Download Miller Electric 3000 Welding System User Manual

Millerfi
March1993
Form:
OM-160518
Effective With Serial No. KD398640
~. r.~1~Ic4...1
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-
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I
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OWNERS
MANUAL
Gold SealTM Model 3000
CC/DC
Welding
For SMAW
90
Welding
Amperes,
25 Volts DC At 60%
1.2 kVA/kW DC
Kohler CH5+
Optional
Generator
Auxiliary
Power With Overload Protection
Air-Cooled, Four-Cycle, Gasoline Engine
Low Oil Pressure Shutdown Switch
Read and follow these instructions and all
safety
blocks
Have
only
trained
or
and
qualified persons
service this unit.
Call your distributor if you do not understand
the directions.
5/92ASt-161
477
Give this manual to the operator.
carefully.
install, operate,
coven
Duty Cycle
For
or:
help,
call your distributor
MILLER ELECTRIC
Mfg. Co.,
1079, Appleton, WI 54912
P.O. Box
414-734-9821
PRINTED IN ~SA
a
s
TRUE BLUETM LIMITED WARRANTY
MILLERS
with
(Equipment
This limited warranty supersedes all
LIMITED WARRANTY
Subject to
u
previous
Effective January 1, 1992
serial number preface of KC
or
a
MILLER warranties end is exclusive with
the terms end conditions below, MILLER Electric
MIg. Co., Appleton. Wisconsin, wsrrsnts to its originsl retell purchsser that new
MILLER equipment sold sfter the effective date of this limited warranty is tree of de
workmanship at the time it is shipped by MILLER. THIS WAR
tects in material end
guerantees
Accessory Kits
*
Replacement Pans
True
BiuanM
Items furnished
1.
NESS.
other
*
MILLERS
RANT? IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
no
newer)
or
warranties eapressed
or
Implied.
Limited Warranty shall not apply to:
by MILLER, but manufactured by others, such as anginea or
are covered by the manufacturers
warranty, it
trade accessories. These items
Within the
warranty periods listed below, MILLER will repair
or
replace any
any.
war
ranted pans or components that tall due to such detects in material or workmanship.
MILLER must be notified in writing within thiny (30) days of such defect or failure, at
which lime MILLER will
provide instructions
on
the warranty claim
procadurea
Consumabla components; such
2.
and
to be
as contact
tips, cutting nozzles,
conlaclorn
relays.
followed.
Equipment
3.
start
and
on
the date that the
are as
*
Original
delivered to the
original
retail
based upon
and necessary maintenance, or equipment which han bean used for
outside of the spacifications br the equipment.
purchaser,
operation
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
3 Years Labor
main power rectifiers
THE USE AND MAINTENANCE OF WELDING EOUIPMENT
In the avant 01 a warranty claim covarad by this warranty, the eacluniva remedies
shall ba, at MILLERS option: (1) repair; or (2) replacement; or, where authorized in
Transformer/Rectifier Power Sources
*
by any party other than MILLER. or equip
improperly installed, improperly operated or misused
industry standards, or aquipmenl which has not had reasonable
Pans and Labor
3 Yearn
2.
was
follows:
5 Yearn Pans
1.
equipment
that has bean modilied
ment that has been
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. All warranty lime periods
Plasma Arc
Cutting
in appropriate cases. (3) the reasonabia cost of repair or replace
service station; or (4) payment of or credit for the pur
price (lass reasonable depracialion based upon actual usa) upon return of the
goods at customers risk and expense. MILLERS option of repair or replacement
will ba FOB., Factory atAppleton, Wisconsin, or P.0.6. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or raimburse
went for transportation costs of any kind will be allowed.
writing by MILLER
Power Sources
ment alan authorized MILLER
Semi-Automatic and Automatic Wire Feeders
chase
*
Robots
Pans and Labor
2 Years
3.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
I Year
4.
the
angina manufacturer.)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL. INCIDENTAL OR CONSEOUENTIAL
Pans and Labor
Motor Driven Guns
*
*
Process Controllers
*
Water Coolant
*
Grids
DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT DR ANY OTHER LEGAL
THEORY WHICH. BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW. CUSTOM OF TRADE OR COURSE OF DEALING. IN
Spot Welders
*
Load Banks
SDX Transformers
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE. WITH RESPECT TO ANY AND ALL EOUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Running Gear/Trailers
Fietd Options
*
(NOTE: Field options are covered under True BIuenM for the remaining
warranty period ol the product they are installed in, or for a minimum of
one
5.
6 Months
6.
90
yaar
Days
whichever is
Some slates in the U.S.A. do not allow limitations of how
citic
Batteries
In
Pans and Labor
Cutting
Plasma
*
Remote Controls
implied warranty
legal rights,
and other
Canada, legislation in
remedies other than
rights may
some
be available, but may vary from stale to stale.
provinces provides
as
br certain additional warranties
staled herein, and to the astant that
waived. Ihe limitations and exclusions set out above may not
Torches
*
an
they may not ba
apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
vary Irom province to province.
or
MIS Guns/TIG Torches
*
long
or the esciusion of incidental, indirect, special or consequential damages, ao
the above liwitatlon or exclusion may not apply to you. This warranty provides spa
lasts,
greater.)
r
I
I
_____________________________
RECEIVING-HANDLING
unpacking equ(pment, check carton for any damage that may have occurred during Shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting
USe the
or
equipment, always provide
infDrmation about this
following spaces to
record Model
Designation and Serial
or
Mode)
Style
Designation
and Serial
or
Sty(e
Number.
Number of your unit. The information is located
on
the
rating
label
namep(ate.
Model
__________
Serial
or
Style
No.
Date of Purchase
miller 5192
Form:
March 1 993
OM-160 518
Effective With Serial No. KD398640
1~oIsfi
OWNERS
MANUAL
(jJOJ1
cI~j\r~J~
PAW 100
CC/DC Welding Generator
For SMAW
Welding
U
90
U
1.2 kVAJkW DC
Amperes, 25
Volts DC At 60%
Auxiliary
Kohler CH5+ Air-Cooled,
Optional
U
U
blocks
8/92
ST-161 477
Four-Cycle, Gasoline Engine
Low Oil Pressure Shutdown Switch
Have
only
U
Give this manual to the operator.
U
For
U
or:
carefully.
trained
or
and
qualified
persons
service this unit.
Callyourdistributorifyoudonotunderstand
the directions.
cover
Power With Overload Protection
Read and follow these instructions and all
safety
install, operate,
U
Duty Cycle
rt~i
help,
call your distributor
MILLER ELECTRIC
Mfg. Co.,
1079, Appleton, WI 54912
P.O. Box
414-734-9821
PRINTED IN ~SA
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
HAVE ALL
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
5.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1.
2.
3.
6.
install and
Manual and national, state, and local codes.
insulating gloves
body protection.
yourself from work and ground using dry insulating
hole-free
dry,
Insulate
and
Disconnect
servicing
input power
equipment.
or
stop engine before installing
or
this
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
this
equipment according
making input connections,
When
7.
Turn off all
8.
Do not
equipment
use
attach
to its
grounding
proper
when not in
use.
damaged, undersized,
worn,
or
poorly spliced
cables.
9.
Do not wrap cables around your
workpiece
body.
10.
Ground the
11.
Do not touch electrode if in contact with the work
12.
only well-maintained equipment.
damaged parts at once.
13.
Wear
14.
Keep all panels
Do not touch live electrical parts.
Wear
ground
conductor first.
mats or covers.
4.
Properly
Owners
electrical
good
to a
(earth) ground.
a
safety
harness if
and
working
covers
or
Repair
Use
ground.
replace
or
above floor level.
securely
in
place.
ARC RAYS
2.
Wear
a
welding
helmet fitted with
a
proper shade of filter
(see
ANSI Z49. 1 listed in
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
3.
4.
hearing.
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
high.
FUMES AND GASES can be hazardous
to your health.
5.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6.
Do not weld in locations
Welding produces fumes and gases. Breathing these
fumes and gases
Keep
If inside, ventilate the
remove
4.
operations.
form highly
your head out of the fumes. Do not breathe the fumes.
1.
2.
3.
be hazardous to your health.
can
welding
area
Read the
use
exhaust at the
arc
to
7.
fumes and gases.
If ventilation is poor, use an
approved air-supplied respirator.
(MSDS5)
and the
coatings,
Safety
Data Sheets
5.
Watch for fire, and
6.
Be
and others from
or
flying sparks
1.
Protect
2.
Do not weld where
3.
Remove all flammables within 35 ft
yourself
flying sparks
can
(10.7 m) of the welding
arc.
If
possible, tightly cover them with approved covers.
alert that welding sparks and hot materials from welding can
through small cracks and openings to adjacent areas
FLYING SPARKS AND HOT METAL
cause
can
that
fire
keep
welding
on
a
can
as
or
spraying
react with vapors to
galvanized, lead,
coating
or
is removed from the
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
Do not weld
Connect work cable to the work
9.
Do not
10.
1.
partition
closed containers such
as
tanks
or
drums.
close to the
welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
use
as
welder to thaw frozen
pipes.
Remove stick electrode from holder
contact
11.
on
or
the hidden side.
8.
tip
when not in
or
cut off
welding
wire at
use.
Wear oil-free
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Wear
approved face shield
or
safety goggles. Side
shields
recommended.
injury.
Chipping and grinding cause flying metal.
cool, they can throw off slag.
unless the
7.
and hot metal.
strike flammable material.
aware
can cause
this is not
Be
coated metals, such
explosion.
fire
fire.
4.
on
plated steel,
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode orwelding wire
to metal objects can cause sparks, overheating, or
can cause
degreasing, cleaning,
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
and cleaners.
WELDING
near
The heat and rays of the arc
toxic and irritating gases.
Do not weld
cadmium
instruction for metals, consumables,
Material
manufacturers
and/or
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
As welds
2.
Wear proper
body protection
to
protect skin.
srI 9/92
CYLINDERS
explode if damaged.
can
away from any
Keep cylinders
3.
welding
or
other electrical
circuits.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
IL~c
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Never allow
4.
Use
5.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
in use or connected for use.
6.
cylinders in
stationary support
prevent falling or tipping.
Install and
them to
secure
an
a
or
excessive
7.
upright position by chaining
equipment cylinder rack to
8.
gas cylinders
mechanical shocks, and arcs.
2.
from
heat,
compressed
Protect
Read and follow instructions
associated
Standards.
WARNING
a
ENGINE EXHAUST GASES
ENGINES
can
kill.
1.
2.
Engines produce
ENGINE
on compressed gas cylinders.
equipment, and CGA publication P-i listed in Safety
can
fire
cause
equipment outside
If used in
a
be hazardous.
in open, well-ventilated areas.
closed area, vent engine exhaust outside and
building air intakes.
away from any
harmful exhaust gases.
FUEL
Use
can
or
1.
2.
explosion.
Stop engine before checking or adding fuel.
Do not add fuel while smoking or if unit is near any sparks
or
open flames.
3.
Engine
fuel is
highly
flammable.
engine to cool before fueling. If possible, check and add
engine before beginning job.
allow room for fuel to expand.
not overfill tank
not spill fuel. If fuel is spilled, clean up before starting
Allow
fuel to cold
4.
5.
Do
Do
engine.
MOVING PARTS
can cause
injury.
3.
Have
only qualified people remove guards or
troubleshooting as necessary.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
Keep all doors, panels,
securely in place.
2.
Stop
en
me before
covers,
installing
and
guards
closed and
6.
or
connecting
4
.
(.~
~
~
Reinstall
panels
or
1.
2.
Always
wear a
Stop engine
face shield when
before
Do not allow tools to
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
generate explosive
can
doors when
servicing
is
working
disconnecting
on a
battery.
connecting battery
or
cables.
4.
The coolant in the radiator
under pressure.
battery.
guards and close
starting engine.
3.
Batteries contain acid and
cable from
Keep hands, hair, loose clothing, and tools away from moving
parts.
finished and before
unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
~
prevent accidental starting during servicing, disconnect
negative () battery
5.
1.
To
Do not
use
remove
sparks when working
cause
welder to
charge batteries
polarity (+
and
)
radiator cap when
on
iump
or
on a
battery.
start vehicles.
batteries.
engine
is hot. Allow
engine
to cool.
gloves and put a rag
2.
Wear
3.
Allow pressure to escape before
over
cap
area
when
removing
cap.
be very h ot and
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA
American
Superinten
Printing Office, Washington,
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.i from American Welding So
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
Sri 9/92
Handling of Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
ciety,
Safe
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices ForOccupationAnd Educational Eye And Face Protec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway. New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
6
5
4
3
2
TABLE OF CONTENTS
SECTION 1
-
SECTION 2
2-1.
2-2.
2-3.
2-4.
SAFETY SIGNAL WORDS
.
1
SPECIFICATIONS
Volt-Ampere Curves
Duty Cycle
Fuel Consumption
DC Auxiliary Power Curve
SECTION 3INSTALLATION
3-1.
3-2.
3-3.
3-4.
Selecting A Location And Moving Welding Generator
Engine Prestart Checks
Grounding The Generator Auxiliary Power System
Connecting To Weld Output Terminals
SECTION 4OPERATING
SECTION 5
5-1.
5-2.
THE WELDING GENERATOR
OPERATING AUXILIARY EOUIPMENT
Auxiliary Power DC Receptacle
Auxiliary Equipment Operation
SECTION 6
7
10
10
MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
6-2.
Changing Engine
6-3.
Adjusting Engine Speed
6-4.
Air Cleaner Service
6-5.
Clean Air Intake And
11
Oil
12
13
13
Cooling
Adjustment And Replacement
Areas
14
6-6.
Drive Belt
6-7.
Overload Protection
15
6-8.
Troubleshooting
16
SECTION 7
ELECTRICAL DIAGRAMS
14
18
SECTION 8- WELDING METHODS & TROUBLESHOOTING
8-1.
8-2.
Shielded Metal Arc
Welding (SMAW)
Welding Troubleshooting
SECTION 9
Figure
Figure
Figure
20
25
PARTS LIST
9-1. Main
28
9-2. Panel, Front
31
9-3.
32
Assembly
w/Components
Panel, Control w/Components
OM.160 518
3)93
SECTION 1
SAFETY SIGNAL WORDS
rnodl.1 2/93
Read all
Obey
all
safety
messages
safety
messages to avoid
Learn the
meaning
throughout
this manual.
injury.
of WARNING and CAUTION.
2
1
1
Safety
Alert
2
Signal
Word
2
\
WARNING
or
L~
;
a CAUTION
3
serious
CAUTION
______________
I
I
can
Do not touch live electrical
Disconnect
installing
or
kill
MOVING PARTS
betore~
~
Keep all panels
operating.
and covers closed
possible minor
I
3
Statement Of Hazard And
Result
4
Safety
/
5
can
Instructions To Avoid
Hazard
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding
6
5
Hazard
6
Safety
Read
7H
NOTE
~
Turn Off switch when
using high frequency.
1-1.
SECTION 2
Table 2-1.
Safety
Special instructions for
Rated Weld
Output
90
Welding Generator
Maximum
75 Volts DC
Process
(CC/DC)
25 Volts DC At 60%
Amperes,
40 To 100 A
Welding
best oper
safety.
Description
Amperage Range
Open-Circuit Voltage
not related to
SPECIFICATIONS
Constant Current/Direct Current
Output
blocks for each sym
Information
Specification
Of
safety
NOTE
ation
Figure
Symbol (If Available)
Banner
bol shown.
7
Type
means
I
I
when
can
injury or equipment damage
happen.
injure.
Keep away from moving parts,
parts.
input
power
servicing.
can
possible death
happen.
means
injury
_______________
ELECTRIC SHOCK
Symbol
(See
Section
Duty Cycle (See Section 2-2)
2-1)
Shielded Metal Arc Welding (SMAW); Flux Cored Arc Welding
Possible With Appropriate Process Options
(FCAW)
And Gas
Tungsten
Arc
Welding (GTAW)
Auxiliary
Power
Rating
1.2 kW, 120 Volts
Engine
Kohler CH5+
Engine Speed (No Load)
1800 rpm Idle
Fuel Tank
2.3 U.S.
Engine
Oil
Capacity
Capacity
22.4
oz
Air-Cooled, One-Cylinder, Four-Cycle Gasoline Engine
Speed;
4150 rpm Weld And Power
Speed
gal (8.7L)
(0.66L)
Drive Belt Size
1/2
Overall Dimensions
See
Figure
Weight
Net:
101 lb
Options
See Rear Cover
.343
x
DC, 10 Amperes
x
32.3
Cogged
3-2
(46 kg); Ship:
113 lb
(51 kg)
OM-160 518
Page
1
2-1.
Volt-Ampere Curves
The
volt-ampere
minimum and
100
curves
show the
maximum
voltage
and amperage output capabilities
of the welding generator. Curves of
90
other
curves
80
fall
settings
between
the
shown.
70
Cl)
0
>
0
60
50
40
30
20
10
0
25
0
75
50
125
100
150
DC AMPERES
rsDl.1 10/91
Figure
2-2.
2-1.
SB-152 541
Volt-Ampere Curves
Duty Cycle
CAUTION
a
EXCEEDING DUTY CYCLE RATINGS will
Do not exceed indicated
damage
duty cycles.
warn7.1 2/92
RATED
300
unit.
Duty cycle
OUTPUT ~......,
without
250
is how
operate within
-
a
long
the unit
ten minute
can
period
causing overheating
or
damage.
-
This unit is rated at 60%
allowing welding
200
duty cycle
6 minutes out of
every 10 minutes.
U)
150
w
a
<
100
.
75
.
50-
10
---
15
20
%
25 30
40
DUTY
CYCLE
50
--
60 7080
100
sbl.2 10/91 SB-152
Figure
OM-160 518
Page
2
2-2.
Duty Cycle
Chart
540
2-3.
Fuel
Consumption
The fuel
typical
er
-J
_j
I-
Q~
ci
1.89
0.42
0.50
1 .66
0.37
0.44
1.42
0.31
0.38
1 .18
0.26
0.31
0.95
0.21
0.25
0.71
0.16
0.19
0.47
0.10
0.12
0.23
0.05
0.06
~
consumption
fuel
use
curve
under weld
shows
or
pow
loads.
ci,
w
~
DC AUX
POWER
-IDLE
0
0
15
30
45
DC WELD AMPERES
0.2
0.4
60
(25
0.6
DC POWER
0.8
75
90
VOLTS)
1.0
1.2
KW
rsb2.I 10/91
Figure
2-4.
DC
Auxiliary
2-3. Fuel
Consumption
SB-153 250
Curve
Power Curve
The dc power curve shows the aux
iliary power in amperes available at
the 120 volt dc receptacle.
140
~80
0
>
Q60
40
20
0
0
2.5
5.0
7.5
10
12.5
15
DC AMPERES
SB.152 758
Figure
2-4. DC Power Curve For 120 Volt
Receptacle
OM-160 518
Page
3
SECTION 3INSTALLATION
3-1.
Selecting
A Location And
a
Moving Welding Generator
WARNING
ENGINE EXHAUST GASES
can
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
kill.
Do not breathe exhaust fumes.
Keep
Use in open, well-ventilated areas, or vent exhaust
outside and away from building air intakes.
ENGINE EXHAUST SPARKS
fire.
can cause
damage.
Lift Unit at handles
only U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
Move
spark arrestor is mandatory in all National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in other areas.
A
spark
unit with
ends of base.
on
Have two persons of
laws.
maintain the
from flammables.
pipe away
FALLING
EQUIPMENT
can
cause
serious personal injury and equipment
Use
Properly
exhaust and
adequate strength
hand
cart
or
lift unit.
similar device of
adequate capacity.
It using a fork lift vehicle,
skid before transporting.
secure
unit on
a
proper
arrestor.
and allow exhaust system to cool down
Stop engine
before servicing spark
Service
spark
arrestor.
arrestor away from flammables.
Keep
rwarnl.1
unit level
leaks and
tilting can cause fuel and
possible fire or engine damage.
oil
1
18 in
(457 mm) Open Space
On All Sides
2
2
Lifting Handles
Lift unit with hands
positioned
help to
centerof handles. Obtain
2
12/91
and
transport unit.
3
Exhaust Outlet
Keep flammables away
from
in
lift
ex
haust outlet.
5T-161 4771 ST-151 556/ Ref. 5T.161 478
Figure
3-1. Location And Movement Of The
Welding Generator
Inches
~<
C
>.-.~<
Figure
OM-160 518
Page
4
3-2. Overall Dimensions
Millimeters
A
19
483
B
14-5/8
371
C
28-3/4
730
Maximum
tilting angles for
proper
lubrication.
fuel cap at
Keep
highest point when
tilted.
200
Do not overfill fuel tank
leave
for expansion a nd tilting with
room
200
out
Do not let fuel leak from cap
causing
leaks.
during tilting.
S-0702
Figure
3-2.
Engine
3-3. Maximum
Welding Generator
Angles
Prestart Checks
a
WARNING
ENGINE
FUEL
can
fire
cause
or
explosion.
Stop engine
before
Do not fuel while
.~
Tilt
fueling.
smoking
or near
sparks
Do not overfill tank; clean up any
spilled
or
flames.
fuel.
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
Rotate fuel cap slowly and wait until
before removing cap.
hissing stops
rwarn3 1 9191
Check all fluids
be cold and
Add
fresh
engine the
Figure 6-1).
I
Fuel
daily. Engine
on a
must
level surface.
fuel before starting
first
time
(see
Cap
Fill fuel tank to within 1 in (25 mm)
of bottom of filler neck to provide
space for expansion.
2
Oil Fill Cap/Dipstick
3
Oil Fill Tube
Remove
Reinsert
dipstick
dipstick
and
wipe
off oil.
in tube so oil fill
cap rests on tube collar. Do not
thread cap onto tube. Remove dip
stick and check oil level.
If oil is not up to full mark, add oil
(see Figure 6-1). Add 4 oz (0.12 L)
oil to raise oil level
on
dipstick
from
L to F.
rsb4,1
Figure
3-4.
Checking
11/92ST-16l
479
Fluid Levels
OM-160 518 Page 5
3-3.
The Generator
Grounding
Auxiliary
Power
System
1
Equipment Grounding
Terminal
The generator
auxiliary
power neutral is connected
to the machine frame.
Tools Needed:
-.~
Ret. ST-i ~7 863-A / Ret. ST-I 81 479
rsb5.1 1/93
Figure
3-4.
Connecting
To Weld
Equipment Grounding
3-5.
Output
Connection
Terminals
WARNING
a
ELECTRIC SHOCK
can
kill.
.
.~
Always
wear
dry insulating gloves.
Do not touch live electrical
parts.
Stop engine before making any
Read
Safety
Precautions at
weld
output connections.
beginning of
this manual.
1
rwarnl3,l 2/92
I
2
DC Negative () Weld Output
Receptacle
~
2
~
DC Positive
(+) Weld Output
Receptacle
~
For Direct Current Electrode Posi
tive
(DCEP). connect work cable to
receptacle and electrode
cable to Electrode + receptacle.
Work
For Direct Current Electrode
tive
(DCEN),
Nega
cable
reverse
connections.
3
Weld
4
Connector
Output Receptacle
Align keyways on
receptacle. Insert
rotate
clockwise
connector and
connector and
until
tight
in
receptacle.
~Ret. ST-I57863-A/ST-161 480
Figure
OM-160 518
Page
6
3-6. Weld
Output
Connections
SECTION 4- OPERATING THE WELDING GENERATOR
WARNING
a
ELECTRIC SHOCK
E NGINE EXHAUST GASES can kill.
kill.
can
Do not breathe exhaust fumes.
Do not touch live electrical parts.
Always
wear
from work and
yourself
Stop engine before installing
Keep
all
panels
WELDING
and
covers
can cause
Do not weld
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
dry insulating gloves.
Insulate
near
or
ground.
servicing.
securely
fire
or
in
ENGINE FUEL
sion.
place
explosion.
!
Do not weld
on
Allow work and
over
welding
equipment
,~
to cool before
handling.
FUMES AND GASES
=~!t?
~
be hazardous.
your head out of the fumes.
or use
Safety
manufacturers
spilled
or
flames.
fuel.
away from
can cause
moving parts
injury.
such
as
fans, belts.
Keep all doors, panels,
securely in place.
covers, and
guards
closed
and
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
near
breathing device.
Data Sheets (MSDS5) and
instructions for material used.
wearers
keep away.
Wearers should consult their doctor before
~_.
Read Material
sparks
and rotors.
I
\
body protection
can
MOVING PARTS
Keep
helmet with correct shade of filter.
Wear correct eye, ear, and
Keep
or near
combustible surfaces.
closed containers.
Ventilate area,
smoking
Do not overfill tank; clean up any
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Wear
explo
or
Stop engine before fueling.
keep extinguisher nearby.
Do not locate unit
fire
flammable material.
Do not fuel while
Watch for fire;
can cause
any
going
welding operations.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
~ 110/91
4
1
Amperage Control
2
Engine
3
Low Oil Level
4
Throttle Control Lever
5
Choke Control
6
Fuel Shutoff Valve
Hour Meter
(Optional)
Light (Optional)
6
ST-161 477/Rel.ST-161 479
Figure
2
4-1. Controls
3
4
U~LE~1
1
Insulating Gloves
2
Safety Glasses
With Side
Shields
_______
3
Welding
4
Hand Shield
Helmet
_______
______
Figure
4-2.
Wear
dry insulating gloves, safety
glasses with side shields, and a
welding helmet or hand shield with
a correct shade of filter (see ANSI
Z49.1).
sb3.110/91
Safety Equipment
OM-160 518
Page
7
Work
1
Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
Tools Needed:
as
close to weld
Use wire brush
area as
possible.
sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
or
sb4.1 2/93
Figure
4-3. Work
Clamp
Amperage Control
1
Use control to select weld amper
age. Engine must be running at
weld/power speed
to
attain
full
weld output. Control may be ad
justed while welding.
1
Electrode Scale
2
Scale shows recommended elec
trode diameter for weld amperage.
3
Scale
Amperage
Numbers
in
scale
are
welding
amperes.
2
3
Figure
4-4.
Ret. ST-157 883-A
Amperage Control
Fuel Shutoff Valve
1
Open
valve before
starting engine.
Close valve when unit is not in
or
use
during transport.
2
Throttle Control Lever
Use lever to start and stop engine
and select engine speed. To start
engine,
3
move
lever to Run.
Choke Control Lever
Use lever to
regulate
carburetor
air/fuel mixture. Move choke lever
right (choke on)
engine. If starting
if
to
starting a cold
engine,
move choke lever to left (choke off).
4
a warm
Starter Handle
Pull
starter
handle
with
quick,
smooth motion.
After
engine
warms, move choke
lever to left.
Keep throttle lever in Run for weld/
auxiliary power. Move lever to Idle
for idle speed.
Stop
unit
by moving lever
to
Stop.
S-0690 / Ret. ST-161 478
Figure
OM-160 518
Page
8
4-5.
Engine Controls
1
Engine
Hour Meter
Use meter to check total
operating
(see Section 6). This meter op
erates only when engine is running.
hours
6
rsb6.1 2/92
Figure
4-6.
Hour Meter
Engine
(Optional)
I
Q~
Low Oil Level
Light
Light flickers when starter handle
pulled if engine has stopped due
1
is
to
automatic low oil level shutdown.
Engine does not start until sufficient
oil is added to engine.
LOW OIL
Fill
engine
stick (see
with oil to F
mark
on
dip
Figure 3-4).
Ref. ST-157 863
Figure
EquIpment~)
)
Install &
Connect
)
________________
_____
Select
Electrode
4-7. Automatic Low Oil Shutdown
Put On
Personal Safety
Equipment
________________
_____
Insert
Electrode
Begin
Into_Holder
I
I
~~JJ
_____
Set
(Optional)
ControI~~)
_____
Start
Eng~~Uia~)__..)
________________
_____
~g~pmen~,~
~-
Weldin~
_________________
rSbO.1 9/92
Figure
4-8.
Sequence Of
Shielded Metal Arc
Welding (SMAW)
OM-160 518
Page
9
SECTION 5- OPERATING AUXILIARY EQUIPMENT
WARNING
a
ELECTRIC SHOCK
can
kill.
before
reconnection.
making internal inspection
Stop engine
Ground
or
~X
to
all
Keep away from
and rotors.
such
covers, and
as
fans, belts,
guards
closed
and
grounding terminal
to a proper
Do not connect to any electrical distribution
normally supplied by utility power.
ELECTRIC SPARKS
serious
cause
moving parts
Keep all doors, panels,
securely in place.
applicable
national, state, and local codes.
Connect equipment
earth ground.
can
injury.
~
generator according
PARTS
MOVING
,~-.
Do not touch live electrical parts.
can cause
DC AUXILIARY POWER
electrical
equipment
incorrect operation.
system
damage
cause
Use DC output only for incandescent
tools rated for DC.
Do not
fire.
use
equipment,
using auxiliary power only and not welding,
disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
can
and
lights
and
DC to power AC motors, transformer
induction motors.
or
If
cii
0
Watch for fire.
Keep
use
a
fire
extinguisher nearby,
and know how to
all hand tools
are
powered by
universal
However, the switches on inexpensive/light
duty tools may be damaged by DC power, and variable
speed tools will run only at full speed on DC.
provides 1200 watts of direct current (DC)
auxiliary power. DC power is suitable for incandescent
lights and portable power tools with 115 or 120 volt
This unit
it.
The weld output terminals are
when the engine is running.
Essentially
motors.
AC/DC
electrically energized
or
power any
DC
ratings. This power must
AC-only rated equipment.
not be used to
rwarn8.1
5-1.
Auxiliary
Power DC
10/92
Receptacle
120V 1OA DC
1
Receptacle
Maximum output at RUN speed is
1.2 kW. Full auxiliary power is avail
able
only
when not
welding.
DC power is suitable for incandes
cent lights and portable power
tools with 115
or
120 volt AC/DC
or
ratings. The switches on inex
pensive/light duty tools may be
damaged by DC power, and vari
able speed tools will run only at full
speed on DC.
DC
2
Use DC output only for incandes
lights and tools rated for DC.
Do not use DC power to run any
AC-only rated equipment, AC mo
tors, transformer equipment, or in
duction motors.
cent
lOAFuseFi
2
Fl
protects generator from
load
or
short circuits
on
over
dc recep
tacle. If Fl
opens, the generator
continues to run but there is no out
put at the receptacle. Weld output
is still available. See Section 6-7 for
fuse
Figure
5-2.
5-1.
Auxiliary
Power DC
Receptacle
replacement.
And Circuit Protection
Auxiliary Equipment Operation
) lnstat&Co~n~ct~)
)
Figure
OM-160 518
Page
10
5-2.
)Turn
OnA
liarY))
Sequence Of Auxiliary Equipment Operation
Begin
Ope~on
Ret. ST.157 863-A
SECTION 6
MAINTENANCE & TROUBLESHOOTING
WARNING
a
ELECTRIC SHOCK
kill.
can
ENGINE FUEL
sion.
Do not touch live electrical parts.
Always
wear
Insulate
Stop engine
Keep
all
from work and
before
panels
and
installing
covers
or
ground.
Do not fuel while
servicing.
Do not overfill
in
securely
ENGINE EXHAUST GASES
fire
explo
can
smoking
or near
sparks or flames.
tank; clean up any spilled fuel
MOVING PARTS
place.
can cause
injury.
Keep hands, loose clothing, and tools away from
moving parts such as pulleys, fans, belts, and ro
kill.
tors.
Do not breathe exhaust fumes.
Keep all doors, panels,
securely in place.
covers, and
guards
closed
and
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
HOT PARTS
can cause severe
burns.
Allow
cooling period
Wear
protective gloves and clothing when working
engine.
on a
before
servicing.
hot
Maintenance to be
performed only by qualified
sons.
6-1.
or
Stop engine before fueling.
dry insulating gloves.
yourself
can cause
per
rwarn9.I 10/91
Routine Maintenance
The maintenance label is located
on
the fuel tank above the throttle control lever
Recommended Oil-API Service Classification SF-SG/CC-CD
Drive Belt
Drive Belt
32F (0C) SAE 5W-20, SAE 5W-30
Above 32F (0C) SAE 1OW-30, SAE 1OW-40
Below
Check oil daily (4
Oil
Oil
~
oz.
Capacity
Change
Add
on
dipstick)
(0.66L)
Normal conditions 100 hours
Air Filter Service 100 hours or less-See Manual
Air filter element
.
.2
~5
to Full
22.4 oz.
Engine
RPM
.
.
.
.
Miller 067101
at
-
1800
If
(Weld & Power)
-
4150
Figure
See Manual
equipped
with
cap
spark arrestor, inspect and
or supplied instructions.
service per Manual
R~J L$~
~ ~
100 hours
Miller 150412
Capacity 2.3 U.S. Gal (8.7L) Vented
grade Regular or Unleaded
least 87 octane
(RON + MON) 2
Fuel
Fuel
IDLE
Inspection
Spark plug gap Resistor & Std .030 in. (.76 mm)
Champion RCI2YC*
Spark Plug
*Resistor Spark Plug Mandatory in Canada
Kohler 1506306
RUN
STOP
4
(see Figure 6-3).
KOHLER CH5+ ENGiNE
SPEED CONTROL
S.146 281-A
6-1. Maintenance Label
OM-160 518 Page 11
Stop engine
Do
not
fluids
~-
before
throw
take to
maintaining.
engine
recycling
away
area
center.
ED
~JJ
500 Hours
engInes
25 Hours
Check
Valve
Clearance
manual
~y~
6-4~J
Clean Air
Cleaner
Foam
Element
Every200 hours havealferna
for brushes, slip rings, bear
ings and optional/ow oil shut
down checked by FactoryAu
thorized Service Station.
Figure
6-2.
6-2. Maintenance Schedule
Changing Engine Oil
Stop engine.
Change engine oil at interval listed
in Figure 6-1. Change oil while en
is still
gine
1
Support
Use blocks
room
2
warm.
Block
large enough to provide
for oil pan.
Oil Fill
Cap/Dipstick
Remove oil fill
draining
3
cap/dipstick
before
oil.
Oil Drain
Plug
Remove plug. Allow enough time
for oil to drain completely. Reinstall
plug.
4
Maintenance Label
Fill crankcase with
mark
Tools Needed:
3/8 in
new
oil to
F
dipstick. Use correct type
and grade of oil. See Figure 6-1 for
specifications.
on
Reinstall oil fill
cap/dipstick.
ST-I 61 481
Figure
OM-160 518
Page
12
6-3.
Changing Engine
Oil
6-3.
Adjusting Engine Speed
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Start and
1
engine
run
at no load.
Throttle Control Lever
Move lever to Run.
2
Speed Adjustment
3
Securing
Loosen
securing
screws
adjustment plate right
engine
Plate
Screw
and
or
Tighten
at 4150 rpm.
runs
move
left until
screws.
Belt Guard
4
If
engine does
not reach
4150rpm,
stop engine and remove belt guard
(see Section 6-6).
5
Speed Adjustment
Screw
Turn screw out (counterclockwise)
two full turns. Reinstall belt guard
and start engine. Move throttle
control lever and speed adjustment
plate left or right to adjust engine
speed (see items 2 and 3). Tighten
securing screws and stop engine.
Tools Needed:
Moving
Parts
Hazard.
guard in place
running engine.
Have belt
before
Figure
6-4.
6-4.
~
3/8, 9/32 in
Ref. ST-161 482
Engine Speed Adjustment
Air Cleaner Service
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Stop engine.
1
Air Cleaner Cover
2
Retaining
Screw
Loosen retaining screw and
air cleaner cover.
re
move
4
3
Wing
Remove
4
2
Nut
as
shown.
Foam Element
(Precleaner)
Wash element in warm water with
detergent. Rinse all detergent from
element and allow to air-dry.
3
Saturate element with clean
gine
oil.
Squeeze
Reinstall
en
out excess oil.
element
on
paper
element.
5
Paper
Element
Replace dirty
or damaged element
element. Do not wash
dirty element or clean with com
pressed air.
with
a new
Reinstall air cleaner
cover.
5T-151 839
Figure
6-5. Air Cleaner Maintenance
OM-160 518
Page
13
6-5.
Clean Air Intake And
Cooling
Figure
6-6.
Drive Belt
Adjustment
And
Areas
6-6. Air Intake And
Cooling
Areas
Replacement
I~
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Tools Needed:
~ 9/16,5/8 in
7/16 in
Ref. ST-161 482
Stop engine.
1
Belt Guard
Remove five
Remove
2
4
To
screws
guard
and
securing belt guard.
inspect belt.
replace belt, remove tensioning screw
securing screws. Remove belt.
Install new belt and hand-tighten securing
screws. Reinstall tensioning screw,
and loosen
Drive Belt
Readjust belt tension if necessary.
cracked belt.
3
sioned, belt deflects inward about 1/8 in (3
mm).
Securing Screw
Replace
Tensioning Screw
Figure
OM-160 518
Page
14
Check belt tension by pressing belt midway
between pulleys. Apply about 8.5 lb (3.9 kg)
pressure to a new belt or 5.5 lb (2.5 kg) pressure to a used belt. When properly ten-
6-7. Drive Belt
Adjustment
and
Adjust
screw
belt tension
in
or
by turning tensioning
out until proper belt tension is
obtained.
Reinstall belt guard and run unit ten minutes.
unit. Remove belt guard and readjust
Stop
belttensionifnecessary.Replacebeltguard.
Replacement
6-7.
a
Overload Protection
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
Stop engine.
~
CAUTION :DC POWER FOR
TOOLS AND LIGHTS ONLY ! DO
NOT USE AC ONLY RATED TOOLS.
CONSULT OWNERS MANUAL!
1
Fuse Holder
2
lOAFuseFl
Fuse
Fl
overload
the
short circuit
receptacle. If
engine continues
120V dc
Replacement fuse rating: 125 volts
or greater, 10 amperes maximum.
protects the unit from
or
on
the
Fl is open
to run but
there is
no output at the receptacle.
Weld output is still available.
Turn fuse holder counterclockwise
to remove fuse. Put new fuse In
fuse holder. Push fuse holder into
panel and turn clockwise to secure.
10 A
If fuse continues to open, contact
120V 1OA
DC
0
Factory
Authorized Service Sta
tion.
-~Fl
Ret, ST-151 ~86/Ret. ST-157 883-A
Figure
6-8. Location Of Fl Fuse
OM-160 518
Page
15
6-8.
Troubleshooting
WARNING
AA
ELECTRIC SHOCK
ENGINE FUEL
sion.
kill.
can
Do not touch live electrical parts.
Always
wear
Insulate
work and
Stop engine before installing
all
Keep
Stop engine
dry insulating gloves.
yourself from
panels
and
covers
or
can cause
before
fire
Do not fuel while
servicing.
Do not overfill tank; clean up any
ENGINE EXHAUST GASES
in
can
explo
fueling.
ground.
securely
or
smoking
or near
sparks
spilled
or
flames.
fuel.
place
kill.
MOVING PARTS
Do not breathe exhaust fumes.
Keep away from
and rotors.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
can cause
moving parts
Keep all doors, panels,
securely in place.
injury.
such
covers, and
as
fans, belts,
guards
closed
and
HOT PARTS
cooling period
Wear
protective gloves and clothing
on a
hot
burns.
can cause severe
Allow
before
servicing.
when
working
Troubleshooting
engine.
to be
performed only by qualified
persons.
rwarnhl.1 11/91
Table 6-1.
Welding Trouble
Trouble
No weld
or
auxiliary power output.
Section
Remedy
-~
Factory
Have
brushes and
Authorized
Service
Station
check
generator
Broken drive belt.
Low weld output.
-~
Have
Factory Authorized Service Station check generator.
-~
adjust engine speed. Tune-up engine forfull horsepow
(see engine manual).
Check weld cable size and
length.
6.3
-~
--
Check internal and external weld output connections.
Have
--
6-6
-..
Check and
er
---~
slip rings.
Factory Authorized Service Station
-~
check brushes and
slip
-a
rings.
Check
Amperage
control
settings
and connections.
--
Check drive belt tension.
Low
or
high
Check and
weld output.
power
adjust engine speed.
(see engine manual).
Tune up
engine
for full horse
Check governor (see engine manual).
Erratic
welding
Change
arc.
to proper electrode
Check and
adjust engine speed.
Check governor
Weld output uncontrollable.
OM-160 518
Page
16
-~
polarity.
Have Factory
control.
Service
6-6
-~
6-3
-a
--
-a
--
6-3
-~
(see engine manual).
Authorized
-~
---
Station
check
Amperage
-~
--
Table 6-2.
Auxiliary
Power Trouble
Trouble
No
auxiliary
power.
Section
Remedy
-~
Check and
Have
replace fuse
Fl.
-~
Factory Authorized Service Station check
brushes and
Slip
-~
Authorized Service Station check brushes and
slip
--a
6-7
-
rings.
Erratic
auxiliary power.
Have
Factory
--
rings.
Check drive belt tension.
Check and
adjust engine speed. Tune-up engine
horsepower (see engine manual).
Low
Move throttle lever to Run
auxiliary power.
Check and
to achieve full
-~
6-6
-~
6-3
position.
adjust engine speed. Perform engine maintenance
horsepower (see engine manual).
as
necessary to achieve full
Check drive belt tension.
Have
Factory
Authorized Service Station check
Table 6-3.
Engine
Trouble
Engine
generator.
Trouble
Remedy
will not start.
Open
fuel shutoff valve.
Check oil level. Check
---~
optional oil
level shutdown switch.
Check fuel level in tank.
Move throttle control lever to Run
See
Engine
runs
rough
or
stalls.
--
engine
Have
position.
manual.
Dirt or water in fuet.
Section
-..
Figure
4-5
Figure 3-4,
Figure 4-7
--~
Figure
3-4
--~
Figure
4-5
---
Replace
fuel.
Factory Authorized Service Station check fuel filter.
Tune-up engine (see engine manual).
OM-160 518
Page
17
U) m C)
POSITVE
WELD
DC
0z
m r m C) -I
a
C)
r a
Cl)
NEGATIVE
OUTP
539-A
58-152
7
15-I2VDC POWER
B
AUX
(POS)
I
25
PLG3/RC
RC2
Genrato
Welding
For
IIRC2
Diagram
PLG2
11/1/ti23456789tP/LG2 _~jA-_~ -~46 ~4)
13 12
Circuit
17
1161
16
15
PLG2/RC
7-1.
I
313
Figure
I
I
RC3
11
ENG GNO
tl\ PLc3
I
kJltJdl2h 23456789 1/3 59241
1~
I
PLG3/RC >1>
>2 PLG3/RC
OIL
LEV L
RUNIG MHEOTURR (OPTINAL) -a rJJ3
1
E!~i~I j
-
ENGI E
0
0) 0 C,
0) -u I, (0 CD
0,
EXCITAON
OIL
LOW
TAB
IGNTO KIL
I
SHUTOWN
L
860-B
SP4
ST-153
Genrato
Welding
ALTERNO HOUSING
For
II
Diagram
NEGATIVE OUTP
Wir ng
7-2.
Figure
-,
~
GR~W silo
BLK
r(~
I
L
r
L
SECTION 8- WELDING METHODS & TROUBLESHOOTING
mcd5.~ 9192
WARNING
a
ELECTRIC SHOCK
Always
wear
Insulate
MOVING PARTS
kill.
can
yourself from
work and
Keep
all
panels and
covers
Keep
securely
or use
breathing
HOT PARTS
can cause
Do not weld
Watch for fire;
fire
or
explosion.
flammable material.
near
fans, belts,
covers, and
panels,
place.
guards closed
can cause severe
Allow
before
cooling period
Wear
protective gloves
touching
and
burns.
welded metal.
clothing.
device.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
as
in
be hazardous
your head out of the fumes.
Ventilate area,
all doors,
in
Keep
and
securely
can
injury.
such
and rotors.
ground.
Do not touch live electrical parts.
FUMES AND GASES
to your health.
can cause
Keep away from moving parts
dry insulating gloves.
4
keep extinguisher nearby.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
near arc
welding, gouging,
or
going
spot welding opera
tions.
Do not locate unit
Do not weld
on
Allow work and
over
combustible surfaces.
WELDING CURRENT can
tronic parts in vehicles.
closed containers.
equipment
to cool before
handling
Disconnect both
vehicle.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Wear
welding
Wear correct eye, ear, and
8-1.
Shielded Metal Arc
~
N OTE
cables before
battery
Place work clamp
helmet with correct shade of filter.
as
close to the weld
See
Safety Rules at beginning of
welding safety information.
body protection.
damage
elec
welding on
as
a
possible.
manual for basic
Welding (SMAW)
Welding
current starts
as soon as
electrode touches the workpiece.
1
Workpiece
Make
4
workpiece is
welding.
2
Work
Place
2
sure
fore
clean be
Clamp
close to the weld as
as
possi
ble.
3
Electrode
A
small
quires
diameter
electrode
less current than
a
re
large
Follow recommendations of
electrode manufacturer when set
weld
ting
(see
amperage
one.
Figure 8-2).
Insulated Electrode Holder
4
5
Electrode Holder Position
6
Arc
Arc
length
arc
a
with correct amperage will
sound.
give
sharp, crackling
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
~
Tools Needed:
Length
is the distance from the
electrode to the workpiece. A short
7
making
another weld pass.
ST-151 593
Figure
OM-160 518
Page
20
8-1. Shielded Metal Arc
Welding (SMAW)
Procedure
w
ow
w
a
0
w
It
I
w
uJz
0
w
-J
w
o
a
0
Lt)
6010
&
o
0
U)
I-
-
0
0
ClJ
0
LI)
C\i
0
0
0
0
LI)
C~
C~
0
~
0
LI)
-~L
5/32
6011
6013
5/32
9115
7,93
1/4
3/32
115
7014
3/IS
7193
1/8
7018
5/32
1115
1132
1/4
7024
5/32
I/IA
I
M
3132
Ni-Cl
U
3/16
308L
~1/8
5/32
2
uJ
a
z
0
0
0
0
I
a
0
I
C,)
It
I
w
0
w
-J
0~
2
uJ
0~
w
6010
EP
6011
EP
6013
E~EN
EP,EN
7014
7018
ER
ALL
DEEP
v
ALL
DEEP
v
ALL
LOW
GENERAL
MED
SMOOTH, EASY,
y
ALL
PREP, ROUGH
HIGH SPATTER
MIN.
FAST
v
ALL
LOW
LOW HYDROGEN,
STRONG
LOW
SMOOTH, EASY,
7024
EP,EN
/
FLAT
HORIZ
FILLET
NI-CL
ER
v
ALL
LOW
CAST IRON
308L
ER
/
ALL
LOW
STAINLESS
*EP
EN
=
=
FASTER
ELECTRODE POSITIVE (REVERSE POLARITY)
ELECTRODE NEGATIVE (STRAIGHT POLARITY)
-
Ref. S-087 985-A
Figure
8-2. Electrode And
Amperage Selection Chart
OM-160 518 Page 21
1
Electrode
2
Workpiece
3
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
2
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049
8-3.
Figure
Striking
An Arc
Scratch Start Technique
Electrode
2
Workpiece
3
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
2
Ii
1
arc.
If
arc
goes out, electrode
was
high. If electrode sticks to
workpiece, use a quick twist to free
lifted too
the electrode.
3
S.0050
Figure
1O0~3O0
8-4.
Striking
An Arc
Tapping Technique
0
\
300
10~\~
~-
~-
<~
End View Of Work
Angle
Side View Of Electrode
Angle
End View Of Work
Angle
Side View Of Electrode
Angle
FILLET WELDS
GROOVE WELDS
S-0660
Figure
OM-160 518
Page
22
8-5.
Positioning
Electrode Holder
POOR WELD BEAD
34~
1
Large Spatter Deposits
2
Rough,
3
Slight Crater During
Welding
uneven
bead
4
Bad
5
Poor Penetration
Overlap
5
S-0053.A
GOOD WELD BEAD
1
Fine
2
Uniform Bead
3
Spatter
Moderate Crater
During
Welding
4
5
Weld
1/8 in
a new
being
welded.
bead or layer for each
(3.2 mm) thickness in metals
4
No
5
Good Penetration Into Base
Metal
Overlap
S-0052-B
Figure
NOTE ~
Weld bead
8-6. Weld Bead Characteristics
shape
is affected
by electrode angle,
arc
length,
travel
speed, and
thickness of base metal.
______________________
Correct
Angle
Angle
Angle
Too Small
Too
Large
H
Drag
ELECTRODE ANGLE
L_]
Li
Spatter
Normal
Too Short
Too
Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-066 1
Figure
8-7. Conditions That Affect Weld Bead
Shape
OM160
518
Page
23
NOTE ~
Normally,
single stringer bead is satisfactory for most narrow groove weld joints;
or bridging across gaps, a weave bead or
multiple stringer beads work better.
a
however, for wide groove weld joints
1
Stringer Bead Steady
Movement Along Seam
2
Weave Bead
Movement
3
Side To Side
Along Seam
Weave Patterns
Use
patterns
weave
to cover
a
wide area in one pass of the elec
trode. Do not let weave width ex
ceed 2-1/2 times diameter of
~~/3
electrode.
S-0054A
Figure 8-8. Ele ctrode Mov ement During Welding
1
Tack Welds
2
Prevent
edges of joint from draw
ing together ahead of electrode by
tack welding the materials in posi
/
/
$~
tior, before final weld.
~
2
Square Groove Weld
I
Good for materials up to 3/16 in
(5 mm) thick.
3
Single
V-Groove Weld
Good for materials 3/16 through
3/4 in (5-19 mm) thick. Cut bevel
with oxyacetylene or plasma cut
ting equipment. Remove scale
from material after cutting. A grind
ercan also be used to prepare bev
els.
Create 30
~
L
degree angle of bevel on
V-groove welding.
materials in
/
4
Double V-Groove Weld
~~I~f
Good for materials thicker than
4jI~t~-
3/l6in(5mm).
9-0662
Figure
8-9. Butt Joints
1
Vise
2
Weld Joint
3
Hammer
Strike weld joint in direction shown.
A good weld bends over but does
not break.
I
2To3in
4..
(51-76 mm)
~
1/4in
(6.4
mm4
0
2
1
1
S-0057-B
Figure
OM-160 518
Page
24
8-10. Weld Test
1
Electrode
2
Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to
provide fusion into the
Square edge of the weld
corner.
surface.
For maximum strength weld both
sides of upright section.
3
Multi-Layer Deposits
Weld
a
second
layer when a
heavi
fillet is needed. Use any of the
in
shown
patterns
weaving
er
Figure 8-8. Remove slag before
making another weld pass.
S-0060 / S-0058-A / S-OO61
Figure
8-11. Tee Joint
300 Or
1
Electrode
2
Single-Layer
Less
Fillet Weld
Move electrode in circular motion.
3
Multi-Layer
Fillet Weld
1
second layer when a heavi
er fillet is needed. Remove slag be
fore making another weld pass.
Weld both sides of joint for maxi
2
Weld
a
mum
strength.
3
Single-Layer
Fillet Weld
Multi-Layer
Fillet Weld
S~oo63 /S-0064
Figure
8-2.
8-12.
Lap
Joint
Welding Troubleshooting
Table 8-1.
Porosity
Porosity
from gas
~
Possible Causes
Arc
length
Damp
too
long.
electrode.
.
or
holes
resulting
in weld metal.
Corrective Actions
Reduce
arc
Use
electrode.
dry
length.
Remove all grease, oil, moisture, rust,
Workpiece dirty.
small cavities
pockets
paint, coatings, slag,
and dirt from work surface before
welding.
OM-160 518 Page 25
Table 8-2. Excessive
.
Spatter
Excessive Spatter
scattering of molten
metal particles that cool to solid form near
weld bead.
.
~.....
~ ~~Possible Causes
Amperage
too
high for
Arc
too
long
length
or
Corrective Actions
electrode.
voltage
too
Decrease amperage
high
Reduce
arc
length
or
select
larger
electrode.
voltage.
or
Table 8-3. Incomplete Fusion
Incomplete Fusion
completely
to fuse
\
preceeding
failure of weld metal
with base metal
or a
weld bead.
hr11
Possible Causes
Insufficient heat
input.
Improper welding technique.
Corrective Actions
Increase amperage. Select
Place
stringer
Adjust
work
bead in proper
angle
or
hold
Keep
leading edge
arc on
location(s)
widen groove to
Momentarily
arc on
at
joint during welding.
access
bottom
groove side walls when
of weld
during welding.
using weaving technique.
puddle.
Remove all grease, oil, moisture, rust,
Workpiece dirty.
increase amperage.
larger electrode and
paint, coatings, slag,
and dirt from work surface before
welding.
Table 8-4. Lack Of Penetration
Lack Of Penetration
shallow fusion be
tween weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Improper joint preparation.
Improper
weld
technique.
Insufficient heat input.
Corrective Actions
Material too thick. Joint
Keep
arc on
leading edge
Page
26
of weld
Increase amperage. Select
Reduce travel
OM-160 518
preparation
speed.
larger
and
design
must
provide
access to
puddle.
electrode and increase amperage.
bottom of groove.
Table 8-5. Excessive Penetration
Excessive Penetration
ing through
weld metal melt
base metal and
hanging
un
derneath weld
~.
Excessive Penetration
Good Penetration
Possible Causes
Excessive heat
input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain
steady
Table 8-6.
travel
speed.
Burn-Through
Burn-Through
pletely through
holes where
Possible Causes
Excessive heat input.
no
weld metal melting com
base metal resulting in
metal remains.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain
steady
travel
speed.
Table 8-7. Waviness Of Bead
Waviness Of Bead weld metal that is not
parallel and does not cover joint formed by
base metal.
Possible Causes
Unsteady
Corrective Actions
Use two hands. Practice
hand.
technique.
Table 8-8. Distortion
Distortioncontraction of weld metal dur
ing welding that forces base metal to
move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Excessive heat
input.
Corrective Actions
Use restraint
(clamp)
Make tack welds
to hold base metal in
along joint
before
position.
starting welding operation.
Select lower amperage for electrode.
Increase travel
Weld in small
speed.
segments
and allow
cooling
between welds.
OM-160 518
Page
27
SECTION 9
PARTS LIST
ST-162 841
Figure
OM-160 518
Page
28
9-1. Main
Assembly
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
147 601
1
..
.
3
.
..
..
4
150 721
.
.
5
150 720
.
.
020 279
.
.
150 123
.
.
6
.
.
.
.
..
.
.
.
..
.
.
.
.
.
.
.
.
.
152 756
.
.
+148 975
.
.
.
152 452
.
.
..
146 994
.
.
10
148976
.
.
11
150 412
.
.
12
146 280
.
.
13
151 209
.
.
14
+148 971
.
.
15
601 965
.
.
16
602 213
.
.
17
602 243
.
.
..
18
148 966
.
.
..
19
150 217
.
.
20
602 215
.
.
7
..
8
..
9
..
..
..
..
.
.
..
..
.
..
..
21
..
...
PLG2,3
..
22
23
RC2
.
..
.
.
.
.
150708
.
.
135 133
.
..
114066
.
.
.
1
1
4
.
.
.
....
.
.
1
1
1
1
1
1
1
1
1
.
1
1
2
1
1
1
2
9
1
1
CONNECTOR, rect skt 20-l4ga Amp 350536-1
9
PULLEY, V sgl grv 3.75Odia x 3.500P x .670 bore
SPACER,fan
FAN, generator 6.469dia
BEARING, ball
BEARING, roller
BRUSH HOLDER ASSEMBLY, generator
1
.
..
150 498
.
.
.
150 502
.
.
.
150 503
.
.
.
150 506
.
..
24
155063
..
25
148 965
.
.
9-3
.
.
155 797
.
.
+157 906
.
.
150 567
.
.
30
150 216
.
..
1
31
150344
.
..
1
150 127
Fig
SR3
.
..
.
.
..
.
33
026 947
.
..
.
.
34
150 128
.
..
.
.
35
150 130
.
.
.
.
36
127 596
.
.
.
37
135 133
.
.
114 066
.
.
.
.
38
9-2
.
.
.
.
39
157 907
.
.
.
.
40
129 527
.
..
.
.
41
600 681
.
..
.
.
42
010 521
.
..
43
600 325
.
..
44
040 234
.
..
Fig
1
1
1
.
..
1
1
.
.
1
SCREEN, handle base
PANEL, control w/components
LABEL, caution use no hooks or slings
HANDLE, front/rear
RECTIFIER, positive/negative (consisting of)
BRACKET, mtg rectifier
INSULATOR, rectifier
RECTIFIER, negative half 3 phase full wave
STAND-OFF, insul .250-20 x 1 .000 Ig x .31 2thd
RECTIFIER, positive half 3 phase full wave
TUBING, stl .625 OD x l2ga wall x 1.125
WASHER, flat stl .344 ID x 1.500 OD x .l25thk
CONNECTOR, rect 9P/S rcpt Amp 1-614765-0
CONNECTOR, rect skt 20-l4ga Amp 350536-1
PANEL, front w/components
CABLE, w/electrode holder (consisting of)
CONNECTOR, twlk insul male (Dinse type) 50 Series
SPLICE, prl 4 wire
WIRE, tie
CABLE, weld cop strd No. 6 (order by ft)
AF-2 HOLDER, electrode 200A
.
RC3
1
BASE
32
.
.
GUARD, belt drive
SCREW, .375-16 x 1.000 hexhd
WASHER, lock sti split .375
WASHER, flat stl std .375
RETAINER, adjuster belt
SCREW, .437-14 x 4.000 hexhd
WASHER, lock sti split .437
CONNECTOR, rect 9P/S plug Amp 350720-1
CONNECTOR, rect pin 20-1 4ga Amp 350218-1
GENERATOR, (consisting of)
CONNECTOR, rectgP/S rcpt Amp 1-641765-0
113 633
1
1
.
PULLEY,Vsglgrv6.75Odiax6.000Px.625 bore
BELT, V cogged .500 wide x .343 deep x 32.300 Ig
LABEL, warning general precautionary
LABEL, warning engine exhaust sparks can cause fire
135 134
1
.
29
.
.
.
28
.
.
1
150497
27
.
.
150 496
26
.
Assembly
CAP, tank screw-on w/vent
HOSE, (see engine parts list)
CLAMP, (see engine parts list)
BRACKET, control idle
BRACKET, tank fuel
CLAMP, stl cush .75Odia x .281 hole
MOUNT, sgl stud 1.000dia .312-18 stud .750 high
BRACKET, mtg eng/gen
BRACKET, adjustment alternator
HANGER, cable 2.750 Ig .625dia nyl
LABEL, warning moving parts can cause serious injury
.
2
..
9-1. Main
Quantity
1
2
2
1
1
2
1
2
2
1
9
1
1
1
.
2
2
2Oft
1
OM-160 518
Page
29
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
45
157908
46
010368
47
026843
48
600325
49
010521
50
600681
51
129527
134746
147552
52
067101
Si
53
..
+154656
54
147544
55
152460
56
152583
57
150126
137690
+When
Part
ordering
a
9-1. Main
Assembly (Continued)
CABLE, w/g round clamp (consisting of)
CLAMP, ground 200A
INSULATOR, vinyl
CABLE, weld cop strd No. 6 (order by ft)
WIRE, tie
SPLICE, prl 4 wire
CONNECTOR, twlk insul male (Dinse type) 50 series
WRENCH, hex 5mm short
ENGINE, Kohler gas (consisting of)
AIRFILTER
1
2
2Oft
1
1
1
1
1
1
1
TANK, fuel 2.3gal (consisting of)
VALVE, fuel 2 way w/micron filter
BUSHING,tankfuel
MOUNT, dual stud .625dia .250-20 stud .625 high
AUTO ARC, hand-held shield
1
component originally displaying
a
precautionary label, the label should also be ordered.
of 042 769 Optional Automatic Low Oil Shutdown Kit.
Page 30
1
SWITCH, oil low level
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-160 518
Quantity
1
1
6
1
Item
No.
Part
No.
Dia.
Mkgs.
Figure
..
..
..
..
Ri
1
.
..
.
2
CS
3
..
..
..
5
..
6
150765
.
.
154663
.
.
152537
.
.
654
.
.
604 176
.
.
073 690
.
.
.
.
154
4
RC1
..
.
Neg,Pos
...
..
129 525
7
601 836
.
.
..
8
010 915
.
.
..
9
131 646
.
.
046 432
.
.
*012 655
.
.
..
..
..
..
..
..
.
.
.
.
C3,4
..
.
10
Fl
11
.
.
.
12
063030
.
.
13
097 924
.
.
.
.
154
14
..
15
..
16
HM
.
154
653
081
Quantity
Description
.
.
9-2.
Panel, Front w/Components (Fig 9-1 Item 38)
RHEOSTAT, WW25W 10/40 ohm
PANEL,front
1
CAPACITOR
1
1
NUT, speed push-on-type .500 stud
1
RECEPTACLE, str dx grd 2P3W iSA 125V
PLUG, str grd armd 2P3W iSA 125V P & S 5266DF
RECEPTACLE, twlk insul fern (Dinse type) 50/70 series
NUT, brs hex .250-20 jam hvy
WASHER, flat brs .250 ID x .625 OD x .O3lthk
1
2
..
3
2
CAPACITOR ASSEMBLY
HOLDER, fuse mintr
FUSE, mintr cer 1OA 250V
1
STUD, brs .250-20x1.750
KNOB, pointer
1
LIGHT, md red lens low oil level
1
NAMEPLATE, (order by model and serial number)
METER, hour 4-4OVDC
1
1
1
1
1
3
2
4
5
16
6
7
8
13
9
12
11
10
ST-162 642
Figure
*Recommended
Part
Part
9-2. Panel, Front
w/Components
Spare Parts.
Optional Automatic Low Oil Shutdown Kit.
of 042 769
of 042 781
Optional Running
Hour Meter.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-160 518 Page 31
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
..
.
.
..
1
2
3
5
..
6
..
..
.
.
.
.
087 111
.
4
.
148 967
137 198
149 243
01,2
035 704
SRi ,2,4
R3,4,VR1,2. 151 530
.
..
.
.
R2
149244
....
152 534
7
8
R3
153 064
....
1
NUT, insert 10-24
CLAMP, capacitor 1 .375dia clip
3
CAPACITOR, elctlt 950uf 100VAC
RECTIFIER, integ 40A 800V
2
SUPPRESSOR
2
RESISTOR,WWadj25W3ohm
1
PANEL, mtg components
RESISTOR, WW adj lOW 1 ohm
1
.
.
.
.
.
.
.
.
.
.
.
Panel, Control w/Components (Fig 9-1 Item 26)
COVER, (consisting of)
.
.
...
...
9-3.
Quantity
2
3
1
-1
(
7
2
3
6
5
Figure
ST.151 475
4
9-3.
Panel, Control w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-160 518
Page
32