it.
~- OPERATOR CONTROLS
Range SWITCh «Le
Amperage & Voltage Adjustment Control. ......... con,
Heat/Start Switch ......124122 11100444 a a 4e ee se ae ee 1 a a een»
Auto idle Switch ......120220010 000001044444 eee ee eee ea ee 6
Battery Charging indicator Light............__e—ere=esexeerverao
Engine Temperatur And Oil Pressure Lamp .........—.eevreseree.
Total Hour Meter (Optional) ............—.—e_mrreseveerreereacen.
Qil Pressure Gauge (Optional) .............e...e. 0.08 о.
Temperatur Gauge (Optional) .................e-er0ereeereee.s
Safety Shutdown Switch (Optional) ..............._e..ereveree.
Polarity Switch (Optional) .................ee2esrerrerreeer
Remote Control Receptacle And Contactor Control Switch
(Optional)... oan
Remote Control Receptacle And Current Control Switch
(Optional)... A AA AA
Meters (Optional) ........112111104 00414 Lee aa ae aa eee eee
Radiator Shutters (Optional) . .... i
SECTION 6 - SEQUENCE OF OPERATION
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Shielded Metal Arc Welding (SMAW) .... aint,
Optional 7.5 KVA Power Plant Operation . ...... eae .
Starting The Engine ............. 0... .......... RS ,
Engine Shut DOWN een s eee ee a ea ea sa sa ee ea ee eee
©) 45 — =
Co CO QO 00 ~J
10
10
10
10
11
12
13
13
14
14
14
15
15
15
15
15
16
16
16
16
16
17
17
18
Section No.
SECTION 7 - MAINTENANCE
- General...........e ee. rererazooerareranaareanrarecrenmna
- Periodic Cleaning And Inspection ...............eeecece0n ....
- Fuel/Water Separator And Sludge DrainPlug ................
- Air Cleaner Service ............... e... enicC.Cre.orramen.
- Electrical System... oot ee ee eee as
Fuse Wire. te ee RR
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Fuse Replacement Procedure For Power Plants And Safety
Shutdown System 12.121000 0 La a ee ee a a a a ea ea ea e
Auto Idle Board PC? Replacement Procedure. ................
Regulator Board PC2 Replacement Procedure ................
~~
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SECTION 8 - TROUBLESHOOTING
00 00 00 CO
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Servicing The Optional Spark Arrestor. . . ....................
Brushes And Sp RINGS «oo iii i iii ieee
Engine Speed Adjustments ........... ii ii 0 00
Maintenance-fFree Battery Charging. ................. coven,
Booster Battery Jump Starting ...............—c_e.eeeeeereeeo.
Resetting Circuit Breakers .............—..—.e_eeeeeeraccorvero.
Troubleshooting Chart .............._..eeeeeeexacededr ee.
mSECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCEm
1-1. INTRODUCTION - We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un-
wise. Let the experience of others teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and fieid experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. 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 at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
These safe practices are divided into two Sections:
1 - General Precautions, common to arc welding and
cutting; and 2 - Arc Welding {and Cutting} (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANS] Z49.1 is
the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements aiso provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases,
and radiation levels. In addition to the information
in this manual, be sure to consuit flux and elec-
trode manufacturers for specific technical data
and precautionary measures concerning their
material. |
A. Burn Prevention
Wear protective clothing - gauntiet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks. and slag. -
Wear helmet with safety goggles or glasses with side ;
shields underneath, appropriate filter lenses or plates
{protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion *
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan-
dard 749.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium -
bearing and similar materials, when welded (or cut) may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us-
ed.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ven-
tilated, or the operator wears an air-supplied respirator,
Work in a confined space only while it is being ven-
tilated and, if necessary, while wearing an air-supplied
respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into
a confined space,
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
OM-473 Page 1
highly toxic gas, and other lung and eye irritating pro-
ducts. The ultraviolet (radiant) energy of the arc can
also decompose trichloroethylene and per-
chioroethylene vapors to form phosgene. DO NOT
WELD or cut where solvent vapors can be drawn into
the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
minute amounts of trichioroethylene or per-
chloroethylene. |
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator, Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in 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, ven-
tilators. If the work cannot be moved, move com-
bustibies at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on {or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire ex-
tinguishing equipment during and for some time after
welding or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
C. openings {concealed or visible) in floors or
walls within 35 feet may expose com-
bustibles to sparks
d. combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions
have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic- vapors when heated, must
OM-473 Page 2
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard AB6.0,
listed 7 in Standards index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com-
bustible's solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.0. Waterfilling just
below working level may substitute for inerting.
A container with unknown contents should be cleaned
(see paragraph above}. Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN
CYLINDERS, listed 11 in Standards index.
1. Pressure Regulators
Regulator relief vaive is designed to protect only the
regulator from overpressure; it is not intended to
protect any downstream equipment. Provide such
protection with one or more relief devices.
Never connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
Remove fauity regulator from service immediately
for repair (first close cylinder valve). The following
symptoms indicate a fauity regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to
rise with downstream valve closed.
Faulty Gauge - if gauge pointer does not move off
stop pin when pressurized, nor returns to stop pin
after pressure release.
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturer's designated
repair center, where special techniques and tools
are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent
leaks and damage to their walls, valves, or safety
devices:
Avoid electrical. circuit contact with cylinders in-
cluding third rails, electrical wires, or welding cir-
cuits. They can produce short circuit arcs that may
lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is
an assurance of safety when the cylinder is properly
handled.
Identifying gas content. Use only cylinders with
name of gas marked on them; do not rely on color to
identify gas content. Notify supplier if unmarked.
NEVER DEFACE or alter 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 or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try 10 mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchang-
ed.
3. Hose
Prohibited use. Never use hose other than that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases. |
Use ferrules or clamps designed for the hose (not or-
dinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings 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 otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT use tape.
4, Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter {available from your sup-
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet {or hose) connections may be iden-
tified by right hand threads for oxygen and left hand
threads {with grooved hex on nut or shank} for fuel gas.
5. Pressurizing Steps:
Drain reguiator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in {clockwise). Draining prevents ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings On
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution tcapful of Ivory
OM-473 Page 3
Liquid* or equivalent per gallon of water}. Bubbles in-
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn,
1-3. ARC WELDING - Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us-
ed. The wise operator avoids unnecessary risks and pro-
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. its radia-
tion can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DON'T GET BURNED; COMPLY WITH PRECAU-
TIONS,
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-
resistant leggings. Avoid outergarments of untreated
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place
over face before striking arc.
*Trademark of Proctor & Gamble.
OM-473 Page 4
Protect filter plate with a clear cover plate.
Cracked or broken heimet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when
‘broken, pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shieided arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision,
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a
separate room or enclosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustible screens or panels. Allow for free air circula-
tion, 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 that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity, Do not overload arc
welding 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 later under rough
handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electricaliy-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part - or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 “Safety In Welding And Cut-
ting,” a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
When instailing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li-
quid such as oil or fuel. |
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground lead to the third (live) wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections. |
If a line cord with a ground lead is provided with the
equipment for connection to a 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 lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacie. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly ~ lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6. Electrode
a. Equipment with output on/off control (con-
tactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normaily are equipped with devices that per-
mit on-off control of the welding power out-
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b. Equipment without output on/off control
{no contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar pro-
cesses may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never touch the electrode unless the
welding power source is off.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip-
ment, shut OFF all power and remove line fuses (or lock
OM-473 Page 5
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cabies from welding power
source, and puli all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be availabie near the
welding power source.
F. Protection For Wearers Of Electronic Life
Support Devices (Pacemakers)
Magnetic fields from high currents can affect
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going near arc welding, gouging, or
spot welding operations.
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards
or their latest revisions and comply as applicable:
1. ANSI Standard 749.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
2. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern-
ment Printing Office, Washington, D.C. 20402.
4. ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
5, ANSI Standard 241.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainabie from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-473 Page 6
10.
11.
12.
13.
14.
15.
ANSI Standard 749.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd.
Р.О. Вох 351040, Miami FL 33135.
NFPA Standard 51, OXYGEN - FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob-
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadeiphia, PA 19103.
American Welding Society Standard AWSF4.1
“Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances”,
obtainable from the American Welding Society,
550 Le Jeune Rd. P.O. Box 351040, Miami, FL 33135.
ANSI Standard Z88.2 ‘Practice for Respiratory
Protection” obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
Es SECTION 2 - INTRODUCTION — —
DC
Amperage Single-Phase
Rated Rated Ranges, Fine Max AC
Output @ Output @ | Adjustment Open Auxiliary Weight
60% 100% In Each Circuit Power
Duty Cycle | Duty Cycle Range Voltage | While Weiding Net Ship
40-312 1.0 Power Factor
250* 200* Min. - 60 3kva/kw 60 Hz
Amperes Amperes 50-100 26 Amps @ 120V | 1303 ibs. | 1327 Ibs.
@ 30 Volts | @ 28 Volts 60-150 95 | 13 Amps @ 240V | (591 kg) | (602 Ка)
DC DC 90-225
140 - Max.
Conforms with NEMA EW1T (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES”, Class (60/100)
*Capable of producing this amperage at 40 volts dc.
Figure 2 - 1. Specifications
21/32 in. Diameter
(16.7 mm)
All Hotes
~~ * (| {Base Mounting Hole Dimensions
Ts Engine End Y Inches Millimeters
un oo
= Pe : $ Вот А 51-1/8 1298.6
и | B 41-1/8 1044.6
[= A С 13-7/8 352.4
ZA D 2-7/8 73
| i
в. i
36-1/2 in. & o] = 23172 >
(927mm) xa > |
7 o
~~ ВЕ
i ой A7 5 + ‚ т | !
us > 53-3/4 in. > Cc il
у” ‚| „А1365.Зтит) - 23-1/2 т. _ D
24-1/4 > о (591 mm) |
(594mm < a
> E TB-110 850
Figure 2 - 2. Dimensions And Base Mounting Hole Layout
2-1. VOLT-AMPERE CURVES (Figure 2-3) 100
90
70
The Volt-Ampere curves show the output voltage and © 60
current of the welding generator available at any point S
from the minimum to maximum of each coarse current >
о
range. < 40
With the use of the Volt-Ampere curves it is possible to 30
determine what the weld current will be at a particular 20 N
arc voltage. The Volt-Ampere curves show the
minimum and maximum curves of each coarse current 10
range. j | ] ] ]
0 150 200 250 300 350 ‘400
AC AMPERES
B-109 295
Figure 2 - 3. Volt-Ampere Curves
OM-473 Page 7
2-2. DUTY CYCLE (Figure 2-4) - The duty cycle of
a welding generator is the percentage of a ten minute
period that a welding generator can be operated at a
given output current setting without causing
overheating and damage to the unit. This welding
generator has dual duty cycle ratings, each for a specific
amperage output range. See Figure 2-1 for various
amperage output ranges and associated duty cycles. If
this unit is operated in the 250 ampere output range,
the duty cycle of the unit is rated at 60 percent. This
means that the unit can be operated at rated load for six
minutes out of every ten. During the remaining four
minutes, the unit should idle {no load) to permit proper
cooling. If the welding amperes decrease, the duty cy-
cle increases. When this unit is operated in the 200
ampere output range, the duty cycle of the unit is rated
at 100 percent. This means that the welding generator
can be operated continuously. Figure 2-4 shows the
output of the unit at various duty cycles.
ELH ELE EXCEEDING DUTY CYCLE RATINGS
will damage the welding generator.
e Do not exceed indicated duty cycles.
600
200
400
Lad
=
|=.
WELD AMPERES
2
—
un
=o
100
10 15 20 25 30 40 50 60 70 80 90 100
% DUTY CYCLE 5-109 235
Figure 2 - 4. Duty Cycle Chart
2 - 3. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip-
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip-
ment.
OM-473 Page 8
The nameplate of this unit uses international symbols
for labeling the front panel controls, The symbols also
appear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Rules For Operation Of
Arc Welding Power Source.
Safety instructions specifically pertaining to thts unit ap-
pear throughout this manual highlighted by the signal
words EXZ LIL and EZ which identify
different levels of hazard.
EZLN statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal! word, Ele highlights instruc-
tions which need special emphasis to obtain the most
efficient operation of this equipment.
2 - 4. RECEIVING-HANDLING - Before installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
2-5. DESCRIPTION - This unit is a diesel engine-
driven dc arc welding generator. It is designed for use
with the Shielded Metal Arc Welding {SMAW) process.
In addition to welding capability, this unit is equipped to
provide up to 3 kva of 120 volts ac, 26 amperes or 240
volts ac, 13 amperes electrical power while welding.
Power available when welding depends on the amount
of welding current used.
Optional equipment includes weld meters, polarity
switch, hour meter, low oil pressure - high coolant
temperature shutdown, remote amperage control,
remote output/contactor control, and 7.5 kva/kw
single-phase power plant.
Es SECTION 3 - INSTALLATION toms mm
3-1. LOCATION (Figure 2-2) - Á proper installation
site should be selected for the welding generator if the
unit is to provide dependable service and remain
relatively maintenance free.
ANNE ENGINE EXHAUST GASES can kill.
Operate in open, well-ventilated areas or if
operated indoors vent engine exhaust outside the
building.
® Keep engine exhaust vent outlet away from
building air intakes.
RESTRICTED AIR FLOW causes
overheating and possible damage to internal
parts.
e Maintain at least 18 inches (457 mm} of
unrestricted space on all sides of unit and keep
underside free of obstructions.
e Do not place any filtering device over the intake air
passages of this welding generator.
Warranty is void if any type of filtering device Is used.
The service life and operating efficiency of this unit are
reduced when the unit is subjected to high levels of
dust, dirt, moisture, corrosive vapors, and extreme
heat.
A. Lifting Of Equipment
EZLN FALLING EQUIPMENT can cause
serious personal injury and equipment damage.
e Use lifting eye to lift unit only, NOT running gear,
gas cylinders, trailer, or any other heavy options,
accessories, or devices.
e Use equipment of adeguate capacity to lift the
unit,
e /f using lift forks to handie this unit, be sure the lift
forks are long enough to extend out of the op-
posite side of the base.
Using lift forks too short will expose internal com-
ponents to damage should the tips of the lift forks
penetrate the bottom of the unit.
This welding generator is provided with a lifting eye for
moving the unit.
B. Mounting
СеЛЫ Е UNCONTROLLED TILTING OF
TRAILER can result in personal injury or equip-
ment damage.
® [Distribute weight so that trailer tongue weight is
approximately 10% of the gross trailer weight.
e Follow trailer manufacturer's instructions when
mounting welding generator onto trailer.
OPERATION ON UNLEVEL SURFACE can cause
improper lubrication and result in severe engine
damage.
e Operate unit in an approximately level position,
e See Figure 3-1 for maximum allowable tilt for pro-
per operation.
e Check crankcase oil level with unit on a level sur-
face.
Exceeding these limits can cause severe engine
damage.
Engine
End
Side View
IF Lt
35° Вр
Ÿ
T
359
End View
45° ~~] —
45° вы <
TA-046 152
Figure 3 - 1. Allowable Tilt Angles
Holes are provided in the base for securing the unit in a
permanent location, or to a trailer, running gear, or
transport vehicle. Figure 2-2 gives overall dimensions
and base mounting hole layout.
The mounting location should aliow sufficient room to
remove the top cover and side panels for maintenance
and repair functions.
Use a properly fitting canvas cover (optional) to cover
the weld generator when not in operation to protect the
unit from the environment. Be sure unit is cool before
installing any cover.
C. Spark Arrestor Considerations
EZULILIGE ENGINE EXHAUST SPARKS can
cause fire.
e Exhaust spark arrestor must be installed in accor-
dance with local, state, and federal regulations.
The engine exhaust system on this welding generator is
NOT equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory If
this welding generator is to be operated in a National
Forest or on California Grasslands, brush, or forest
covered land (see Section 4442 of California Public
Resources Code). For other areas, check your state and
local laws. If a spark arrestor (optional) is desired, con-
tact your dealer/distributor.
OM-473 Page 9
3 - 2. CONNECTING THE BATTERY
BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
e Wear a face shield and proper protective clothing
when working with batteries.
ABNORMAL VOLTAGE can cause damage to
engine electrical components.
® Do not operate engine without the battery con-
nected. |
e Do not disconnect the battery while the engine is
running.
This unit is equipped with a maintenance-free battery.
To place the unit in service, connect the negative (-)
battery cable to the negative battery terminal. No other
preparation should be required. If the battery does not
supply enough power to crank the engine, the battery
will require charging. See Section 7-10 for battery
charging procedures,
3 - 3. FUEL (Figure 3-2)
ET GRE ENGINE FUEL can cause fire or ex-
plosion.
Do not spill fuel; if spilled, wipe up.
Do not fill fuel tank if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill fuel tank completely; cold fuel will ex-
pand when subjected to heat causing overflowing
and spillage.
USE OF GASOLINE will damage engine.
e Do not use gasoline to fuel a diesel engine.
Lack of lubrication in the fuel will damage the injector
pump and injectors.
This welding generator is shipped with a small amount
of fuel in the fuel tank, and the fuel shut-off valve,
located under the fuel tank, in the open position. See
the Engine Manufacturer's Manual for fuel recommen-
dations. The capacity of the fuel tank 1s 11.3 gallons
{42.8 liters).
IMPORTANT Fil fuel tank with fresh fuel before
starting engine the first time. Rust and corrosion
preventative was added to inside of fuel tank and engine
at the factory and could cause rough engine running if
not properly diluted with a full tank of fresh fuel.
Keep the fuel tank filled to ensure that the injector
system receives an adequate supply of fuel. If the fuel
tank is allowed to empty, air will enter the system caus-
ing starting problems. The Engine Manufacturers
Manual outlines procedures for air venting the fuel
system.
Figure 3-2 illustrates typical fuel consumption under
specific load conditions. Fuel consumption will vary
from one engine to another. Different brands of fuel,
operating conditions, condition of the engine, etc., will
affect the fuel consumption of this engine.
OM-473 Page 10
LITERS/HR
IMP. GAL./HR,
U.S. GAL/HR
m -
m in
м оч
— el
Bow
п ©
= MM
“=
по ©
1.25
tn
Tn
|
“а
ch
=
4.73 1.04 1.25
3.78 083 1.00
284 062 0.75
1.98 0.40 60.50
0.95 0.21 0.25
М.
0 50 100 150 200 250 300 350
DC WELD AMPERES AT 100% DUTY CYCLE
B-109 224
Figure 3 - 2. Fuel Consumption Chart
3-4. LUBRICATION - The engine is shipped with its
crankcase filled with SAE 20 break-in oil. If the oil level
is not up to the full mark on the dipstick, add oil accor-
ding to the recommendations in the Engine Manufac-
turer's Manual before starting the engine.
3 - 5. EQUIPMENT GROUNDING TERMINAL
EQUIPMENT
— GROUND
This unit is equipped with a grounding terminal for
grounding the generator case. Since the generator
neutral is connected to the frame, the equipment groun-
ding terminal must be connected to a proper earth
ground. Additionally, comply with alt national, regional,
and local codes concerning portable generators for the
specific application.
For detailed grounding instructions consult your na-
tional, regional, and local codes and the latest issue of
the National Electrical Code. If additional information
regarding your particular operating circumstances
and/or grounding requirements is needed, consult a
qualified electrician or your dealer, After determining
the extent to which any grounding requirements apply
to your particular situation, follow them explicitly.
3-6. WELD OUTPUT CONNECTIONS {Figure 3-3)
4 ©
WELD OUTPUT
To obtain the full rated output from this unit, it is
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
A. Welding Cables
If welding cables were not ordered with this unit, the |
steps listed should be followed to ensure the best
welding performance:
1. Keep cables as short as possible and place cables
close together. Excessive cable length adds
resistance which may reduce output or cause
overloading of the unit.
2. Select adequate size welding cable for the an-
ticipated maximum weld current. Use total
length of welding cable in the circuit to deter-
mine cable size. For example: If the electrode
holder cable is 75 feet 123 m) long and the work
cable is 25 feet (8 m) long, select the size cable
recommended in Table 3-1 for 100 feet (31 m).
3. Do not use damaged or frayed cables.
4. Install electrode holder onto cable following
manufacturer's instructions. An insulated elec-
trode holder must be used to ensure operator
safety.
5. Install correct size lugs of adequate amperage
capacity onto remaining end of electrode holder
cable and onto both ends of work cable.
Table 3 - 1. Welding Cable Size
*TOTAL LENGTH OF CABLE (COPPER) IN WELD CIRCUIT
WELDING
AMPERES | "50 | 100 150 200 250 300 350 400
100 4 4 2 2 2 7 1/0 1/0
150 2 2 2 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1/0 1/0 1/0 2/0 3/0 4/0 4/0 2-2/0
300 2/0 2/0 2/0 3/0 4/0 4/0 2-2/0 | 2-3/0-
350 3/0 3/0 3/0 4/0 4/0 2:2/0 1 2-3/0 2-3/0 |
A-002 702-A
NOTE: *A. S50FEET OR LESS.
*B. CABLE SIZE 15 BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
"С. 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.
6. Install work clamp onto cable,
B. Installation (Figure 3-3)
POSITIVE NEGATIVE
+ =
KZUWIETSE ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Shut down the engine and disconnect negative {-)
battery cable before making any weld output con-
nections. |
MOVING PARTS can cause serious injury. |
e Keep clear of moving parts, ie., fans, belts,
rotors, ete.
For Shielded Metal Arc Welding (SMAW) (Electrode
Positive/ Reverse Polarity)
1. Open left side door and route weld cables
through bracket on left front upright. Connect
end of electrode holder cable to POSITIVE (+)
weld output terminal.
The connection shown is
for Direct Current
Electrode Positive
Equipment
Grounding
Terminal
Negative Weid
Output Terminal
Positive Weld
Qutput Terminal
TA-110 849-4
Figure 3 - 3. Weld Output Connections
2. Connect one end of work cable to NEGATIVE (-)
weld output terminal and remaining end to
workpiece.
3. Close and secure side door.
EURO NURNUE For Direct Current Electrode
Negative/ Straight Polarity connections, reverse cable
connections to weld output terminals, electrode
becomes negative. |
3-7. REMOTE CONTROL RECEPTACLE INFOR-
MATION AND CONNECTION (Optional) (Figures
3-4 And 5-1)
De IO Although the term CONTACTOR is
used on the nameplate and throughout this manual, the
output is not switched on or off by a physical output
contactor; rather, the output is controffed by opening
and closing the windings of the revolving field, thereby
functioning as a contactor.
The five-socket Amphenol REMOTE receptacie RC3
provides a junction point for connecting a Remote Con-
tactor and/or Amperage Control to the control circuitry
of the welding generator. To connect the remote con-
trol device, align keyway, insert five-pin plug from
remote control device into REMOTE receptacle, and
rotate threaded collar fully clockwise.
OM-473 Page 11
Receptacle RC3 socket connections to the welding
generator control circuitry are as follows:
Socket A: Contactor control switch connection.
Socket B: Contactor control switch connection.
Socket C: Amperage control connection {maximum
side).
Socket D: Amperage control connection (minimum
side).
Socket E: Amperage control connection (wiper con-
tact).
—— SECTION 4 - AUXILIARY POWER
[D (>
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT can
damage internal parts.
e Do not touch live electrical parts.
e Shut down the engine and disconnect negative {-}
battery cable from battery before making internal
inspection or reconnection.
e Keep clear of moving parts, Le, fans, belts,
rotors, etc.
e Do not connect to any electrical distribution
system normally supplied by utility power unless a
proper transfer switch and grounding procedure
are employed.
® Ground generator as required by any applicable
national and local electrical codes.
e Keep all covers and panels in place while
operating.
Warranty is void if the welding generator is operated
with any portion of the outer enclosure removed.
ELECTRIC SPARKS can cause fire.
e Disconnect welding cables when using auxiliary
power.
e Watch for fire.
e Have a fire extinguisher nearby and know how to
use it.
The weld output terminals are electrically energized
when the engine 15 running.
LOW VOLTAGE AND FREQUENCY
can damage electrical equipment.
e Turn off or unplug all electrical equipment con-
nected to the 120 or 240 VOLTS AC receptacle
and the 7.5 kva ac power plant before starting,
stopping, or idling the engine.
When starting, stopping, or idling the engine has low
speed which causes low voltage and frequency.
WER :UNR This unit is designed to supply single-
phase 60 Hz ac auxiliary power when operating at
weld/ power rom only.
De] 9: UE Auxiliary power outputis independent
of the Range switch and Fine Amperage/ Voltage Ad-
justment contro! positions.
OM-473 Page 12
A-111 367
Figure 3 - 4. Front View Of 5-Socket Amphenol
Receptacle With Socket Locations
4-1. 120 VOLTS 26 AMPERES AC DUPLEX
RECEPTACLE AND CIRCUIT BREAKERS (Figures
4-1 And 5-1)
120V 26 A № АС
Rated auxiliary power output is 3 kva of 120 volts ac 60
Hz at the 120V 26 A duplex receptacle RC1. This duplex
receptacle provides auxiliary power for operating cord-
connected accessory equipment when the engine is
operating at weld/power rpm.
Up to 15 amperes can be drawn from either half of the
120 VOLTS AC duplex receptacle; however, total load
on the duplex receptacle cannot exceed 26 amperes.
The combined continuous load of all receptacles cannot
exceed the kva rating of the generator.
Circuit breakers CB1 and CB2 are provided to protect
each half of the 120V 26A duplex receptacle from
overload and fault conditions. If either half of this
duplex receptacle is overloaded, only the overloaded
half becomes inoperative; the remaining portion is fully
operational.
260 130
250 125
240 120
230 115
Po
Mo
©
—
—
=
210 105
200 100
AC POWER VOLTS
190 95
180 90
| | ] 1
0 10 20 30 49 50
AC POWER AMPERES AT 120V.
5 10 15 20 25
AC POWER AMPERES AT 240V.
TB-109 236 |
Figure 4 - 1. AC Power Curve For 120 And 240
Volts AC Receptacle
4-2. 240 VOLTS 13 AMPERES AC DUPLEX
RECEPTACLE AND CIRCUIT BREAKERS (Figure
5-1)
240V 13A 4Ny AC
Rated auxiliary power output is 3 kva of 240 volts ac 60
Hz at the 240V 13A duplex receptacle RC2. This duplex
receptacle provides auxiliary power for operating cord-
connected accessory equipment when the engine is
operating at weid/power rpm. However, the power
available is dependent on the amount of power being
drawn from the 120 VOLTS AC duplex receptacle.
Up to 13 amperes can be drawn from either half of the
240 VOLTS AC duplex receptacle. The combined con-
tinuous load of all receptacles cannot exceed the kva
rating of the generator.
Circuit breakers CB3 and CB4 are provided to protect
the 240V 13A duplex receptacle from overload and fault
conditions. If either half of this duplex receptacie 1s
overloaded, the respective circuit breaker will trip and
stop output to both receptacie halves.
4-3.7.5 KVA AC POWER PLANT (Optional)
(Figures 4-2 And 4-3)
A. General
150 ; 300
- 7,5 KW
2 190 1 200 Г
— L
o
р
с 75 | 150 FF
< fs
50 1 100
25 SOF
O 1 1 | Г 1 I à 1 1 | I
O IO 20 50 40 50 60
AC AMPERES IN 240V MODE
0 20 40 60 80 190 120
AC AMPERES IN I20V MODE
В-110 807
Figure 4 - 2. AC Power Curve For 120/240 Voits
AC Terminais {No Welding Load
Condition)
The terminals, located behind the right side door, pro-
vide 7.5 kva of 120/240 volts ac, 31 amperes, 50/60
Hz power for operating power tools or providing stand-
by service to rural, residential, or other buildings requir-
ing 120/240 volts ac, 3 wire connection. The voltage at
the 120/240 volts ac terminals will vary according to
the applied load. The voltage at various loads can be
determined from Figure 4-2.
B. Connection Procedure
RNE ELECTRIC SHOCK can kill.
Keep junction box cover in place while engine is
running.
® Shut down the engine and disconnect the
negative {-) battery cable before making connec-
tions or changing fuses.
® Ground in accordance with NEC, state, and local
codes; install circuit grounding lead (inside junc-
tion box} to box mounting hardware and ensure
that a proper ground is connected to the Equip-
ment Grounding Terminal provided on the equip-
ment frame.
INCORRECT FUSE SIZE can damage equipment.
® Use fuses no larger than 45 ampere rating.
INCORRECT VOLTAGE OR FREQUENCY can
damage equipment.
® Read all equipment instruction manuals before
making connections.
© Use only equipment suitable for operation on
50/60 Hz power.
e Turn off or disconnect electrical equipment from
120/240 volts fuse block before starting or stopp-
ing the engine.
® Rotate AMPERAGE & VOLTAGE ADJUSTMENT
control to 100.
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Single-Phase Power
Figure 4 - 3. Power Plant Connections:
OM-473 Page 13
1. Open right side door, and secure in open posi-
tion.
2. Remove cover from junction box.
3. Install circuit grounding lead if required.
4. Remove snap-in blank from junction box.
5. install proper connector (not supplied) into open-
ing, and route load leads through connector into
junction box.
6. Strip approximately 3/4 (19 mm) of insulation
from ends of leads, and connect to proper load
terminals (see Figure 4-3); tighten connectors
securely.
7. Reinstall cover onto junction box.
8. Close and secure right side door.
Ts SECTION 5 - OPERATOR CONTROLS sess
Range Switch
Engine Temperature
And
Oil Pressure Lamp
Sy
Auto Idle
Switch —
Battery Charging
| ON indicator
| [ve 1
mm HEAT/START
Heat/Start
Switch
———————— Amperage & Voltage
Adjustment Control
120 VAC Receptacle
TB-110 848
Circuit Breakers
Figure 5 - 1. Front Panel Controls
DOE Once a week move al! controls and.
switches through their entire sequences. This pro-
cedure will provide better general performance and less
downtime, especially in corrosive or dirty environments.
5-1. RANGE SWITCH (Figure 5-1)
A
AMPERE RANGES
The Range switch provides five coarse amperage
ranges. The range of each switch position is displayed
on the nameplate.
ARCING can damage switch con-
tacts. |
e Do not change the position of the Range switch
while welding or under load.
Arcing causes the contacts to become pitted and even-
tually inoperative.
5-2. AMPERAGE & VOLTAGE ADJUSTMENT
CONTROL (Figure 5-1)
A/V
The AMPERAGE & VOLTAGE ADJUSTMENT control
permits the operator to select a welding amperage and
OM-473 Page 14
open-circuit voltage between the minimum and max-
imum values of the coarse range selected by the Range
switch. The scale surrounding the AMPERAGE &
VOLTAGE ADJUSTMENT control is calibrated in per-
cent and does not indicate an actual amperage value.
5-3. HEAT/START SWITCH (Figure 5-1)
wc HEAT/START
The HEAT/START switch actuates the engine starter,
controls the glow plug circuitry, and turns battery
voltage to the engine gauges on or off.
A. OFF Position
Placing the HEAT/START switch in the OFF position
shuts the welding generator down and removes battery
voltage from the engine gauges.
B. ON Position
Piacing the HEAT/START switch in the ON position
energizes the welding generator glow plug system,
places the welding generator in a ready-to-start status,
and applies battery voltage to the engine gauges.
C. HEAT Position
This unit is provided with glow plugs to aid initial start
up. Placing the HEAT/START switch in the HEAT posi-
tion causes the glow plugs in the cylinder head to heat
up, thereby providing a warm air-fuel mixture for com-
bustion. At 70°F (21°C) ambient temperatures, the
HEAT/START switch should be held in the HEAT posi-
tion approximately 20 seconds before starting engine;
at -4°F (-20°C) the HEAT/START switch should be
held in the HEAT position approximately 25 seconds
before starting engine.
IMPORTANT 4 Fuse wire protects the engine cir-
cuitry from damage caused by glow plug failure. If the
fuse wire opens, the glow plugs are disconnected from
the engine circuitry. See Section 7-6.
D. HEAT/START Position
Placing the HEAT/START switch in the HEAT/START
position causes the start motor and glow plug system to
function, thereby starting the engine. Release the
switch as soon as the engine starts. The HEAT/START
switch will automatically return to the RUN position.
REENGAGING STARTER MOTOR
while flywheel is rotating can damage starting
components.
e Do not reengage starter motor until starter pinion
and flywheel have stopped rotating.
® Do not use ether to start engine.
5-4. AUTO IDLE SWITCH (Figure 5-1)
o
AUTO
IDLE
When the AUTO IDLE switch is in the ON position, the
idle device automatically throttles engine speed down to
¡dle rom (1200) when the welding generator is not ioad-
ed. When an arc is struck or a 120 volts ac power load is
applied to the generator the engine automatically comes
up to weld speed {1850 rpm). Place the AUTO IDLE
switch in the ON position for Shielded Metal Arc
Welding (SMAW).
When the AUTO IDLE switch is in the OFF position, the
engine runs continuously at weld speed.
LOW VOLTAGE AND FREQUENCY
can damage electrical equipment.
e Turn off and disconnect all electrical equipment
connected to auxiliary power receptacles and ter-
minals, if applicable, before starting, stopping, or
idling the engine.
When starting, stopping, or idling, the engine has
low speed which causes low voltage and frequen-
су.
5 - 5. BATTERY CHARGING INDICATOR LIGHT
(Figure 5-1)
The Red BATTERY charging indicator light will be on
when engine battery charge current is not flowing.
When the engine is running, this light should not be on.
If this light comes on while the engine
is running, immediately shut down the engine and
determine the cause. Do not attempt to operate the
engine again until the trouble has been remedied.
BATTERY
5-6. ENGINE TEMPERATURE AND OIL
PRESSURE LAMP (Figure 5-1)
QT, E OIL & TEMP.
The OIL € TEMP warning lamp turns on if the oil
pressure decreases below 8 psi or if the coolant
temperature increases above 240°F. It is normal for this
lamp to be on when the Heat/Start switch is in the ON
position and the engine is NOT operating.
If this light comes on while the engine
is running, immediately shut down the engine and
determine the cause. Do not attempt to operate the
engine again until the trouble has been remedied.
5-7. TOTAL HOUR METER (Optional) - This unit
can be equipped with an hour meter. The meter, labeled
TOTAL HOURS, registers the total hours of engine
operation. This information is useful for routine
maintenance on the engine.
5-8. OIL PRESSURE GAUGE (Optional) - This
unit can be equipped with an optional OIL PRESSURE
gauge which registers the lubricating system pressure in
pounds per square inch. The pressure registered by the
gauge should remain constant for a given engine speed.
Should the pressure fluctuate or drop, stop the engine
and do not operate until the trouble has been corrected.
5-9. TEMPERATURE GAUGE (Optional) - This
unit can be equipped with an optional TEMPERATURE
gauge which will register the coolant temperature and
indicate when an abnormal condition occurs.
5-10. SAFETY SHUTDOWN SWITCH
(Optional) - The Safety Shutdown switch will
automatically shut down the engine if oii pressure drops
to an unsafe level or coolant temperature becomes too
high. When starting the engine, depress the Safety
Shutdown switch and hold in until the engine starts and
the OIL & TEMP. pilot light goes off.
OM-473 Page 15
This switch is protected by a fuse located on the bottom
of the switch assembly directly behind the front panel.
Should this fuse open, the engine would not start.
5-11. POLARITY SWITCH (Optional) - The
POLARITY SWITCH provides a means of selecting
either dc STRAIGHT (Electrode Negative) or dc
REVERSE (Electrode Positive) polarity without chang-
ing cable connections.
To ensure that the weid current output will be in accor-
dance with the labeling of the position on the POLARI-
TY SWITCH, connect the electrode holder cable to the
ELECTRODE terminal and the work cable to the WORK
terminal.
ARCING can damage switch con-
tacts.
e [Do not change the position of the POLARITY
SWITCH while welding or under load.
Arcing causes the contacts to become pitted and even-
tually inoperative.
5 - 12. REMOTE CONTROL RECEPTACLE AND
CONTACTOR CONTROL SWITCH (Optional)
(Figure 5-1)
REMOTE CONTROL
| on
O or
CONTACTOR
CONTROL
PUISE ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Do not touch the weld output terminals when the
contactor is energized.
e Do not touch electrode holder and work clamp at
the same time.
When the CONTACTOR CONTROL switch is in the
OFF position, open-circuit voltage is present at the weld
output terminals for as long as the engine is running.
If remote contactor control is desired, make connec-
tions to the REMOTE CONTROL receptacle as in-
structed in Section 3-7. Place the CONTACTOR CON-
TROL switch in the ON position. Open-circuit voltage is
present at the weld output terminals when the CON-
TACTOR CONTROL switch is closed.
if remote contactor control is not desired, place the
CONTACTOR CONTROL switch in the OFF position.
Open-circuit voltage will be available at the weld output
terminals whenever the engine is running.
OM-473 Page 16
5-13. REMOTE CONTROL RECEPTACLE AND
CURRENT CONTROL SWITCH (Optional) (Figure
5-1)
REMOTE CONTROL
| on
OPTION"
О =
CURRENT
CONTROL
ELECTRIC SHOCK can Kill,
e [Do not touch the live electrical parts.
e Do not touch the weld output terminals when the
contactor is energized.
® Do not touch electrode holder and work clamp at
same time.
If remote current contro! is desired, make connections
to. the REMOTE CONTROL receptacle as instructed in
Section 3-7. Place the CURRENT CONTROL switch in
the ON position.
When a Current Control is being used, the current con-
trol functions as a fine amperage adjustment for the
AMPERAGE & VOLTAGE control setting on the
welding generator. For example: If the AMPERAGE & |
VOLTAGE control on the welding generator is set at
mid-range, the Remote Current Control will provide
(from minimum to maximum adjustment) fine amperage
adjustment of one half of the weiding generator output
for the amperage range selected on the AMPERE
RANGES switch.
If remote current control is not desired, place the CUR-
RENT CONTROL switch in the OFF position.
5-14. METERS (Optional) - The meters are provided
to monitor the welding operation. They are not intended
for exact amperage or voltage measurements. These
meters are internally connected to the output terminals.
The voltmeter indicates the voltage at the output ter-
minals, but not necessarily the actual voltage at the
welding arc {due to cable resistance, poor connections,
etc.) The ammeter indicates the amperage output of the
unit.
5-15. RADIATOR SHUTTERS (Optional) - The
radiator shutters limit the volume of cold air passing
through the radiator, thereby maintaining higher engine
coolant temperatures. See the Engine Manufacturer's
Manual for engine coolant temperature range for max-
imum fuel economy and engine performance.
To move the shutters, pull the shutter control back and
then up or down to either open or close the shutters. As
the shutter control is moved upward, the shutters will
open and permit more airflow. Moving the shutter con-
trol down will close the shutters and permit less airflow.
—_ Ds SECTION 6 - SEQUENCE OF OPERATION damn DO TIT sm
ELECTRIC SHOCK can kitl; MOVING
PARTS can cause serious injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT can
damage internal parts.
® Do not touch live electrical parts.
® Shut down the engine and disconnect negative [-)
battery cable from battery before inspecting or
servicing. |
e Keep clear of moving parts, l.e., fans, belts,
rotors, etc.
® Keep all covers and panels in place while
operating.
Warranty is void if the welding generator is operated
with any portion of the outer enclosure removed.
ARC RAYS can burn eyes and skin; NOISE can
damage hearing.
® Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
e Ventilate to keep from breathing fumes and gases.
© / ventilation is inadequate, use approved
breathing apparatus.
® Use in open, well ventilated areas or vent exhaust
out of doors.
HOT METAL, SPATTER, SLAG, AND EXHAUST
can cause fire and burns.
e ¡Watch for fire.
® Have a fire extinguisher nearby and know how to
use it.
e Allow work and equipment to cool before handt-
ing. |
ENGINE FUEL can cause fire or explosion.
Stop engine before checking or adding fuel.
Do not spill fuel: if spilled, wipe up.
Do not refuel if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill fuel tank to top; allow room for expan-
sion.
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
e Wearers should consult with their doctor before
going near arc welding, gouging, or spot welding
operations.
See Section 1 - Safety Rules For Operation Of Arc
Welding Power Source for basic welding safety infor-
mation.
6 - 1. SHIELDED METAL ARC WELDING (SMAW)
1. Install and prepare unit as instructed in- Section
3.
2. Rotate the AMPERE RANGE switch and
AMPERAGE AND VOLTAGE ADJUSTMENT
control to the desired position {see Sections 5-1
And 5-2}. |
3. Prepare for welding as follows:
a. Connect work clamp to clean, bare metal at
workpiece. |
b. Select and obtain proper electrode, and in-
sert into electrode holder.
4. Wear dry insulating clothing and gloves and
welding helmet with proper filter lens according
to ANSI 749.1.
5. Start the engine as instructed in Section 6-3.
6. Place the AUTO IDLE control switch in the
desired position and begin welding.
6-2. OPTIONAL 7.5 KVA POWER PLANT
OPERATION
Read and follow safety information at
beginning of entire Section 4 before proceeding.
1. Be sure that the unit has been prepared for
operation as instructed in Section 3.
2. Make connections to the 120/240 volts ac ter-
minals as instructed in Section 4-3.
3. Rotate the AMPERAGE AND VOLTAGE AD-
JUSTMENT control to 100 (full clockwise), if ap-
plicable.
4. Start the engine as instructed in Section 6-3.
5. Place AUTO IDLE control switch in OFF posi-
tion.
6. Once the engine is operating properly at
weld/power rpm, power may be obtained from
the welding generator.
6 - 3. STARTING THE ENGINE
IMPORTANT Read entire engine Owner's Manual
(4.108 Perkins Engine) before operating engine.
1. Engine Prestart Checks
a. Oil Level
Check engine oil level. Fill to top mark on
dipstick if necessary (see engine manual for
oil selection specifications).
b. Fuel Level
Check fuel level. Fill tank with fresh, clean
fuel if necessary (see engine manual for fuel
specifications).
c. Coolant Level
Check coolant level. Fill radiator with fresh
coolant if necessary (see engine manual for
coolant specifications}.
2. Make all welding and electrical connections to
the welding generator.
OM-473 Page 17
3. Place the AUTO IDLE control switch in the ON
position. This should be done to permit the
engine to warm up at idle rpm.
4. Place the HEAT/START switch in the HEAT
position for 20 seconds (see Section 5-3).
5. Place the HEAT/START switch in the START
position.
6. When the engine starts, release the
HEAT/START switch.
1 REENGAGING STARTER MOTOR
while flywheel i is rotating or EXCEEDING RATED
CRANKING TIME can damage starting com-
ponents.
e [Do not reengage starter motor until starter pinion
and flywheel have stopped rotating.
----_—_—_ _————" SECTION 7 -
КОДОВ ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Shut down engine and disconnect negative (-}
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts, Le, fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
e Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
7-1. GENERAL - The service life of this welding
generator can be proionged and operating efficiency
maintained under normal conditions by following the
routine service and workshop maintenance procedures
outlined in this section and in the Engine
Manufacturer's Manual (4.108 Perkins Engine). Where
operating conditions are severe, more frequent atten-
tion must be given to all routine service categories;
however a special effort must be made to maintain
clean internal and external engine surfaces.
7 - 2. PERIODIC CLEANING AND INSPECTION
RU IDE ELECTRIC SHOCK can kilt.
® Do not touch live electrial parts.
e Shut down engine and disconnect negative {-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts, f.e., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
A schedule for cleaning- and inspection should be set
up, based on the type and conditions of service, to in-
clude the following:
OM-473 Page 18
e Do not exceed engine manufacturer's maximum
cranking time.
® Do not use ether to start engine.
Allow two minutes cooling time before attempting to
restart engine.
6 - 4. ENGINE SHUT DOWN
1. Stop welding and turn off or disconnect all aux-
itiary equipment.
2. Allow the engine to idle for a few minutes to per-
mit the internal engine temperature to equalize.
Increase the idling time if the engine has been
operating for an extended period or at full load.
3. Place the HEAT/START switch in the OFF posi-
tion.
MAINTENANCE:_ ET
Keep the inside of the unit clean by blowing out the unit
with clean, dry compressed air. Blow out the radiator
fins with compressed air in the direction opposite to fan
circulated air. Clean sludge, scale, and rust off cooling
surfaces.
Check for fluid leaks indicating loose oil, fuel, or water
connections. Tighten loose connections and clean oil or
fuel spills or leaks off of engine surfaces.
Every 6 months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part number of
precautionary labels.
7 - 3. FUEL/WATER SEPARATOR AND SLUDGE
DRAIN PLUG
EZULILICE ENGINE FUEL can cause fire or ex-
plosion.
® Stop engine before working on fuel system.
e Do not spill fuel; if spilled, wipe up.
® Do not service fuel separator if engine is hot c or
running.
® Do not service fuel separator near sparks or open
flame.
Do not smoke while servicing fuel filter.
Have a fire extinguisher nearby and know how to
use it.
Maintenance to be performed only by qualified persons.
The fuel/water separator, located below the fuel tank
on the left side of the welding generator, is provided to
drain off water from the fuel tank. Before starting the
engine for the first-time each day, open the petcock on
the bottom of the separator and drain the water into a
metal container. Close the petcock at the first signs of
fuel.
The fuel/water separator should be changed every 125
hours of operation or 4 months, whichever occurs first.
A sludge drain plug is provided on the bottom of the
fuel tank to drain off sediment from the fuel tank. Once
a week, drain the sludge into a metal container. If ex-
tremely dirty fuel is encountered, a more frequent drain-
ing will be necessary.
7 - 4. AIR CLEANER SERVICE (Figure 7-1)
y DIRTY AIR can damage engine.
Do not operate engine with dirty air cleaner ele-
ment in place.
e Do not operate engine without air cleaner element
in place.
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. An engine
consumes several thousand cubic feet of air per hour
when operating. If dirty air gets into the engine, It can
wear out a set of piston rings within a few operating
hours. Every 50 hours or less depending on conditions,
empty the dust cup and inspect the element.
LEONE A dirty air cleaner element is usually
accompanied by a loss of power and black smoke in the
engine exhaust.
When it becomes necessary to service the air cleaner in
the field, follow the steps in Figure 7-1. Keep a spare
element on hand for replacement. New elements are
available from your distributor.
Compressed air is recommended
when element will be re-used
immediately because a washed
element must be dried before
re-use. However, washing does
Re-Use
Compressed Áir
Direct air through element in
the direction opposite to normal
air flow through the element.
Move nozzle up and down while
rotating element. Keep nozzle
at least one inch from pleated
paper. Maximum air pressure
- 100 P.S.1..
Foliow 1. Stop engine. 5. Wipe out element chamber 7. Reinstall element.
with clean, damp cloth.
These 2. Wipe off cover before opening 8. Replace cover,
Easy air cleaner. 6. Inspect new element and
Steps: all gaskets for shipping damage
3. Remove cover. before use.
4. Remove element.
Important | 1. Don’t attempt to service air 3. Don't leave open air cleaner 5. For Donacione air cleaners -
cleaner with engine running. exposed to blowing dust while don't blow out Donaclone tube
you ciean element. Replace section without element, cover
2. Don't blow out the inside of the cover. and inner cover (if any) correctly
air cleaner with compressed air. installed or you will blow dust
4. If air cleaner is horizontally into the engine.
mounted, be sure that dust cup
Is positioned so arrows point up.
How To Clean element by one of the a better job and must be used (When cleaning Cyclopac
Clean following methods: when exhaust soot has lodged in elements, do not remove plastic
fine pores of the filter madia. fin assembly - back-flowing with
Elements Compressed Air or Washing. Use Donaldson D-1400 detergent compressed air ar washing will
For which contains a special additive
for removing soot and carbon.
Replace element after 6 cieanings
or annually, whichever
occurs first.
Washing
1. Soak element 15 minutes or
more in Donaidson D-1400 and
water solution. See carton for full any rupture, holes or damaged
instructions.
2. Rinse until water is clear
¡Maximum water pressure
40 P.S.1.)
3. Air-dry or use warm flowing
air, max. 160°F. Do not use
compressed air or light bulbs.
remove dust from beneath the
fin assembly.)
Inspection
Place bright light inside element
and rotate element slowly. If
gaskets are discovered - replace.
Figure 7 - 1. Air Cleaner Service
TA-072 606
OM-473 Page 19
7 - 5. ELECTRICAL SYSTEM
RIDE ELECTRIC SHOCK can kill.
e [Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, fe., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
LW NV RE /nspect cables, wiring, and battery
when performing routine oil changes at intervals
specified on the unit maintenance label.
A. Cables And Wiring
Check interconnecting wiring and connections for
tightness and flaws. Ensure that the weld output cable
connections are clean and tight. Check the insulation
for breaks or other signs of damage. Repair or replace
cables or wiring as necessary.
B. Battery
EZULILICE BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
e Wear correct eye and body protection.
Inspect the battery for loose connections, defective
cables, corrosion, cracked case or cover, loose hoid-
downs, and loose or deformed terminal posts.
Clean and tighten connections, replace cables, or
replace battery if necessary.
7 - 6. FUSE WIRE
KLLUILTEE ELECTRIC SHOCK can Kill.
e Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
e Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
This unit is equipped with a fuse wire {lead 88} which
runs from the glow plugs to relay CR1. The fuse wire
protects the glow plugs from a short circuit. The fuse
wire will open if the amperage of the glow plug system
exceeds 30 amperes (see Figure 7-3 for location of fuse
wire).
OM-473 Page 20
FAURE [oI INCORRECT FUSE WIRE can damage
unit.
® Be sure replacement fuse wire is same size, type,
and rating.
® Use only MILLER Part No. 089830 for replace-
ment fuse wire,
7 - 7. SERVICING THE OPTIONAL SPARK AR-
RESTOR
LLG ENGINE EXHAUST SPARKS can
cause fire.
e Exhaust spark arrestor must be installed in accor-
dance with local, state, and federal regulations.
® Shut down engine before cleaning spark arrestor.
® (Clean spark arrestor in a noncombustible environ-
ment.
HOT ENGINE PARTS can cause severe burns.
e The exhaust system must be cold when servicing
the spark arrestor.
The engine exhaust system on this generator set is not
equipped with a spark arrestor. A spark arrestor, main-
tained in effective working order, is mandatory if this
generator set is to be operated in a National Forest or on
California Grasslands, brush, or forest covered land (see
Section 4442 of California Public Resources Code). For
other areas, check your state and local laws. if a spark
arrestor (optional) is desired, contact your
dealer/distributor.
Internal combustion engines operating in a highly com-
bustible environment are a common fire hazard. Glow-
ing carbon particies blown out with the exhaust can re-
tain sufficient heat to ignite materials. While no prac-
tical spark arresting device will stop all sparks, this
device will minimize fire hazards by removing and trapp-
ing most solid particles provided that it is properly main-
tained.
The carbon trap should be serviced weekly or every 50
operating hours, whichever occurs first. The entire
spark arrestor should be inspected every 1000 operating
hours or three times per season.
Removal of the device from the exhaust system is not
necessary for servicing.
Proceed as follow to service the spark arrestor:
1. Stop the engine and allow the exhaust system to
cool.
2. Remove the cleanout plug from the bottom of
the spark arrestor. If a crust has formed over the
hole, break it loose with a screwdrive or similar
tool.
3. Start the engine and run it at idle rpm to blow
collected particles out the cleanout hole. If par-
ticles are slow to discharge, momentarily cover
the end of the exhaust stack.
4. Stop the engine, and allow the exhaust system
to cool.
5. Replace and secure the cleanout plug.
7 - 8. BRUSHES AND SLIP RINGS (Figure 7-2)
MULLER ELECTRIC SHOCK can kilt,
e Do not touch live electrical parts.
e Shut down the engine and disconnect negative [-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, Le., fans, belts,
rotors, etc,
HOT ENGINE PARTS can cause severe burns.
e Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
Brush life is very good under normal operating condi-
tions. The brushes and slip rings should be inspected
every six months or whenever excitation voltage is lost.
Check for cleanliness of the slip rings and freedom of
motion of the brushes. If the welding generator has
been operating under extremely dusty or dirty condi-
tions, increase the frequency of inspection,
If the welding generator has not been used for an ex-
tended period of time, oxidation may form on the slip
rings causing excitation voltage to be lost.
Under normal use the slip rings will discolor to a dark
brown. If a buildup of brush material is noted, it may be
necessary to clean the slip rings. Use a 3/0 or finer
sandpaper followed by a crocus cloth. Never use emery
cloth as part of the emery will embed itself into the rings
and in turn destroy the carbon brushes.
Replace the brushes if they become chipped or broken
or if less than 1/2 inch (12.7 mm) of brush material is
left (see Figure 7-2). |
1/2 in.
{12.7mm}
Minimum
Figure 7 - 2. Brush Replacement
TA-083 205
7-9. ENGINE SPEED ADJUSTMENTS (Figure
7-3)
ALAN IMERE ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, i.e., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
1. Start engine and check weld and idle rpm (no
load applied).
2. Place AUTO IDLE control switch in OFF posi-
tion.
3. Loosen locking nut and adjust high speed adjust-
ment screw for 1800 rpm. Tighten locking nut.
4. Shut down engine.
5. Push throttle arm in direction of solenoid unti!
solenoid plunger is fully bottomed in solenoid
body. Be sure that the plunger is bottomed
BEFORE the low speed adjustment screw hits
the stop. If low speed adjustment screw hits the
stop before the plunger is fully bottomed, back
out low speed adjustment screw.
FE INCORRECT IDLE SPEED ADJUST-
MENT can damage idle device.
e Be sure that solenoid plunger is fully bottomed in
solenoid body at idle (1200) rom.
6. Start engine and place AUTO {DLE control
switch in ON position.
7, Loosen locking nut on throttle arm and rotate
throttle arm until 1200 rpm is obtained. Tighten
locking nut.
Throttle Lock
Fuse Wire Arm Nut
\ Ч
High Spead
Adjustment Screw
Solenoid
Solenoid
Body Plunger
: TA-110 869
Figure 7 - 3. Engine Speed Adjustments
OM-473 Page 21
7-10. MAINTENANCE - FREE BATTERY CHARG-
ING
ATZUGEILISE CHARGING A FROZEN BATTERY
can cause the battery to explode and result in
serious personal injury or damage to equipment.
® Allow battery to warm up to 60°F (16°C) before
charging If battery is frozen.
LGN BATTERY ACID can burn eyes and
skin and destroy clothing and other materials;
BATTERY GASES can explode and shatter the bat-
tery.
e ¡ear a face shield, proper protective clothing,
and remove all metal jewelry.
e Do not spill or splash battery fluid.
® Do not apply pressure to walls of filled bat-
tery—use battery carrier or place hands on op-
posite corners when lifting battery.
e Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
e Use enough ventilation to keep battery gases from
building up during and for several hours after bat-
tery charging.
e Turn battery charger off before making connec-
tions to battery.
e Do not touch or move connections on battery
while battery charger is on.
® Do not lean over battery when charging.
e Be sure battery charger connections to battery are
clean and tight.
® Keep vent caps in place and cover top of battery
with damp cloth. |
e Be sure battery charger output matches battery
voltage.
e Turn the battery charger off before disconnecting
the charger from the battery.
1. Remove battery from unit, and place on a level
worktable or other suitable surface.
2. If battery has removable vent caps, check the
condition of the electrolyte as follows: |
a. Check electrolyte temperature in one of the
center cells with a battery thermometer. For
each 10°F (6°C) increment above 80°F
{27°C), a correction factory of 0.004
specific gravity must be added to the
specific gravity reading taken in Step 2b. For
each 10°F (6°C) increment below 80°F
(27°C), 0.004 must be subtracted from the
reading taken in Step 2b.
b. Check the specific gravity of each cell with a
hydrometer. {Draw in and expel the elec-
trolyte two or three times from the first cell
to be tested to adjust the temperature of the
hydrometer to that of the electrolyte).
c. If a corrected specific gravity reading of
1.225 at 80°F (27°C) is not .obtained,
replace the vent caps and recharge the bat-
tery following the battery charger manufac-
turer's instructions.
OM-473 Page 22
3. If battery does not have removable vent caps,
check the condition of the battery as follows:
a. Check the stabilized open circuit voltage of
the battery. For a 12 volt battery any reading
below 12.4 volts indicates the battery needs
charging. Disconnect both battery cabies
from the battery and allow battery voltage to
stabilize for several hours.
b. If the stabilized open circuit voltage is below
12.4 volts, charge the battery following the
battery charger manufacturer's instructions.
4. Remove damp cloth from battery.
5. Reinstall battery in unit.
6. Replace battery holddown and tighten securely.
Do not overtighten,
7. Connect positive (+) battery cable to positive
{ +) battery terminal.
8. Connect negative (-) battery cable to negative (-)
battery terminal.
7-11. FUSE REPLACEMENT PROCEDURE FOR
POWER PLANTS AND SAFETY SHUTDOWN
SYSTEM
ELECTRIC SHOCK can kill.
e Do not touch five electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, elc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Maintenance to be performed only by qualified persons.
el E INCORRECT FUSE can damage unit.
e Be sure replacement fuse is same size, type, and
rating.
A. Power Plant Fuses
Proceed as follows to replace fuses:
1. Open left side panel and remove cover from junc-
tion box.
2. Check fuses, and replace if necessary.
3. Reinstall junction box cover. Close and secure
left side door. ;
B. Safety Shutdown Fuse
Proceed as follows to replace the fuse at MS1:
1. Open right side door.
2. Locate fuse on bottom of MST.
3. Remove and check fuse, and replace if
necessary.
4. Close and secure right side door.
7-12. AUTO IDLE BOARD PC1 REPLACEMENT
PROCEDURE (Figure 7-4)
RIZGDNIDNEE ELECTRIC SHOCK can kill.
e [Do not touch live electrical parts.
® Shut down the engine and disconnect negative (-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
® Keep clear of moving parts, i.e., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns,
® Wear protective gloves and clothing when work-
ing on a hot engine.
Only qualified persons are to perform maintenance and
servicing procedures.
ELECTROSTATIC DISCHARGE (ESD)
can damage circuit board components.
® Put on properly grounded wrist strap BEFORE
handling circuit boards.
® Transport all static-sensitive components in pro-
per static-shielding carriers or packages.
® Perform work only at a static-sensitive work area.
EXCESSIVE PRESSURE can break
circuit board.
® Use only minimal pressure and gentle movement
when disconnecting or connecting board plugs
and removing or installing board.
[XVII INCORRECT INSTALLATION or
misaligned plugs can damage circuit board.
e Be sure that plugs are properly installed and align-
ed before reinstalling right side panel. |
All directions, such as left or right, are
with respect to the operator facing the welding
generator front panel. Retain all hardware removed dur-
ing this procedure for reinstallation unless specifically
instructed otherwise.
1. Open both side doors and tie together across the
cover.
2. Remove bolts from cover, and slide cover with
side doors approximately 1 ft. (0.3m) back over
radiator.
3. Remove bolts securing Auto Idle Board PC1
enclosure to stabilizer bracket (see Figure 7-4).
4. Disconnect leads 601, 602, 603, 604, and 605
from terminal strip 2T. |
5. Disconnect leads 606 and 607 from coil ter-
minals on relay CR99.
10.
11.
12.
13.
Stablizer
Bracket
Auto Idle
Board PC1 @
TD-110 885-B
Figure 7 - 4. Auto idle Board PC1 Location
Remove four screws securing PC1 to inside rear
of enclosure, pull PC1 to inside rear of enclosure,
pull PC1 leads through grommet, and set PC1
aside. |
Insert leads from new circuit board through
grommet, and secure PC1 to inside rear of
enclosure using four screws removed in Step 6.
Connect leads 601, 602, 603, 604, and 605 onto
2T as follows:
a. Connect lead 601 to terminal K.
b. Connect lead 602 to terminat L.
c. Connect lead 603 to terminal M.
d. Connect lead 604 to terminal N.
e. Connect lead 605 to terminal P.
Connect leads 606 and 607 onto CR99 where
leads were removed in Step 5.
enclosure onto
Reinstall and secure PC1
_ stabilizer bracket (see Figure 7-4).
Reinstall and secure cover.
Reconnect negative (-) battery cable.
Close and secure side access door.
OM-473 Page 23
SCR/ Integrated
Rectifier SR2
Integrated
Rectifier SR1
Amperage And
Voltage Adjustment
Control R1
Terminal
Strip 2T
Ref: B-109 773
Resistor R2
Regulator
Board PC2
Figure 7 - 5. Identification And Location Of Components
7-13. REGULATOR BOARD PC2 REPLACEMENT
PROCEDURE (Figures 7-5 And 7-6)
LUIS ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
® Keep clear of moving parts, i.e., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Only qualified persons are to perform maintenance and
servicing procedures.
ELECTROSTATIC DISCHARGE (ESD)
can damage circuit board components.
® Put on properly grounded wrist strap BEFORE
handling circuit boards.
® Transport all static-sensitive components in pro-
per static-shielding carriers or packages.
® Perform work only at a static-safe work area.
EXCESSIVE PRESSURE can break
circuit board.
e Use only minimal pressure and gentle movement
when disconnecting or connecting board plugs
and removing or installing board.
OM-473 Page 24
INCORRECT INSTALLATION or
misaligned plugs can damage circuit board.
e Be sure that plugs are properly installed and align-
ed before reinstalling right side panel.
All directions, such as left or right, are
with respect to the operator facing the welding
generator front panel, Retain all hardware removed dur-
ing this procedure for reinstallation unless specifically
instructed otherwise.
1. Open both side doors and tie together across
cover.
2. Remove bolts from cover, and slide cover with
side doors approximately 1 ft. (0.3m) back over
radiator.
3. Remove four bolts securing Regulator Board
PC2 enclosure to rear of front panel (see Figure
7-5).
4. Loosen setscrew on AMPERAGE & VOLTAGE
ADJUSTMENT control R1 and remove knob.
5. Remove hardware from shaft, remove RT from
front panel/nameplate, and allow R1 to hang
from PC2. с ;
6.. Cut and remove necessary cable ties on PC2 wir-
ing harness. |
7. Disconnect lead 627 from terminal G1 and lead
626 from terminal G2 on SCR/integrated rec-
tifier SR2. ;
8. Disconnect lead 632 from positive (+) terminal
on SR2.
9. Disconnect lead 633 from resistor R2.
10. Disconnect lead 621 from terminal E and lead
622 from terminal F on 2T.
11. If remote control option is not used, disconnect
lead 625 from lead 623 and lead 628 from lead
634 at insulated friction terminals hanging from
rear of enclosure.
12. If remote control option is present, disconnect
leads 623, 625, 628, 632, and 634 at insulated
friction terminals hanging from rear of enclosure.
13. Remove four screws securing PC2 to inside rear
of enclosure, pull PC? leads through grommet,
and set PC2 aside.
14. insert leads 621, 622, 623, 625, 628, and 634
from new circuit board through grommet, and
secure PC? to inside rear of enclosure using four
screws removed in Step 13.
15. Install and secure R1 onto front panel/ nameplate
from rear using supplied shaft hardware. Be sure
to tighten shaft hardware so that R1 does not
turn freely.
16. Rotate control shaft fully counterclockwise, and
reinstall knob onto shaft with point indicating
zero (0); tighten setscrew 10 secure knob,
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
If remote control option is present, connect leads
623, 625, 628, 632, and 634 to respective leads
at insulated friction terminals.
If remote control option is not used, connect
lead 625 to lead 623, and lead 628 to lead 634 at
insulated friction terminals.
Connect lead 621 to terminal E and lead 622 to
terminal F on 2T.
Connect lead 633 to temrinal on R2 where lead
was removed in Step 9.
Connect lead 632 to positive (+) terminal on
SR2 where lead was disconnected in Step 8.
Connect lead 627 to terminal G1 and lead 626 to
terminal G2 on SR2 where leads were removed
in Step 7.
Tape or tie leads to existing wiring harness to
maintain lead dress and to avoid contact with hot
or moving parts.
Reinstall and secure PC2 enclosure onto rear of
front panel using four bolts removed in Step 3.
Reinstall and secure cover,
Reconnect negative (-) battery cable.
Close and secure both side doors.
A SECTION 8 - TROUBLESHOOTING wm sm
8 - 1. GENERAL - It is assumed that proper install-
tion has been made according to Section 3 of this
manual, the operator is familiar with the function of
controls, the welding generator was functioning proper-
ly, and that the trouble is not related to the welding pro-
cess.
8 - 2. BOOSTER BATTERY JUMP STARTING - If
jump starting is attempted, use the following safety
precautions and the step-by-step procedures in order of
appearance.
BATTERY GASES OR A DAMAGED
BATTERY can explode thereby shattering the bat-
tery; BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other. material; MOVING
PARTS and IMPROPER CONNECTIONS can cause
serious personal injury and damage equipment,
® Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
e Be sure that all personnel are a safe distance from
batteries and clear of moving parts while starting.
e Do notjump start a frozen or completely discharg-
ed battery.
® Do not jump start a battery which has loose ter-
minals or one having evidence of damage such as
a cracked case or cover.
Be sure that vent caps are tight and level on both
batteries and cover both batteries with a damp
cloth.
Wear correct eye and body protection and remove
all metal jewelry.
Keep jumper cables clear of moving parts.
Be sure that both batteries are the same voltage.
Do not jump start a trailer mounted welding
generator with the towing vehicle battery unless
the trailer is completely disconnected from the
towing vehicle.
Do not jump start a vehicle-mounted welding
generator from the vehicle battery.
If booster battery is installed in a vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
Do not jump start by applying power to weld out-
put receptacles or terminals.
Do not allow jumper cable clamps to contact any
other metal while attaching or removing cables.
Use properly insulated jumper cables of ade-
quate size.
Connect ends of one cable to positive (+) ter-
minals of each battery.
OM-473 Page 25
3. Connect one end of other cable to negative (-)
terminal of booster battery.
4. Connect remaining end of cable to welding
generator engine block at least 18 inches (457
mm} from battery (do not connect to welding
generator case, frame, or equipment grounding
terminal as damage to equipment can result).
b. Wait at least one minute after connecting cables
before starting engine.
6. Start engine following procedures outlined in
Section 6 (Sequence Of Operation) of this
manual and allow engine to return to idle speed.
If the unit does not start after cranking for thirty
seconds, stop the jump starting procedure. More
than thirty seconds seldom starts the engine
unless some mechanical adjustment is made.
7. Remove jumper cable from engine block.
8. Remove other end of same cable from booster
battery negative (-) terminal.
9. Remove other jumper cable from welding
generator battery positive (+) terminal.
10. Remove remaining end of cable from booster
battery positive (+) terminal.
11. Discard damp cloths.
8 - 3. RESETTING CIRCUIT BREAKERS (Figure
5-1) - The circuit breakers are automatic-trip type and
are not manually operable. When the circuit breaker
button is in {ON position), the circuit breaker is func-
tional. When the button is out (OFF position), the
breaker is open and not functional.
if a circuit breaker trips when equipment use begins, a
fault is probably present in the equipment. If a breaker
trips after prolonged equipment use, an overload condi-
tion is probably present. Should a breaker trip, proceed
as follows:
WARNING ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
. Shut down the engine and disconnect equipment
from deenergized receptacle before repairing a
fault or overload.
OM-473 Page 26
1. Locate and repair fault or reduce receptacle load.
2. Reconnect equipment to receptacle and start
engine.
3. Reset circuit breaker {depress button); it may be
necessary to allow a cooling period before the
breaker can be reset.
4. Resume operation.
8 - 4. TROUBLESHOOTING CHART
EU L eR ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
e Wear protective gloves and clothing when work-
ing on a hot engine.
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
e Wearers should consult with their doctor before
going near arc welding, gouging, or spot welding
operations.
Troubleshooting of internal parts to be performed only
by qualified persons.
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding generator.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In all cases of equipment
malfunction, the manufacturers recommendations
should be strictly followed.
Le iA
= PCT plan nya Pe A ETA 5.
PTE ER PPS ER PT 1e
TROUBLE
PROBABLE CAUSE
REMEDY
Engine fails to starts.
Battery problem.
Check engine battery charging system according
to engine service manual (not supplied with
engine).
Inspect the electrical system (see Section 7-5). If
the battery requires recharging, see Section 7-9
and follow all applicable safety procedures and the
battery charger manufacturers instructions.
Never use a battery charger without these instruc-
tions. If the battery does not recharge, replace the
battery.
Jump start the engine employing approved safety
practices and booster. Jump starting instructions
are provided in Section 8-2.
IGNITION switch $1.
Check 51 and replace if necessary.
Engine problems.
See Engine Owner's Manual (4.108 Perkins
engine).
Glow plug fuse wire.
Check fuse wire and replace if necessary {see Sec-
tion 7-6).
Fuse on optional Safety
Shutdown switch MS1
open.
*Replace fuse on MS1 {see Section 7-11B).
Battery discharges between
uses.
IGNITION switch $1 left in
ON position.
Place S1 in OFF position when unit is not in use.
Buildup of acid on top of
battery (white-grayish
substance).
Clean battery with soda solution; rinse with clear
water.
infrequent use,
Recharge battery approximately every 3 months.
Battery.
Replace battery.
No 120 VOLTS AC output.
Weld output is normal.
Circuit Breaker{s} CB1
and/or CB2 open.
Reset CB1 and/or CB2 (see Section 8-3).
No 240 VOLTS AC output.
Weid output is normal.
Circuit Breaker(s) CB3
and/or CB4 open.
Reset CB3 and/or CB4 (see Section 8-3).
Low 120 and/or 240
VOLTS AC output at op-
tional 7.5 kva/kw.
AMPERAGE & VOLTAGE
ADJUSTMENT control Rt
set to position other than
100.
Rotate R1 to 100 (see Section 6-2).
Erratic weld output.
Damp, or wrong type of
electrodes.
Try different electrode.
Improper connections to
electrode or workpiece.
Check and tighten loose connections.
Erratic weld and power out-
put.
Dirty slip rings and/or worn.
brushes.
Clean slip rings and/or replace worn brushes (see
Section 7-8).
OM-473 Page 27
TROUBLE
PROBABLE CAUSE
REMEDY
No output at 120 VOLTS
AC receptacie RC1; no
weld output.
Optional circuit breakerís)
CB1 and/or CB2 open.
Reset CB1 and/or CB? (see Section 8-3).
Poor contact between slip
rings and brushes.
Clean the slip rings (see Section 7-8).
High or low voltage at 120
volts receptactr RC1 and
weld output terminals.
Improper engine speed.
Check the engine speed. The engine must run at
1850 rpm when Engine Control switch is in RUN
and no load is applied (see Section 7-9).
Regulator board PC2
and/or resistor R2.
Contact Factory Authorized Service Station. If so
instructed, replace PC2 (see Section 7-13).
Engine remains at idle
(1200) rpm when S4 is in
ON position and an arc is
struck.
Auto Idle control board
РСТ.
Contact Factory Authorized Service Station. if so
instructed, replace PC1 {see Section 7-12).
Erratic weld output.
Improper and/or loose con-
nections to electrode or
workpiece.
Check and tighten loose connections.
Engine ran fine but slowly
stopped; unable to restart
engine.
If fuel tank cap is equipped
with an inside valve, it may
be in the CLOSED position
(other probable causes can
be found in the engine
manual).
Examine the inside of the fuel tank cap. if the cap
is equipped with an adjustable valve, rotate the
valve to the OPEN position.
OM-473 Page 28
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OM-473 Page 30
FURNIVI, VIVIT Гос) +“
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Effective With Serial No. JG098154
PARTS
LIST
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ASSY 093365
099749
2 DE
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O
RS4
CSI G50 |
77 76 75 74
Ref: 8-093 366
Figure À - Main Assembly
OM-473 Page 1
6 67
69 686
.36 37
41
ТО-110 885.5
OM-473 Page 2
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure A Main Assembly
1 109 432 FITTING, brass-flaredunion5/16 TBG.......... cco... 2
2 109 429 LINE, fuel 10 inches tong.................—.emmeorerrarecon. 1
3 109 431 LINE, fuel 32 inches long. .............ocoreeeredarriarea 1
4 070 010 BOLT, J 1/4-20 x2-5/16 ...................0 0.200 0reaa0 2
5 089 517 STRAP, fuel tank ...........e..e—..esemseocrrcecorerececa. 2
097 507 STRIP, adhesive 1/8 x 1 x20-1/2 .............. 0... .... 2
6 010 434 STRIP, rubber 1/2 x2 x2... i, 2
7 107 972 TANK, fuel (consistingof) .......... cc. iii... 1
8 115 000 . САР eae 1
111 383 HTTING, brass-flared union1/4TBG....................... 1
111 382 GASKET, copper-flanged 3/8 0ODx1/41D ..... уевненннннноо 1
9 110 744 FITTING, brass-flaredel M 1/4 TBGx 1/8NPT............... 1
605 288 FITTING, pipe-plug sq hd 1/4 NPT ......... 0... 1
10 111 384 LINE, fuel 20 inches long w/swivel both ends ................ 1
11 010 314 VALVE,shut-offfuel ............ iii iit. 1
12 017 479 SEAL, weather-lifteye........... cc iim нее н еее. 1
13 CR1 070 109 CONTACTOR, solenoid 12 volts de 400 amp..........ec_..eo.. 1
089 830 FUSE LINK ..............s00errereearereerrernrvranenemen. 1
14 601 945 SCREW, cap-hexhd5/8-18 x4... ... iii, 4
15 071 731 \МАЗНЕВ, На? 21/32 10 х 2-1/4 х 3/16 ..................... 4
16 SR3 099 286 RECTIFIER, silicon 3 phase 300 amp........._...eresererraa. 1
17 108 131 BRACKET, mtg-rectifier ............... «cc. iii unn. 1
18 R4,VR1 046 819 SUPPRESSOR ....1 1020000204 a a ae a aa eee a ea a ea een eee 0 0 1
19 071 890 RETAINER, mount-engine/ generator Ce eee aa 4
20 071 730 TUBING, steel 7/8 OD x 12 gax2-3/8.............—eeececcaro 4
21 072 848 ТуВ!№6, пеоргепе 2-1/2 ОО х 7/8 Ю х2 ................... 4
22 108 079 COVER, top ..................s0sr0xarearieoroveroa renovar 1
23 | 035 968 WASHER, neoprene 5-7/8 OD x 3-5/8 IDx1/16............. 1
24 108 487 LABEL, warning use lifting eye etc ............. 5..5... к... 2
25 028 089 DOOR, access-radiator ..........._.ee0eereereenaran rec, 1
26 004 130 BRACKET, support-door ..............e_eesecorreorecnnao 2
090 281 LABEL, caution: usingethertoetc ......................... 1
110 452 LABEL, enginemaintenance ............ ccna 1
087 341 BUMPER, door... . oi ieee ences 4
27 +108 076 DOOR, side ......11120000 00e a aa a ea eee a ee eee 2
28 089 343 RIVET, truss hd 1 MC к ине кк у вкл вк уве нане о 6
29 109 591 CLAMP, muffler 1-3/4 dia .. 022200000441 4011111 100 00 1
30 107 913 MUFFLER, exhaust-engine............c_eerrevrecoorrerrea. 1
31 107 968 BAR, mtg-muffler ............. 0 iii ea 0 aa e +0 1
32 107 969 ENCLOSURE, radiator.............eeJremereerirecereoren_. 1
33 007 352 RADIATOR {consisting (0) à PA ee ee ee AAA ко 1
34 605 982 .CAP........ 0.2.0 rer0serareceecroreanaaeareonvenvao 1
35 087 336 LATCH, door .........._.eoe _oerecorarverrerrecorrerer vera. 2
36 011 198 LABEL, danger fan..........__._.eeoerreorereerocrrecsnver 0 0 2
37 +053 966 GUARD, fan .............eoececé_eorvreorrerererrevarrerceza 2
38 010 861 CLAMP, hose 1-1/16x2dia ............e»eeeoerenorvenea. 2
39 107 651 HOSE, radiator-upper ............_eeo_reeereorrene cani. 1
40 006 015 FITTING, pipe-brass drain cock 1/4 NPT ..........0.exe-.0—.. 1
41 010 860 CLAMP, hose 13/16 x 1-3/4 dia ............eeerecerereroo. 2
42 007 446 HOSE, radiator-lower KK 1
43 108 256 ENGINE, diesel-electric (consistingof) ...................... 1
44 109 432 . FITTING, brass-flared union5/16 TBG..................... 2
45 . 108 129 .BRACKET, mtg-switch......... PS 1
46 108 259 . SPRING, extension 1/41D .......... iii. 1
47 089 520 . STRIP, mtg-spring............._oeeeiaecereeororecerere 1.
48 024 799 » BALL JOINT, 1/4-28 +hd ...........:...—- eee 1
49 108 456 .ROD, throttle .........—......eee-—.—eeeere. 4 оовевоньвеенье, 1
50 049 839 .BRACKET, adj-solenoid PS 1
B1 605 277 .PIN, cotter 3/32 x3/4............—r—emesrecscravorvervene_. 1
OM-473 Page 3
item Dia. Part
No. Mkgs. . No. Description Quantity
Figure À Main Assembly (Cont'd)
52 TS1 109 436 . SOLENOID, 12 volts dce........22000 0 04e aa a aa ea a Lean 0 1
53 108 126 . BRACKET, mto-idle device..............20020000 0002 see. 1
54 57 025 473 .SWITCH, pressure oil ............e_..eoeeeeonreaeaarecarrra 1
55 108 257 . PIPE, exhaust .......... ccna... ¿e 1
56 S6 025 4/4 . SWITCH, thermo-temp...........__eeemreeorrveoerecerenoo 1
57 . FILTER, fuel (see enginepartslist). ................. 0, 1
58 109 739 . MOUNT, engine-LH ..........e.._em—reoresvorerecrerece. 1
59 109 738 . MOUNT, engine-RH ...............r=meermeaceereaeer.cenon, 1
60 047 812 CABLE, battery-negative ........._.e_.eresscorerar recon... 1
61 108 081 TERMINAL, protector-batterypost . ........................ 2
62 BAT 107 867 BATTERY, 12 volts 425 amp .......e..._.eereemrereneeonre. 1
03 108 124 HOLDDOWN, battery ...........o__eo-re=erreoreearrecoren. 2
64 032 452 CABLE, battery-positive ..........24400000 0e 0 sea 1e 2100 1
111 786 STRIP, mtg-shunt ............. cc iii iii, 1
010 862 CLAMP, hose 1-13/16x2-1/2 .... irri iirc a a 0 1
65 Figure B_ GENERATOR (Pg6) ............. me me0rerraeraer ire 1
66 010 863 CLAMP, hose2-1/18x3 dia ..........—_—.ee—eeeerromedcenveno 1
67 107 800 HOSE, air cleaner ............eeccemerorrianor re een. 1
68 049 525 NUT, speed-push on 5/16-18 ........ ccc... 1
69 107 866 AIR CLEANER, intake (consistingof} ....................... 1
*065 604 ELEMENT erie ee, 1
70 109 742 BASE... i tetera ea aa 1
71 107 961 UPRIGHT, base-center ...........o_._..renereanore EA 1
72 111 310 UPRIGHT, base-front ............._—e.—exeereroerr ooo enn. 1
73 113 087 GUARD, panel ....... HRG 1
74 108 261 BRACKET, mtg-enclosure ............. cco iia, 1
75 CR99 090 104 RELAY, enciosed 12 volts de SPST 30 amp...............—..é. 1
080 509 GROMMET, SCR No. 8/10 200000 RR RR es 3
073 344 GROMMET, 1/8IDx5/8mtghole ......................... 1
76 105 727 ENCLOSURE, circuitcard..............ee-mrrecorverrecro.. 1
PC1 099 749 CIRCUIT CARD, idle control {consistingof) .................. 1
А50 096 275 .1С, Ппеаг 324 ........ iirc aaa 1
C50 080 507 .CAPACITOR, tantalum 22 uf 15 volts. ........ _—..eew_e.eevemo 1
C51 000 859 .CAPACITOR, electrolyte 220 uf 35 volts de..............e..e. 1
C52,53 073 739 . CAPACITOR, ceramic0.1ufB0wvoltsdc ................... 2
D50,51,53,54,57,60 026 202 .DIODE, 1 amp 400 volts SP .............oo-reesrcervevnno 6
D55,56,58 028 351 . DIODE, signal 0.020 amp 75 volts SP .........ee_reesrevora 3
D59 039 110 . DIODE, zener 8.2 volts 0.5 watt............44220000 020100 1
Q50 005 274 . TRANSISTOR, NPN 10amp80volts ...................... 1
‚ О51 037 200 . TRANSISTOR, NPN200MA40volts. .. ................... 1
R51,54,56,57 035 827 . RESISTOR, carbon film 0.25 watt 10Kohm ................ 4
R52 000 039 . RESISTOR, carbon 2 watt 680 ohm ..............—_—eeeeme.. 1
R53,61,64,68 035 825 . RESISTOR, carbon film 0.25 watt 1K ohm ................. 4
В55 074 056 .RESISTOR, carbon0.5watt390 ohm ..................... 1
R568 039 328 . RESISTOR, carbon film 0.25 watt 1.5K ohm................ 1
R59 035 823 . RESISTOR, carbon film 0.25 watt 100 ohm. .......... nana 1
R60 003 272 . RESISTOR, carbon film 0.25 watt 1 megohm............... 1
R62 044 633 . RESISTOR, carbon film 0.25 watt 1.2K ohm................ 1
R63 030 038 . RESISTOR, carbon 0,5 watt 220 ohm ............... coh. 1
R65 071 595 . RESISTOR, carbon film 0.25 watt22ohm.................. 1
R66 030 089 . RESISTOR, carbonQ.bwatt2.7ohm...................... 1
R67 035 884 . RESISTOR, carbon film 0.25 watt 100K ohm _.............. 1
007 752 .HEAT SINK. ........ ee eee eee eee 1
77 R3 108 469 RESISTOR, WW fixed 2b wattb50ohm...................... 1
OM-473 Page 4
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure A Main Assembly (Cont'd)
78 +093 559 PANEL, front-lower .,............ ee. _—._.-eeeocacociere nao 1
79 046 392 LABEL, general precautionary ........._e.—..2errerocoreoco. 1
80 Figure C PANEL, front-w/components{Pg8)........................ 1
81 CT1 105 370 TRANSFORMER, current..............e.eeeceemeccaoroneoa 1
82 Z1 005 727 REACTOR 0000000 cia ees 1
83 Figure D TERMINAL ASSEMBLY, power-output(Pg12) .............. 1
84 108 163 FRAME, mtg-reactor&fueltank ........................... 1
85 110 069 FITTING, brass-flared elbow M 1/4 TBG ........... I 7
86 108 125 STRIP, mtg-fuelfilter. .. ........ RK iin. 1
*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-473 Page 5
Hem Dia. Part
No. Mkgs. No. Description Quantity
Figure B Generator {Fig A Pg 4 Item 65)
1 049 650 BRACKET, mtg-brushhoider.........._._.eeee._.ersvervecorvrorre verte. 1
2 018 614 BRUSH SET (consisting of) ................eee=reeerecaareracer ear TD 3
3 *044 755 BRUSH oe ae ert eae a a aa 1
4 600 270 . HOLDER, brush ............ee.e.0eceareeaoreaoreeaareonnocacearan e 1
5 018 665 .CAP, brushholder..............—_—eecoc_eenn0arereeermooaraco rara naa 1
6 013 367 LABEL, warning moving parts can cause serious iNJUy...........e_.cecee.e. 1
7 109 493 GUARD, generator,............._o__eoonccrcrrenvarervrere er rorverreo 1
8 + 108 168 STATOR, generator or. .............eeecreaae rre arre Are eE 1
8 +110 472 STATOR (used w/7.5 kva option) .............e_m_em_eeexereamooramen em. 1
9 039 207 BAFFLE, air-generator ......... ..o ceecceeoerreverevorri ro eereneerne,. 1
10 108 468 ROTOR, generator (consisting of) ..........._..r.0eeremorvrenarenaca a 1
11 024 617 .RING, retaining-external .............._eoxeoereenrnetvortronereraren e. 1
12 053 390 . BEARING, ball ................ 2... .e0rrrecorenerrecnrrena a 1
13 089 737 . FAN, rotor.....1.121200 04 4444 a a a 4 eee 4 4 4 a ue 4 4e a 4 4 ee a a aa a sa aa ea eau 0» 1
035 776 KEY, 3/8 X 3/8 X 2 i eee ee aaa 1
14 108 302 STATOR, exciter-aux power 120/240... .. iii 000 1
15 049 235 ENDBELL, generator ............__eeeeeravarenererereareoreore rr en... 1
16 004 203 STRIP, nylon .O50 x 4x9 ................e..r0merareerennr ener .. 2
Figure B - Generator | | : TD-110922
*Recommended Spare Parts.
+ When ordering a component originaliy displaying a precautionary label, the label should also be ordered,
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
| | OM-473 Page 6
Fig C2
19 18 17 16 15
TC-110 851
Figure C - Panel, Front-W/Components
OM-473 Page 7
*Recommended Spare Parts
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Item Dia. Part
No. Mkgs. No, Description Quantity
Figure C Panel, Front-W/Components (Fig A Pg 5 Item 80)
1 NAMEPLATE (order by model € serial number) ............... 1
2 54 011 609 SWITCH, toggle SPDT 15amp 125volts..................... 1
3 51 108 133 SWITCH, start .........o_o.eeeercrenvesrerorrecar e remvvreve. 1
D8 087 970 DIODE, 3 amp 600 volts ...........eo_sreerrecorrerenecameca 1
4 099 263 PANEL, front-upper...........eeecre=rrrererccaaoraso e 1
5 53 005 015 SWITCH, range (Fig C2 Pg 11) .........recervenrermecsermar: 1
6 109 205 REGULATOR, field current (Fig C1 Pg 10) .............—.—.o—... 1
7 CB1-4 053 283 CIRCUIT BREAKER, manual reset 1 pole 15 amp 250 volts ...... 4
8 RC1 039 864 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 125 volts 1
9 RC2 604 103 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 250 volts 1
10 601 836 NUT, brass-hex 1/4-20 ...... iii ii ies 3
11 083 030 STUD, brass-grounding 1/4-20 x 1-3/4 ..............reem.... 1
12 072 590 LOCK, shaft ...............e._eeeemerearvenooearerarer ee... 1
13 097 926 KNOB, pointer .............oe.ereenrrsererreceerereererrez 1
14 108 165 PLATE, identification-control/rating ...... —..._.._—e—_—— reverec. 1
15 108 894 CHAIN, key ................—...e00rmemeareaorecartrene een 1
16 021 385 BOOT, toggle switch lever ..........—.—.—_—.—ec_ex=nerrorecerree.. 2
17 082 788 HOLDER, light ................oomesxervarerearereoneverer. 2
18 PL1,2 *048 155 BULB, indicatorlight-red ............ co iii. 2
19 082 789 LENS, lightred ....... ci eit ena 2
20 019 754 HANDLE, rangeswitch ......... iii iii но 1
21 010 647 PIN, spring 5/32 x 1-1/4... oi ieee ie 1
OM-473 Page 8
Ref: C-110 001
Circuit Card, Regulator - Field Current
Ref: B-109 773
Figure C1 - Regulator, Field Current
OM-473 Page 9
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure C1 109 205 Regulator, Field Current {Fig C Pg 8 Item 6)
1 SR2 097 363 DIODE/SCR, bridge-integrated .............. .... oh 1
2 099 191 CURRENT REGULATORBOX ..... ieee ieee 1
3 010 378 GROMMET, 9/16iDx3/4mtghole................. cut. 1
4 2T 107 298 BLOCK, terminal 10 amp 14 pole. ........._e_oeeeeeoneevao. 1
5 R2 099 262 RESISTOR, WW fixed 2b watt0.250hm.................... 1
6 080 509 GROMIMET, SCR No. 8/10 .......e...eeeerrecerarareen e. 1
7 РС2 107 849 CIRCUIT CARD, field current (consistingof) ................. 1
A1 096 275 .1C, linear 324 ............ —..00rrevrvrercacerenerereran e. 1
C1 035 834 . CAPACITOR, metalfim1.buf100volts ................... 1
C2/3,4/5,6/7,9/11,13 073 739 .CAPACITOR, ceramic 0.1 uf 50 volts de ................—.—.. 9
C8 035 832 . CAPACITOR, mylar0.0015uf100volts ................... 1
C10 000 859 . CAPACITOR, electrolyte 220 uf 3b voitsdc. ................ 1
C12 072 130 . CAPACITOR, tantalum 1 uf3bvoltsdc .................... 1
C14 007 742 . CAPACITOR, electrolyte 10 uf3bwvolts .................... 1
D1 028 351 . DIODE, signat0.020 amp 75 volts SP ...................... 1
D2-4 026 202 .DIODE, 1amp400voltsSP ........ coi. 3
Q1,2,4 037 200 . TRANSISTOR, NPN 200MA 40 volts ................ee.e.. 3
Q3 039 355 .TRANSISTOR, UJT 15MA 40 volts ...........eeeeenvecon. 1
Q5 035 842 . TRANSISTOR, PNP 0.6 amp 40 volts ..........ee..ee.eme.. 1
R1 072 623 . POTENTIOMETER, carbon tT turn 2 watt 1000 ohm.......... 1
RZ 035 848 . POTENTIOMETER, cermet 25 turn 0.5 watt 10K ohm. ....... 1
R3 039 335 . RESISTOR, carbon film 0.25 watt 47K ohm ................ 1
R4 039 326 .RESISTOR, carbon film 0.25 watt 88K chm ................ 1
R5 039 325 . RESISTOR, carbon film 0.25 watt 82K ohm .............—..> 1
RE 038 584 .RESISTOR, carbon film 0.25 watt 470K ohm ............... 1
R7 035 888 .RESISTOR, carbon film 0.25 watt 2.2K ohm................ 1
R8 039 360 .POTENTIOMETER, cermet20 turn 0.5 watt 25K ohm........ 1
R9 039 331 . RESISTOR, carbon film 0.25 watt 4.7K ohm. ...........—.—... 1
R10 039 332 . RESISTOR, carbon film 0.25 watt 15K ohm ................ 1
R11,14,16,17,20,24,25 035 827 .RESISTOR, carbon film 0.25 watt 1OK ohm ................ 7
R12 044 633 . RESISTOR, carbon film 0.25 watt 1.2Kohm................ 1
R13 039 337 .RESISTOR, carbon film 0.25 watt 330K ohm ............... 1
R15 035 887 . RESISTOR, carbon fim 0.25 watt3.3Kohm................ 1
R18,27 035 896 . RESISTOR, carbon fiim 0.25 watt 33K ohm ................ 2
R19,29 039 106 . RESISTOR, carbon film 0.25 watt 470 ohm ................ 2
R21,23,28 030 025 . RESISTOR, carbon 0.5watt100ohm ..................... 3
R22,26 035 825 . RESISTOR, carbon film 0,25 watt TK ohm ..............—e.. 2
R32 030 045 . RESISTOR, WW fixed 3.25 watt 100 ohm ............—..... 1
092 648 .RESISTOR, carbon film 0.25 watt zero ohm .............e.. 3
SR1 035 841 . RECTIFIER, integrated 1.5amp 200 volts .................. 1
VR1 081 832 .IC, linear 78M15 ..... ee 1
8 SR1 035 704 RECTIFIER, integrated 30 amp 600 volts .................... 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-473 Page 10
Item Part
No. No. Description Quantity
Figure C2 005 015 Switch, Range (Fig C Pg 8 Item 5)
1 114 235 BRACKET, mounting - switch (consisting of} ........... iii iii... 1
2 010 671 . SPRING, @XteNSION «oo ttt ee ea ae aa 1
3 017 428 LOCATOR, quadrant............oe..eeeeeedieri revocar iterranear encarece. 1
4 004 998 CONTACT BOARD ASSEMBLY, switch - range (consisting ofl....….….….....0.0000000 1
5 100 623 . GUIDE, contact board -movable...........222000 0000000001 aa ea nee PAS 3
6 011 012 . SHIM, guide - contact board ......120.220120000 04440 aa a ea ea eee ae a sea ae rene ns 3
7 011 980 . CONTACT BOARD, movable switch ......2002 00002042 a star ee LL a ane 2
8 004 999 CONTACT BOARD, stationary ...... 0004 10 4 4 4 a a a a ea ee ee ee se teen 0 2
9 011 645 . CONTACT ASSEMBLY, movable {consistingof) . ................... oo... 3
10 011 075 ..SPRING, pressure ............—.e_eecrorverrrerecoreracerecereeervecorer: 1
11 011 953 .. СОМТАСТ tie ete A AAA a a 4 4 A a AA settee iene 2
12 011074 ..SPRING, pressure ...........—.—.oererererrrrrrecarerorecrececeerarecereao 1
13 011 644 .CONTACT, stationary............ec_eecerddaorere oararrrararererenrereonerno 15
9 13°
TB-011 273
Figure C2 - Switch, Range
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-473 Page 11
Includes 11 12
TB-011 100
item Dia. Part
No. Mkgs. No. | Description Quantity
Figure D ~ Terminal Assembly, Power Output (Fig A Pg 5 Item 83)
1 108 127 BRACKET, mounting-terminal poweroutput ........ cc... 1
2 Neg 039046 TERMINAL, power output-black tconsisting of} ......-.-.000200 000 een nca ces 1
3 601 879 .NUT, hex-fuil 1/2-13 ............. i a ee ee eee see ee eee ee rene 5 1
4 039 044 .BUSBAR ....... iii уве нвкк о eres 1
5 601 880 NUT, hex-Jam 1/2-13 . ii it teria sites sansa sas 1
6 039 045 . TERMINALBOARD, black ......... coir ican es 1
7 601 976 .SCREW, cap-hex hd 1/2-13 x 1-1/2 ...... cities 1
8 Pos 039047 TERMINAL, power-output-red (consisting Of) .........re-.e.»-recerereraree. 1
9 601 976 . SCREW, cap-hexhd 1/2-13 x 1-1/2 ... iii iii anne» 1
10 039 049 .TERMINAL BOARD, red ..... cco it ie a ieee nas 1
11 601 880 .NUT, hex-jam 1/2-13 ............es0recsierrreerererereacertecrrernece, 1
12 039 044 .BUSBAR.........._....eeerrareocrrreaiararrerenrarerareartevereccer 1
13 601 879 NUT, hex-full 1/2-13 i i ities aan 1
TB-048 150-B
Figure D - Terminal Assembly, Power Output
BE SURE TO PROVIDE MODEL AND: SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
- { : | OM-473 Page 12
Dia.
Mkgs.
Item
No.
Part
No.
Description
Quantity
Optional Equipment
510
511
RC3
C8,9
1,2
A2
Shunt
MS1
D8
HM
*Recommended Spare Parts.
041 526
047 842
047 841
047 843
602 946
605 784
602 898
010 089
041 952
041 961
089 085
011 609
035 523
108 864
021 385
094 206
097 749 .
041 954
012 625
039 169
080 497
079 496
057 358
601 158
601 165
048 489
044 383
603 107 .
041 568
046 559 .
046 654
030 081
003 645
046 545
041 965
110 909
086 309
059 866
010 647
110 598
027 657
046 392 .
041 959
011 072
048 317 ..
087 970
032 936
091 703
041 056
ENGINE METER KIT (consisting of}. .
. GAUGE, pressure 5-100 Ibs
. GAUGE, temperature 100/250 deg.
. TUBING KIT, pressure gauge..........__eeecerreeaerromeero.
. FITTING, pipe-brass tee 1/8 NPT
. FITTING, pipe-elbow st 45 1/8 NPT sq
. FITTING, pipe-brass nipple 1/8 NPT
. FITTING, pipe-brass coupling 1/8 NPT
SPARK ARRESTOR MUFFLER
и ит тии че нива ® ENE ENE 4 m ENE NE mE =m > a
= + = = = ® EEK = §F ENE 4 ®W BB EN = & ® =: m= Ww
E + 4 N & = k + = = 4 = =m = = = = ® 4 & # 4 98
= = = = # | bu нк 4 4 ss ss ss ss Ps = = à
LC A a
REMOTE CONTROL FACILITIES (consisting of)..............
. SWITCH, toggle SPST 20 amp 125 volts ac
= 4 = = = = m RAEE
. SWITCH, toggle SPDT 15 amp 125 volts............—.—.—..—...
. RECEPTACLE, 5 socket MS-3102A-16S-8S ................
. CAP, dust
. BOOT, toggle switch lever
. CAPACITOR (consisting of)
"= = = = = ки ны в # 4 8 4 WNW FN HE & mw ow 4d NE
FE = = pp = = = =
. FUSE, cartridge 45 amp 250 volts ..
. HOLDER, fuse
. FUSE BOX
. COVER
"= = = = = = % gpg mg d тн няни т Ww
т т &% % 4 § N 5g 3 om т авки ни чи АА ®
"= A = ® = = pg 4 F 4 4 FE HE kE ня
. CAPACITOR, ceramic 0.05 uf 500 volts. ..........._ e .—.e”.
7.5 KVA AUXILIARY POWER (consisting of)
LL § = = d 4 EB & % 8 F §F =m x =x uw & & QE 32
= = = % & 4 4 = » = дли ти м = % EB WN & N um
. BUSHING, snap 1IDx1-3/8mtghole. ....................
. BLANK, snap-in 7/8 inch
. BLANK, button plug 1 inch dia
. CLAMP, 1 inch dia x 1/2 wide
4 * * = = = F = +
+ § = = = EE 4 w 5 1 & m 2 & ss ss sms 8 CN
. LABEL, warning 120/240 voltjunction box................
HOSE, 5/32 ID x 11/32 OD (order by ft)
DC AMMETER & VOLTMETER (consisting of)
METER, amp dc 50MV 0-500 scale.
. METER, volt dc 0-100 scale
SHUNT, meter 500MV 500 amp
. BUS BAR, shunt/sec stud
RESTRICTION INDICATOR
POLARITY REVERSING SWITCH (co
. ANGLE, mtg-panet
. SWITCH, polarity
. HANDLE, switch
. PIN, spring 5/32 x1-1/4..........
. PANEL, front lower
. LABEL, caution equipment ground .
LABEL, general precautionary
AUTOMATIC SHUTDOWN LO O!-H
. SWITCH, magnetic {consisting of) .
: = = =: = = HE #6 #4 x = = = k
HN rp & = A = mE mE нд ®% ww uw NN
т ци: в кин ини WwW вин
|L = = = = = mE них Авин
. DIODE, 3 amp 600 voits
METER, hour 4-40 volts de .........
SHUTTER ASSEMBLY, radiator ....
FA-1 FLAME ARRESTOR FUEL CAP
FUSE, miniature-glass 14 amp 32 volts
nsisting of) .............
| TEMP (consisting of) .
E = = = = #% ци ны нии &® ня вин =
и ия + =: = = 3 3g EE m # EB WN BE mo» m a % =m =m * +
4 2A RF moa vw mom oN mow om EEN OW WR EEA
: — :
+ 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-473 Page 13
=
ACCESSORIES
WELD AMMETER AND
VOLTMETER
Stock No. 041 568 (Factory)
Stock No. 041 569 (Field)
installs on welder control panel.
FA-1 LOCKABLE FLAME AR-
RESTOR FUEL CAP
Stock No. 041 056 (Field Only)
ENGINE GAUGE KIT
Stock No, 041 526 (Factory)
Stock No. 041 606 (Field)
Mechanical gauges for oil pressure-
water temperature in addition to stan-
dard indicator lights.
POLARITY REVERSING SWITCH
Stock No. 041 965 (Factory)
Stock No. 041 966 (Field)
RADIATOR SHUTTER KIT
Stock No. 041 416 (Factory)
Stock No, 041 417 (Field)
NO. 4WA WELDING ACCESSORIES
Stock No. 040 045
35’ (10.7 m} No. 2/0 electrode cable
with electrode holder and lug, 30° (9 m)
No. 2/0 ground cable with lugs attach-
ed, welding helmet and wire scratch
brush.
LOW OIL PRESSURE HIGH WATER
TEMPERATURE SHUTDOWN
Stock No. 041 959 (Factory)
Stock No. 041 960 (Field)
SPARK ARRESTOR MUFFLER
Stock No. 041 952 {Field Only)
Mandatory when operating on Califor-
nia grasslands, brush or forest covered
land and ail National Forests. For other
areas, check your state and local laws.
RUNNING HOURMETER
Stock No, 000 915 (Factory)
Stock No. 000 273 (Field)
7.5 KVA AUXILIARY POWER
Stock No. 041 954 (Factory Only)
Provides 120 or 240 volts 50/60 Hz
single phase power when not welding.
Connections are made at junction box
inside the side panel.
EM-13 ELEVATION MODIFICATION
Stock No. 041 980 {Factory only)
For use when operating above 5500 ft
(1674 m).
REMOTE CONTROL KIT
Stock No. 041 961 (Factory)
Stock No. 041 962 (Field)
Consists of 5 pin ampehnol receptacle
and 2 switches for full remote control
and contactor control.
*RFCS-23
Stock No. 041 148
Foot current and contactor/exciter
control. 20 ft. (6 mi cord and 5 pin
amphenol plug.
*RHC-23
Stock No. 041 326
Miniature hand current and contac-
tor/exciter control. 20 ft. (6 m) cord
and 5 pin ampheno! plug.
*RHS-24
Stock No. 041 203
Momentary and maintained contact
rocker switch for contactor/exciter
control. Push forward for maintamed
contact back for momentary contact.
20 ft. (6 m) cord and 5 pin amphenol
plug.
*FTC-23 REMOTE CONTACTOR
AND CURRENT CONTROL
Stock No. 006 342
Fastens to electrode holder or GTAW
torch. Includes 28 ft. 18.5 m) cord and
5 pin amphenol plug.
"EXTENSION CABLES For Remote
Controls and Switches
5 pin to 5 pin amphenol
25’ (7.6 m) Stock No. 041 294
50" {15.2 m) Stock No. 041 293
*CV-1 CONSTANT VOLTAGE CON-
TROL KIT
Stock No. 041 975 (Field)
CC to CV converter, Plugs into remote
control facilities receptacle.
*To use switches and controls in-
dicated, remote control facilities or
CV-2 kit must be installed.
CV-2 CONSTANT VOLTAGE CON-
TROL PANEL
Stock No. 041 973 (Factory)
Stock No. 041 974 (Field)
Converts constant current dc to cons-
tant voitage dc welding current and pro-
vides ac single phase welding output.
The ac output is at 80% of the dc out-
put and duty cycle. Panel includes a
switch for dc polarity reversing and ac
selection, circuit breaker protected 14
and 5 pin amphenoi receptacles, and
standard/remote switches. Adaptor
cord Stock No. 041 948 listed below in-
cluded with CV-2.
ADAPTOR CORD
Stock No. 041 947
14 pin amphenol plug to 5 pin amphenol
receptacie, 1 ft (254mm), for HF-250
high frequency unit or remote controls.
ADAPTOR CORD
Stock No. 041 948
14 pin ampheno! to 2 and 3 pin Hubbel
connectors, 1 ft (254mm), for use with
all standard Miller wire feeders. {Provid-
ed with CV-2).
HF-250 HIGH FREQUENCY ARC
STARTER AND STABILIZER
Stock No. 041 779 (115V)
Stock No. 041 780 (230V)
See catalog sheet AD/5.1
SPOOLMATIC 3 FEEDER/GUN {24
volts)
Stock No. 109 940
Constant speed. Has 30 ft (9m) control
cord which plugs directly into 14 pin
amphenol receptacle on CV-2 panel
providing contactor control and 24 volts
power for feeder operation.
SEMIAUTOMATIC WIRE FEEDERS
Listed by Model, Stock Number and
Catalog Sheet Index Number.
S-32 SERIES
Model Stock No, Index No.
S-32P 188 817 M/6.2
5-325 188 816 M/6.2
S-32SL 109 294 M/6.3
Note: 5-32P, $-325, and $-32SL wire
feeders are available with a 1 ft
(254mm} cord with 14 pin amphenol
connector for remote voltage and con-
tactor control, Order feeder with:
Stock No. 109 925 (Factory)
Stock No, 109 926 (Field)
INTERCONNECTING CABLES SET,
14 pin to 14 pin amphenol
10 ft (3m) Stock No. 109 896
25 ft (6.7m) Stock No. 109 897
50 ft (15m) Stock No. 109 898
75 ft (23m) Stock No. 109 899
PORTA-MIG CONSTANT SPÉED
‘Requires 115 volt and contactor con-
trol.
Plastic case 048 941 M/7.1
Metal case 081 574 M/7.1
OPTIONAL EQUIPMENT
Total Width 72%” (1.8 m)
Tread 63” (1.6 m)
Length 163%” (4.2 m)
Height of Bed 19” (480 mm)
Road Clearance 107 (254 mm)
GVWR 3000 №5. (1360 ка)
Shipping Wt. 757 Ibs
The EDT 2400-2 trailer when equipped
with fender and light kit and 2” (50mm)
ball hitch and the No. 3000-4 trailer
conform to all applicable U.S. Federal
Motor Vehicle Safety Standards in ef-
fect on date of manufacture.
EDT 2400-2 TWO WHEEL
TRAILER Stock No. 041 722
A 2100 Ibs. (953 kg) capacity traiter
with welded structural steel frame,
heavy duty axle with roller bearing hubs
and leaf spring suspension. Mounting
holes for all large Miller engine driven
welding generators are prepunched.
Hardware for mounting is provided.
Also included is a jack stand for raising
and lowering the tongue, safety chains
and universal tongue mounting for
optional hitches. An optional fender
and light kit ts required when trailer
is used on the highway. NOTE: Hitch
must be ordered separately.
Specifications
GVWR: 2400 Ibs. (1087 kg)
Trailer weight: 300 Ibs. (136 kg)
Trailer capacity 2100 lbs. (953 kg)
Total width (without optional fender kit)
62" (1.6 m)
Total length (without optional hitch}
96" (2.4 ka)
Width of bed 40%" (1029 mm)
Track Width 53%" {1359 mm)
Height of bed 21” (533 mm)
Tire size P205D-14
Shipping weight 300 Ibs. (136 kg}
3" (80 mm) DIAMETER LUNETTE
TOWING EYE
For use with No. 3000-4 Trailer.
Stock No. 041 628 (Factory)
FENDER AND LIGHT KIT
Stock No. 041 723
Includes fenders, lights, wiring harness
and mounting hardware.
Shipping weight 50 Ibs. (23 ka)
HITCHES
2” (51mm) BALL
Stock No. 041 724
Shipping weight 5 Ibs. (2 kg)
CLEVIS
(Not for highway use)
Stock No. 041 726
Shipping weight 11 lbs. (5 kg)
2%” {64mm} LUNNETTE EYE
Stock No. 041 725
Shipping weight 9 Ibs. (4 kg)
No. 3000-4 FOUR-WHEEL TANDEM TRAILER
Stock No. 041 015
The tandem axle design enables this trailer to ride
smoothly over rough terrain. The unit is equipped
with fenders, lights, a leveling jack, 2” (50mm)
ball hitch and safety chains,
The two wheel self-actuating hydraulic brake system
operates automatically as pressure is put against
the tongue of the trailer. Another feature is a break-
away device which would automatically lock the
brakes should the trailer become loose. À hand
operated parking brake is standard.
TOOL BOX Stock No. 040 638
For use with 4 wheel trailers
Keeps tools handy. Sturdy steel construc-
tion with hinged cover. Five inch (130
mm) high divider in center of box. Attach-
ment hardware included. Height 11” (280
mm}, Depth 10” (254 mm), Length 44”
11120 mm).
No. CC4 CANVAS COVER
Stock No. 040 144
Heavy-duty, olive drab, waterproof and
mildew resistant.
No. 74X FOUR-WHEEL TANDEM
TRAILER Stock No. 041 086
For off the road use only.
The tandem axle design enables this
trailer to ride smoothly over rough terrain.
The unit is equipped with fenders, 12 voit
stop, directional and taillights and leveling
jack. A bolt on clevis hitch and 2”. (50
mm) ball hitch are also included.
Tire Size F78-14
Tread 62” {1.6 m)
Total Width 72” (1.8 т)
Road Clearance 11” (280 mm)
Shipping Wt. 790 Ibs. (358 kg)
No. 64X Trailer Stock No. 041 223
Same as 74X but without fenders and
lights. Weight 710 lbs. (321 kg)
Shipping Wt. 740 lbs. (336 kg)
When ordering off-road
trailers the purchase order
must inciude the statement,
“For off the road use only.”