January 1980 FORM: OM-410J Effective With Serial No. HK273699 MODEL AEA-200L 60 Hz. AEA-200L 60 Hz. AEA-200LE 60 Hz. AEA-200LE 50 Hz. OWNER'S MANUAL MILLER ELECTRIC MFG. CO. 718 8, BOUNDS ST. P.0. Box 1079 "APPLETON, Wi 54912 USA. ADDITIONAL COPY PRICE $1.00 WSA CODE NO. 4579LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 “This warrenty suporsods all provious MILLER warrant ands x clusive wath na other guarentees or warranties dxprossed or implied LIMITED WARRANTY-Subject tothe torms and conditions betoo!, Mile Elctie Mfg. Co.,.Applston, Wisconsin warants to it Distrbutor/ Dealer that sll new and unused Equpment furnished by Miter Is fra from detect in workmanship and ‘material as ofthe time and place of delivery by Miler. No war ‘anty is mado by Miler with respect to anginas, tao 2c ‘cestries or other toma manulactured by others, Such fenginas, ade accessories and oihar items avo sl8 aubject 10 the wartentog of thoi repectivo manatactirors, any. Al fnginos ao warranted by ther manulcture for ne year fom ‘ate of original purcsoe, Excopt as specified below, Mile’s waranty doos not apply to components having normal ussfl eof less than on (1) oar, such as spot welder tips, relay and contactor points, MILLERMATIC pars that come in contact with the wolding Wire including morales and nocle rsulstors whore fare des hot result from dfect in workmanship or materi. Miler shal be required to honot warranty claims on wa: rantod Equipment in the avent of flrs ruling from a detect within the flowing paris from the dst of deiver of Equip ‘ent tothe oignal user 1. Arewolders, power sources and componenis .. 1 yeer 2. Orginal main poworreetiies 3yeas (bor 1 yest only 43, Allwolding uns and feeder/auns s0doys 4 Allothor Milermatic Feeders year 5. Replacamont or repair parts, excivsive of labor - 6D days 6. Batteries. months provided that Mile is note in iting within tity (30) days fof the date of such faire AAS 9 mater of garaal policy only, Siler may Honor cans submited by the ginal user within the foregoing pores. In tho caco of Ail’s breach of warranty or any other dy with reapect to the quatty of any goods, the exclusive remadios thetuforo shal bp, ot Mil's option (1 reper or (2) mplacemant fr, bore outhraed in wtng by Mer m approprate case, 6) the ransonable cost of ropir of repiscament at an euthotzd Miler sence station or (2) paymont of or credit forthe purchase Drie (ws reasonable depreciation bate upon sctul Us) upan ‘atur ofthe goods ot Customers vk and expense. Upon recap. of notice of apporent defect oe fae, Mlle sha insvuct the ce front onthe waranty dim procadues to be foloed. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND [ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA, TION AS TO PERFORMANCE, AND ANY REMEDY FOR [BREACH OF CONTRACT WHIGH, 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 HIINESS FOR PARTICULAR PURPOSE, WITH RESPECT 10 ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS 6 CLUDED AND DISCLAIMED BY MILLER. EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRITING, (MILLER PRODUCTS ARE INTENDED FOR ULTIMATE "PURCHASE BY COMIMERCIAL/INDUSTELAL USERS AND FOR OPENATION BY PERSONS TRAINED AND, EXPERIENCED is THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE, MILLER” WARRANTIES DO NOT EXTEND YO, AND NO RESELLER IS AUTHORED TO EXTEND IMILLER'S WARRANTIES TO, ANY CONSUMER,ERRATA SHEET After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. ‘Mechanical Start Models Only Effective with Serial No. JC640406 delete all reference to 1 kva, 115 volts, 8.7 amperes dc power while welding as this unit is designed to supply 1 kva 116 volts, 8.7 amperes, 100 Hz. ac power while welding. AMENDMENT TO SECTION 4 - ENGINE PREPARATION ‘Amend Section 4-3, PREPARING NEW BATTERY FOR SERVICE This unit may be equipped with a maintenance-free battery, a conventional wet charged battery, or a dry charged bat- tery. Maintenance-free batteries do not have conventional vent caps since they do not require the addition of water during normal service. Once the battery type is determined, read the following WARNING and proceed to the ap- propriate section: A. Maintenance-Free Battary; B. Wet Charged Battery; C. Dry Charged Battery. BATTERY ACID can burn eyes and skin and destroy clothing and other mat ‘© Wear correct eye and body protection when working with batteries. ABNORMAL VOLTAGE can cause damage to engine electrical component: ‘Do not operate engine without the battery connected. © Do not disconnect the battery while the engine is running. A. Maintenance-Free Battery To place this battery in service connect the negative (-) battery cable to the negative battery terminal. No other preparation should be required. B. Wet Charged Battery Connect the negative (-) battery cable to tha negative terminal on the battery. if the battery has enough power to start the engine, it will charge up while the engine is running. However, if the battery fails to supply enough power to crank the engine, the battery will require recharging. : CHARGING A FROZEN BATTERY can cause the battery to explode and result in serious por sonal injury or damage to equipment. ‘© Chock the state of the electrolyte solution and allow battery to warm to 60°F (16°C) before charging it elec- trolyte is frozen or slushy. Remove the vent caps and refer to Section 4-3C, Steps 7-9 for charging instructions, C. Dry Charged Battery 1. Obtain battery grade (1.265 specific gravity) electrolyte solution, 2, Remove battery from unit and place on a level worktable or other suitable surface, 3. Remove vent caps. BATTERY 1g and other mat BATTERY ACID can burn eyes and skin and destroy clot GASES can explode and shatter the battery. © Wear correct eye and body protection. Do not spill or splash battery fuid. © Donat apply pressure to wall of filled battery-use battery corrier or place hands on opposite corners when lit ting battery, Do not lean over battery when testing. Keen sparks, flames, cigarettes, and other ignition sources away from batteries. Use enough ventilation to keep battery gases from building up during activation. 4. Fill battery cells to top of separators with electrolyte, 5. Allow battery to stand for 20 minutes. 6. Recheck electrolyte level and add if necessary to fill to top of separators. 3/28/82 oma104 Page7. Check electrolyte temperatura in one of the center cells with a battery thermometer. For each 10°F (6°C) incre- ment above 80°F (27°C), a correction factor of 0.004 specific gravity must be added to the specific gravity reading taken in Step 8, For each 10°F (6°C) increment below 80°F (27°C), 0.004 must be subtracted from the reading taken in Step 8. 8. Check the specific gravity of each cell with a hydrometer. (Draw in and expel the electrolyte two or three times from the first cell to be tested to adjust the temperature of the hydrometer to that of the electrolyte). Follow the precautionary steps below in addition to those given in the previous WARNING statements, © Use enough ventilation to keep battery gases from building up during and for several hours after battery charg- ing. Turn battery charger off before making connection to battery. Do not touch or move connections on battery while battery charger is on. Do not lean over battery when charging. Be sure battery charger connections to battery are clean and tight. ‘Keep vent caps in place and cover top of battery with damp cloth. Be sure battery charger output matches battery voltage. Ifa corrected specific gravity reading of 1.260 at 80°F (27°C) is not obtained, replace the vent caps and recharge ‘the battery following the battery charger manufacturer's instructions. BATTERY GASES can explode and shatter the battery. ‘© Turn the battery charger off before disconnecting the charger from the battery. 10, Recheck electrolyte level and add if necessary. BATTERY ACID is corrosive to metals. 11. Thoroughly rinse with water and mutilate empty electrolyte containers before discarding. 12. Reinstalt battery in welding generator. . 13. Replace battery holddown and tighten securely. Oo not overtighten. 14. Connect positive (+) battery cable to positive (+) battery terminal. 18. Connect negative (-) battery cable to negative (-) battery terminal. AMENDMENT TO SECTION 5 - FUNCTION OF GENERATOR CONTROLS ‘Amend Section 6-8. 120/240 VOLTS AC TERMINAL STRIP Add the IMPORTANT block at beginning of Section: This unit is equipped with a ground terminal below terminal strip 1T for making ground connections Nee jood. Delete all rferance to mating ground connections using the cap screw on the generator end. bell. om-410J PageAMENDMENT TO SECTION 10 - TROUBLESHOOTING ‘Amend Figure 11-1. Circuit Diagram For Electric Start Welding Generato's 4 opal Circuit Diagram No. B-070 746 Figure 11-1, Circuit Diagram For Electric Start Welding Generators Effective With S/N J8502784 ‘Amend Figure 11 Circuit Diagram For Manual Start Welding Generators a Te ¥ Circuit Diagram No. B-047 687-A Circuit Diagram For Manual Start Welding Generator Effective With Serial No. HK273699 Thru JC640405 ON-8104 PageCircuit Diagram No. 8-086 956 Circuit Diagram For Manual Start Welding Generators Effecti With Serial No. JC840406 And Following Figure 11-2. Circuit Diagrams For Manual Start Welding Generators OM-410J Pageo‘Amend Figure 11-3. Circuit Diagram For Automatic Idle Control Circuit Board DioDE Ds2 ISOLATED p ¢@—__5 RESET POSITIVE 8 o@,3. Ps output a0 ouTPUT, (DELAY OFF) C (DELAY ON) PINVIEW | =O as RESeTa BURDEN RESISTOR o a ag scRs0a 51 NEGATIVE J pining 4 Circuit Diagram No. A-071 600 Figure 11-3. Circuit Diagram For Automatic Idle Control Circuit Board Effective With Serial No. JA440663 And Following Amend Figure 11-4. Circuit iagram For Power Voltage Regulator Circuit Board Circuit Diagram No. A-049 506-A, Figure 11-4. Circuit Diagram For Power Voltage Regulator Circuit Board ON-4104 Page &Model Item Dia. Part‘ Replaced 200. | 200 No. _Mkgs. No. With Description Manual Electric 2 017 222 070 213 HOLD DOWN, battery (EFF W/J8502784) 1 3 052 653 071 970 COVER, cable battery post red (Eff W/JB02784) 1 4 904 647 082 314 CABLE battery posite (EH W/JB602784) ... 1 6 919.021 910 021 CLAME,(aty cho) (EHW/J8602784) . 5 1 2 Pg2 12 045046 070070 TRANSFORMER, control . 1 Paz 032 184 Deleted 17 015712 010 493 BUSHING, snap 6/8 1D x7/8... 1 1 21 TS1__ 048-852 045.060 SOLENOID, 12 vlts20 amp (et w/J602784). 1 25 048.964 048 984 CHAIN, throttle .... 1 26 064 646 SPRING, high speed 14 39 FI (075.426 Deleted (Ett W/JB502784) 40 049711 Deleted (Eff W/J8502784) 50 602 184 602 814 INSULATION, jack -plugrred.... 1 o4 53 003 474 070211 SHELF, battery (ff W/JB502764) 1 54 004 648 082316 CABLE, battery - negative (Eff WW/J8502784) . i 82 003 $23 047 885 CAP, brush holder (Eff W/JB385333) ....... 30 3 a3 007 249 047 878 BAR, retaining - brush holder (Eff W/JB385333) . 1 04 84 047 273 086 961 STATOR, generator 60 Hz (Eff W/JC840406) . Het 84 087 274 086 960 STATOR, ganorator 0 He (Ef W/sC540406). 14 87 039123 Deleted (Eff W/JC840406) 88 1-3 037572 Deleted (Eff W/JC840408) 30 020 847 Deleted (Eff W/JC840408) 139 052 403 011 644 CONTACT, stationary’. s.e.esvs sevens tod 154 PC1_ 049.443 071 609 CIRCUIT CARD, woid/idie control (EHF W/JA440 1 P99 057,58 027369 070 250 DIODE, rectifier 3 amp 600 volts straight polarity 2 Pg 10 C51,52 031 651 045 868 CAPACITOR, electrolytic 100 uf 25 volts de 2 Pg 10 AS1,56 605919 605 919 RESISTOR iqty chg) (EFF W/JA440663) 2 Pg 10 R6A 071.595 RESISTOR, carbon film 0.28 watt 22. ohm’ (Eft W/JA440663) 5 1 Pg 10 R64 035 824 035 824 RESISTOR (aty chg) (Eff W/JA440663) 1 Pg10 REO 035 822 RESISTOR, carbon film 0.25 watt W/sA440663) 5 1 P10 R65 000 885 Deleted (Eff W/.JA440663) Bi 045 061 CIRCUIT BREAKER, 24 volts de 7 amp (Eft W/JB602784) 071 971 COVER, cable - battery post black (Eff W/.JBE02784) 1 070 010 BOLT, J 1/4-20 x2-5/16 (EM W/JB502784) ........ 2 603.097 GROMMET, rubber 1-1/4 mounting hole (ett W/ 48502784) «..... foc 1 603 120 STRIP, felt 1/4 x3/4 x28-1/4 (EH W/JB602784).--. S22 057 357 BUSHING, snap 16/16 ID x 1.12 mounting hole. 1 4 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-4104 Page Fes TABLE OF CONTENTS mens D Section No. Page No. SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction 5 1 1-2. General Precautions .. 4 1-3. Arc Welding. 3 1-4, Standards Bookiet Index 4 SECTION 2 - INTRODUCTION 2-1. General. 6 2-21 Receiving-Handiing - 5 2-3. Description 5 2-4. Safety... 5 SECTION 3 - INSTALLATION 3-1. Location. 6 3-2. Equipment Grounding 6 3-3. Weld Output Connections 6 SECTION 4 - ENGINE PREPARATION 4-1. Lubrication 8 4-2. Fuel ene 8 4-3... Preparing Now: Battry For Service (Electric Start Models Only) 8 4-4. AirCleaner ees 9 SECTION 6 - FUNCTION OF GENERATOR CONTROLS 5-1. Range Switch ....... 9 5-2. Fine Amperage Control . 9 5-3. 118 Volts DC Receptacle 10 5-4, 120 Volts AC Duplex Receptacle 10 5-5. Weld/Power Switch... : 10 5-6. 120/240 Volts AC Terminal St " 5-7. DutyCycle... 2 5-8, Volt-Ampere Curves. 2 5-9. 240 Volts AC Duplex Receptacle 2 ‘SECTION 6 - FUNCTION OF ENGINE CONTROLS 6-1. Choke Control 18 6-2. Ignition Switch ..-.. : 13 6-3. Starter Switch (Electric Models Only). B 6-4. Automatic Idle Control Switch (Electric Start Models Oniy) «....... 13 6-5. Throttle Control (Manual Start Models Only) ...... se 14 8 -8. Stop Switch (Manual Start Models On) «00... ia . 6-7. HourMeter is : 4 - SECTION 7 - SEQUENCE OF OPERATION 7-1. Shielded Metal-Arc Welding 4 7-2. PowerPlant Operation ..... 4 7-3, Starting The Engino 18 7-4, Stopping The Engine 6Section No. SECTION 8 - GENERATOR MAINTENANCE 8-1. 8-2. 8-3 General... Collector Ring Brushes Welding Cables . SECTION 9 - ENGINE MAINTENANCE Periodic Service Lubrication, Cleaning The Engine Spark Piugs Fuel Filter. Air Cleaner . Governor .- Engine Speed Adjustments - Idle Contro! Circuit Protection (Electric Start Models) High-Altitude Carburetor Modification. . ‘i Spark Arrestor . . SECTION 10 - GENERATOR TROUBLESHOOTING SECTION 11 - ENGINE TROUBLESHOOTING 16 15 16 16 16 16 "7 18 18"—=SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE == 1. INTRODUCTION Wo learn by experience Learning safety vwoudh personal Esperience, ikea chill touching a hot stave harm teabtful and unis. et doe maperinnce of others teach you Sale practices developed from expenence in the wie of weld {ng and cutting ae described i tis manual. Restores, dav fopmant, and held exponnce have evolved mshle agwprment {and sate sotalleton, operation, pd seeing practess Ace! tained. The reson forthe sale practacs may mot aways be tren, Some sre bated on common sense, overs oy recur {echnical volumes to explain” Its witor to fellow he rakes Read nd understand hese sate practces before attempting fo install, opernoy or sewvice the equipment. Comply wt these precadures ss appicabie to the peruculer equipment Used anc heir instvetion manus, Tor petsond stuty and forthe story of others Failure to observe thee safe practices may cause serious in jury. or death, Bon safety becomes a Mobi, the equipment an be used with confidonce Those sae practices are divided into two Sections: 1 Gunera Brecsvtion, common to a welding and cutting: 2nd 2M are Welding tard Cutuna}tonvh Reference standards: Published Standards on efety ae aso Salle for adaitonal and more complete procedures than {hoes piven in thie manual. They are etd in te Standard Inge n this manual ANSI 249," the most complet The Notional Electrical Code, Occupmtional Safety and Haalon Agministration, loca industria! codes, and local in ection requirements also provide a base for quent in ftallation, use, and servic. GENERAL PRECAUTIONS Burn Prevention Worr protective clothing - leather (or sbestos) gauntlet Bova, hat high safety too these. Button shirt colar and Bestet taps: and war cuties trousers 10 gon! envy of pares and sag Wiegr elmer with safety gogges or lases with se shits Underneath, approprtate titer lenses Or plates protected by Clear cover laa). Ths sa MUST for welging oe euting. (ond Ehinpingh ta protect the eyes fom tadkant anergy and ying neta, Replace cover glee when broken, pied or spattered See aa Avoid oly oF greasy clothing. A spark may ignite them Hot metal such et electrode stubs and workpieces should fnover be anche without ves Modica fst ald and eye teatment, Fist id foci: and 9 uae fast ald person shauld be evalcbe for each shift Snes mecca Tailites ava close by fox immediate Wearment ‘of fat burns of the eyes ang skin Barns. Ear plugs should be worn when working on ovehead or in 8 contin space. A hard hat should br wom when Ofer Work cvorhoed Flammable hair preparations should not be used by persons inganding to weld or cut ‘Toxic Fume Prevention Audaquate ves tiation, Severe discomfort, illness or dest ean foauit ter fumes, vapors, heat, oF oxygen ennchment oF Geplevon that welding (or cutting) may preiuce. Provent them with cdecuate ventilation ae described! in ANS Stan. Gdnrd 24911 lefad 1 in Standarct index. NEVER. venote with oxyoen Lead, exdmiurn «tine », moreury ~ and berytium - bearing and sinitar materials, when welded (or eut) may produce harnful concentrations of tome fumes, Adeauate toca! {rel the operator must wosr an ir supplied rxpiator For beryiiom, oth must be ured Metals costed with or containing mater that emit toxic ‘Kanes should note heated unless coating i rernawed From the work waste, the gras wel wenttated, oF he NperavOF nd. nacetsary, waule wearing an mesupplieg respirator Gar leaks 9 » confined space should be avoided. Leaked gos Irvlarge avates can cng oxygen eoncentestion danger busiy: a not rng got cylinders nt » conned space Leaving contined spece, shut OFF gos supply at source to prevent possi accurnation of gases inthe space dows Sleam vaiver havy Deen accdentiy opened or sft open {Chock a be sure thatthe space Is sate elore reastring Vapors trom chlorinated solvents can be decomposed by the Ihest ot theme or farm) to form BHOSGENE, 9 Mah row 25, ond athe Tung and eye trating products The attr Moet Vacant] energy oF the are can aso compose Chioroethyene ond perchlorosthytene vapors 10 form phos frne. DG NOT WELD or cot where saben vapors ca be ran into the weiding or cuting atmosphere or whee the ‘minute emcanis of wielorosinylone 9 parcloroctnvene Fire and Explosion Prevention Cause offre and explesion re: combuetibius reaches by the Su tinma, fying spar, Hot sg heat ate rive BE AWARE THAT tivng sparks or falag ay can sss through wall oF tloor openings, out of sight of the goggled ‘persion: Spark an tg ea ty 35 feat Topmvent tives and explosion Keep equioment clear and operable, fee of ol, ores, and {in slecteal pars} of metal particles that can couse thort Uf combustibles ae in ares, do NOT weld or eut. Move the Work Hf pritiessie, toon ares fay of cammbustbles. Av Sway out of reach of sparks and heat, oF protect against, ignition with aultable and snp ting, fveresstant covers oF sl Walls touching combustibles on apposite sides should not be welded on (or cul. Malls, clliogs ged floor near work outa be protected by heat isistant covers oe Set Fire watcher mutt be standiag by with tuteble fre ex Linguishing equipment during ane for some time afer wale Ingoreuttog tt 2, apptecisbie combustibles (including building construc lon) ave within 35 fot Sopreciblo combustibles are further than 36 fet but ean . epenings(eoncnsed or visible) inflate or was withing ‘eet may expose combustibles ta sparks 4, combustibles adja to wis, clliys, r008, or metal Dartiion ean Be ignited by radiant or condusted heat. Hot work permit should be dbtained bere operation to eaure supiwinor® approval that wlecuate precautions have boon token, After work is done, check that wows fre of spars, slowing ‘An empty container that hald combustibes, or that can pro- Ge lamb or tox vapors when heated, mutt never be ‘welded on oF ut unless container hat fist baon cleaned 3 Asteribod In AWS Stendoré ABO, listed 3 in Standard nde OM-410 Pege tPage? Includes: a thorouah steom or caustic eeaning lor a ee mating, dpendiog ‘on the combustibles Echaolity) followed by purging and ineting with nivoge oF Chibon dioxide, and wang proteetiae equipment 3 reeon ngeied in 6.0. Watering just Below working fevel may obstitue Torimerting ‘A eantainer with unkown contens should be cleaned (seo ‘perageah sbove). Do NOT depend ansense at smetl or ih Nouttonmine iis ante towed or cut otto cattingt ar containess must be vented before welding forcutting Thay esh explode Explosive atmospheres. Never weld or cut where the ar may ‘conto flammable doit 9, Or hid vapors Touch 35 390- lin! Compressed Gas Equipment Standard preceutions, Comply. with precautions manual, ard tho Setaled i CGA Standard Pol, PRECAU: TIONS FOR SAFE HANDLING OF COMPRESSED GASFS IN'CYLINDERS, ist 8 io Standares index 1 Pressure Reyulators Regulator ie! valve ie dasionad toproitet only the regalo: oe'tecm. erpressum: It ie not intended 9 pratect ONY ‘downstream suuipmant, Provide ruck protection wth ond OF ‘row ret devices Never connect a regulator t0 2 cylinder containing gas ther than ther for whieh the woglator nas desianed Remove faulty regulator fram service immediate for repaie {fr close cylinder vaio) The folwng Symptons ndieate 3 tauty regulator Lee if gatas exteraty Exeotva Crenp if delivery prssue continues (0 ise with ‘onrateam valve close Faulty Gauge ghuge pointer dors not mave off step pin trinesprensuized, nar feurne to slop pin afer presure Repdin, Be NOT atomot pn Sd fly repltotfor Fepoir to. menulacturer®, designated vepait center, where ‘Speoieltaciiques and tools ae ued by Uisnad personnel 2, Cylinder. Gylinders must be handled carefully to prevent laks ond ‘damage father wail, vals, este devices: ‘Avoid electrical sieuit eoatact with eyes including third Fails, electiesl yates, oF welding elcults. They cen produce ‘hott cieeut arer that may toad to 0 Serious accident, (S00 V5cu) IoC oF DOT marking must be on each evlindsr. It an “surance of safety auhen tho cylinder is property handle Identifying is content. Use only eylindes with name of gas Tats fonty supplir if unmarked. NEVER DEFACE orate ame, numer or other markiogs on # eyliader Tt Moga dd haze Emptis: Keep values cloud, mptace caps securely:mark MT: faep them separate from FULLS and return prompay Prohibited use, Nover use eylineer or its content for other ‘han is Inndad use, NEVER ae a support or rls Locste or seeure cylinders s0 they cannot be knocked over. Pasiagewsys ond work aras. Koop cylinders clear of areas ‘hore they may be stuck Traiporting cylinder. With a crane, use 9 s9eue support ch platen or eraie. Do NOT It eylinder of he round by’ thar valor or cap, or by chain, sings, Or mage Do NOT expare cylinder to excessive heat, seeks, sap, and flame, ete. {uot may couse rupture. Do not alow contents 10 ‘exceed 130°F- Cool with water spray where Such exposure Protier cylinders valves tom bumps, falls, ting fjece, nd weather Replace caps secuvely when mowing, Stuck vave Do NOT use 4 hamier oF wrench to ope & Syliner value that can nor bv openly hand. Nowy your Stpsher Mixing gues. Never iy 19. any gas ina eylinde Never weil any evi Cylinder fitting shoud never be meshlied oF exchanged. 2. Howe Promnites ute, Nevur use hosa ores than that designed for the apeeiind gan A genoya! era ensiieaton rule red for aig, green for oxygen, ane tock for ert pass wre ‘or othersubet tia. ps designed for the hose (net ordinary eh os 9 inden 10 Connect hot 10 No copper tubing slices, Use only stand bras fags to spice hose ‘Avoid long run fo prevont kinks and sbuse. Suspend hose off ‘round to kaep it trem being us ove, Seppe on, oF oer tse damage Co excess howe to prevent kinks and tang. Protect hose from damoa® by sharp eds and by sparks Sag, and open lame Examine hora regularly for leaks, wear, and looue connec hone Immerse presured hose sa waters bubbles tndheate Teak Repair Inky or worn howe by cutting 16a out ove slicing (7209), Be NOT use ape 4, Proper Cononetions Clean cinder valve outlet of imousitis that may cloa ‘nice and damage sees belore connecting roglatarExctpt forhydrosen, cack vale mementeiy, prmung Gute omy from people and sources of ignition. Wipe with a clean Ii Insreiots. Match regulator to cylinder: etre connecting. check to the regulator Tabs! and eylinder marking age, al that the fagulator inlet_and cylinder outlat match. NEVER CON ECT" regulator designed fora partealor gus OF gues tO 8 Cylinder containing say other ge Tighten conretons When sanding sete connacins. Jing coat ene where eee gh. conn ‘tm iat umame, lon, and regen nn) reper tng nen ‘Adapter. Usn a CGA adapter (available fram your supolice) ‘betweon cylinder and regulator, it one krawutved. Use wo forenches. to tghen sdaptar marked RIGHT and LEFT AND them. Regulator outlet (or Noss) connections may be idenitied by ight hand threads tor axygon and lott hand threads ath grooved hex on nut or sank) for fas gs 5. Pressurizing Steps: Dain regulstar of eesidual gas theouph suitsbie vent before ‘pening eyinder (or-manifetd valve) by turning adjusting drew i (clockaise) Orsining prvonts excessive compresion bea at high pressure seat by allowing seat to open on presur- Teaton, Loove adjusting serew engaged sghty on single stage regulators. Stand to se of regulator while opening cylinder valve ‘Open cylinder valve slowly so that rgulator pressure in- creases slowly, When gouges rewsurized (gauge reathes regu or maximim) teae cylinder valve in fellewing position: ‘or oxygen, and inert gases, pen fully to 29) stm gain Dpowibie Teak. For fuel ge open to less than one’ wen to perme quick emergency shutot13, Use pressure charts available from your supple) lor safe and eficlnt, recommended pressure satings on regulator Check tor aks on fst pressurization ond regulay there Bfter Brush with som sclution (eapfu of Ivory Liquid or {equivalent per gallon of water) Gunbles indicate leak. Clean fff soapy war efter est dried sogp is combustible, User Responsibi Remove teaky oF detsetivn exipmant trom service immed: Iotely for repair See User Respansbiity statement Sap ment man Leaving Equipment Unattended Close ga supply atscurew and drain ou. Rope Staging Support ope steningsupport should not be used for welding or eut- ting operation: rope may Burm ARC WELDING Comply with prosoutions in 1-1, 1:2, ane this section, Are Woalding, propery done, i sate Groce, but a eaeless oper tor invites trouble, Tha equipment carries high currents at gaint voltage. The ares very beight and hot, Sperks fy, {mas rise, ultraviolet and infcared energy vadiotes, wel rants are hat, and compresses gases may De used The vise Operator avoids unnecessary sks and protecte Mvset and ‘thers trom seeisent. Pracuuions ave deseibed here ac it Stndarde rferencad i index Burn Protection “The welding ate intense ond visibly bight. tradition can damage eyes, penetrate ligutweight clothing reflect trem lightesioredsurfecs, snd burn the skin angeyes, kon buras resamblo. acute sunburn, ose. fron ga ahllded ae. ore ‘mom severe and painful’ DON'T GET BURNED; COMPLY With PRECAUTIONS, 1. Protective Clothing Wear longsleave clothing iarticuarly for qa-shielded arc) in tition fo goves, Rat and shoes (ZAI Ac necessary, Use Sciationd protective ioting such leaterlacket or Meeves; Rameproot apron, and fvereisant legging AVG utergumen of ancwated cotton. ‘ Bere skin protection, Wear dat, substantia clothing. Button collar to protect chest and neck and burton pockets to pie. ‘ene entry of spa 2. Eye and Head Protection Protect eyes trom exposure to are. NEVER look at on eee fe ae without protection Wilding helmet oF shisié containing » ft pate shade no. 12 or denser must be Used when welding, Ploce over Tacs betove stiking oe Protect filter plate with sclear eover pte. Cracked or broken helmet or shitid should NOT be wom; fadttion com poss through to cause busts Cracked, broken, o Loose Hlter plates must be replaced I MEDIATELY: Raplace clear conor plate whon broken, pitted, Flash goggles ith side shields MUST be worn under the himat ta gw some protection tothe ayer should the helt hot be lowered over the fate before an se src, Looking tran ne momentarily vith unprotected syer (particuley 8 igh intenaity gavshietded ae] com cause retin buen Wat may lowe apatmanont dk pres inthe Held of vision. 2. Prowetion of Nenty Personne Enclosed welding area. For production welding, a separate Four of anclosed buy i bast. In epen ares, seround Me “Trademark of Proctor & Gambia, operation with lowvetective, noncombustibie screens. or nels Allow for fee sit ciculation, particulary at floor teva Viewing the weld, Provide face shilds forall presons who vrilbe foking ivetty atthe weld Other working in area. See th sit persons se we Before starting to weld, make sure that screen flaps or bay ‘door oe lod Toxle Fume Prevention ‘Comply with precautions in 1-28, Fire and Explosion Prevention Comply with preutions in 1-26, Equipments sated capscity. Do aot verioad a wilcing ‘nupmont it may overheat cables and cous fre LLoote cable connections may overheat or fash and couse a fi Never strike an re on a eylindue or other prostuee vote. It frente abil area that can couse #vicont rapt or lead {ewuch s niptore eter uncles rough nendlng Compressed Gas Equipment ‘Comply with precautions ia 1-20. ‘Shock Prevention Exposed hot conductors or other bare met in the welding ‘reuit, or in ungrounded, lectlealy-HOT equipment can fatally shock e person whose body beceres eeordurtar DO NOT'sTANO, S17, LIE, LEAN ON, OR TOUCH a wet sur: "ace when noting, Witney stable rotwcton “To protec painst shock: Keep body and clothing dry. Nover workin damp area with- fut adeguste insulation epinstslectical shock. Stay on 9 “iy duekboord, or ruber mat wen dampness or sweat can ‘hot be acided, Sent, sea water, or morte between Day land on slectneally HOT part= or grounded sats reduces the body surface wletrica velsance, enabling dongerous ona possibly lea currants to lay through the Boy, 1. Grouncing the Equipment When installing, connect the tramet of each unit such ot Uelaing power fource, contro}, work table, and water circus: tor to the sutding ground, Conductors must be sdeqst 10 Camry ground currants sat. Equigmant made slectricaly HOT by stay current may shook, possibly Tatly Da NOT GROUND to dlectical conduit, or t0 9 pipe carrying ANY 86 oF a flammeble liquid such a ll orf Thronphas conneetion. Check pte requirement of oq iment before installing If only phase power is swale, Gornect sngo-nese equipment to only two wines of the Sophase lim. Do NOT connact the equipment ground eed ihe third vel wie, or the aguipment will become elect tally HOT" 8 dangérous cond von tat cen sock, pombly ‘ora Before welding, check ground tor continuity. Be sure conde fors ate faiching Bae metal at equipment frames nt cane 1a ina cord with a graund lead is provided with the equine ‘ment for conection to asultshbox, connect the ground oad to the grounded switchboe Ha thiceprong plug aioed for oangetion to 3 grounded mating Yecoptorl, Ine ground ead must be ccnnected tothe ground prong only. 1s ine cord oes wil tree;rong plug, connact to 8 grounded mating fecaptacle. Naver romove the ground prong fom Blut, Use plug witha broken off ground prong OM-410 Peges2, Electrode Holders Folly insulated slctrade holders should be used. Do NOT tse Holders with protnading seer 3. Connectors Fully ineulated loek-tyoe connector should be uted to jain Welding eable lengths. 4 Cables Erequantly_ingpect cables for wert, cracks and damage IMMEDIATELY REPLACE those wiih excessively worn oF damaged inition 16 ovoid possibly - tahal shock trom bared enble, Cables with damaged arcas may be taped to give rorntance equivalent to origina cable Keep cable dry, fte0 of il and grease, end protected from hot metal en barks 5, Terminal And Other Expoted Ports Terminals and other exposed parts of alectical units should ‘Rae insulating covers secured eto 6, Electrode Wire Electrode wire becomes elscrically HOT when the power ‘ste of gas metahare welding uquipment ON end welding fun tigger is pressed. Keep hands and bady clear of wie and ‘Sher HOT parts 7, Safety Devices Safety devices such as interlocks end circuit breaker should not be dizconnecte or shunted out Before installation, inspection, or service, of equipment, shut OFF all powor ond remove line rer (or lock oF edt Sutehet) to prevent acedantalturaing ON of power, Oacon act a cables from welding power soutee, ond pull a 15 ‘ols tne-cord plage. 14, Do not open power circuit or change polarity while welling. Honan emergency. it must be Sisconnecte, guard spainet shiek burns oF ah team suite org, Loving eauipiment unattended. Always shut OFF and si Connect al power to aquipment Power chiconnect switeh mutt be avaiable near the weicing STANDARDS BOOKLET INDEX For more information, refer to the following standards or ‘hole Tatrtrvisone and comply we appbesbe 1. ANS! Standerd 249.1, SAFETY. IN WELDING AND CUTTING obtaincbie trom. the American Welding Sociew, 2501 NW 71h St, Miami Fa, 33125. 2. ANSI Standard 287.1, SAFE PRACTICE FOR OCCUPA. ‘TION AND EOUCATIONAL EVE AND FACE PROTEC TION, obtainable trom American Netonal Standards Insite, 1490 Browday, New York, NY. 10016. 3. Arorican Welding Society Standard A6.0. WELDING ANI “CUTTING CONTAINERS WHICH HAVE HELD COMAUSTIBLES, obtainable some a tem 1 4. NEPA Standiea 51, OXYGEN FUEL GAS SYSTEMS FOR WELDING ANNO. CUTTING, obtainable trom the National Fire Provetion Artclation, #70. Atantle ‘Avenue, Boston, Mas 02210, 5. NEPA Standard 518, CUTTING AND WELDING PRO- (CESSES, beinabie sna ae item 4 6. CGA Pomphiet P-1. SAFE HANDLING OF COW. PRESSED GASES IN CYLINDERS, cbiainsble from the Compressed” Ger Association, 600" Fifth “Avenuo, New Yor, Nv. 10038 7. OSHA Standora 29 OFA, Part 1810, Subpart Q, WELD: ING, CUTTING AND BRAZING. 8. Gade for So wane ty in Welding and Cutting, OSA StandaraSECTION 2- INTRODUCTION =——esemmrssscsmecesn Wang Gove Rano 7 ramoess_| Areas — ‘Output 100% | Welding in Ampores, Circuit Dimensions {Pounds} zo | ate | iio | Seth | Ye] sive tao wun Namcng conan] he Be | as ata Snoe evo a3 44a, 115/230 volts, 36/17 ompetes 80 He, ee feng phase on 80 He, Models Figure 2-1. Specifications 2-1. GENERAL - This manual has been prepared especially for use in familiarizing personnel with the dasign, installation, operation, maintenance, and troubleshooting of ‘this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment, 2-2, RECEIVING-HANDLING - Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may hhave ocourred 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 and freight bill wll be furnished by the carrier on request if occasion to file claim arises. When requesting information concerning this equip- ‘ment, it is essential that Model Description and Serial {or Style) Number of the equipment be supplied. 2.3, DESCRIPTION - ‘This unit is a gasoline engine: driven constant current ac arc welding generator. It is desinned to be used in conjunction with the Shielded Metal-Are Welding (SMAW) process. acne SECTION 3 ~ INSTALLATION ENGINE END _ ., 14.3/4" ell || 25/8 4 I 2" I Ltt “Moda wien cactie 18.78) aus nous tert Oy in ein In addition to welding capability, this unit is equipped to provide 1 kva of 115 volts (8.7 amperes) de electrical ower while welding and 5 kva of 120/240 volts (42/21 amperes) 60 Hz. ac electtical power when operating at power tpm. 2-4, SAFETY ~ Bofore the equipment is put into ‘operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The following definitions apply to CAUTION, IMPOR TANT, and NOTE blocks found throughout this ‘manual Under this heading, installation, ‘operating, and maintenance procedures or practices will be found that if not carefully followed may create @ hazard to personnel. Under this heading, installation, ‘operating, and maintenance procedures or practices will be found that if not carefully followed may result in damage to equipment. Under this heading, explanatory statements will be found that need special emphasis to obtain the ‘most efficient operation of the equipment. Figure 3-1. Dimensions And Base Mounting Hole Layout OM-410 PagesFigure 3-2. Allowable Tilt Angles 3. 1, LOCATION (Figure 3-1) - A proper installation site should be selected for the welding generator if the unit is to provide dependable service, and remain relatively maintenance free. This unit must be located on an ap- proximately level surface to ensure proper engine lubrication and gasoline engine carburetor operation. Figure 3-2 shows the maximum alfowable tilt for safe operation. Exceeding these limits can cause severe engine damage. Oil level in the crankcase must be checked when the unit is on a level surface. If this unit is to be operated indoors, it should be located in a place where the exhaust furres from the engine can be vented out of the building. Foilure to comply with proper venting may result in serious bodily injury or loss of lite. Wf this welding generator is to be ‘mounted on a trailer (optional), ensure that the engine end is mounted toward the front (hitch end) of the trailer to maintain proper weight distribution. Also en- sure that the tongue weight of the trailer is approx- imately 10% of the gross vehicle weight. It is recom- mended that a properly fitting canvas cover (optional) be placed over the welding generator when not in operation to protect the unit from the environment. The engine exhaust system on this welding generator has not been equipped with a spark arrestor unless it was specifically ordered as an optional accessory. A spark arrestor, maintained in effective working order, 's 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. ‘A proper installation site permits freedom of air move- ment into and out of the welding generator, and also least subjects the unit to dust, dirt, moisture, and cor- rosive vapors. A minimum of 18 inches of unrestricted space must be maintained between the welding ‘generator front and rear panels and the nearest obstruc- tion. Also, the underside of the welding generator must bbe kept completely free of obstructions. The installation site should also permit easy removal of the outer enclosure for maintenance functions. Poae6 Do not place any filtering device over the intake air passages of the welding generator as this would restrict the volume of intake air and thereby sub- ject the internal components to an overheating cond tion and subsequent failure, Warranty is void if any type of filtering device is used. Holes aro provided in the base for mounting purposes. Figure 3-1 gives overall dimensions and the base ‘mounting hole layout. On all welding generators a lifting device is provided for moving the unit. However, if a fork lift vehicte is used for lifting the unit, be sure that the lift forks are long ‘enough to extend completely under base. The use of lift forks too short to ex- tend out of the opposite side of the base will expose i- ternal components to damage should the tips of the lift forks penetrate the bottom of the unit 3-2, EQUIPMENT GROUNDING (Figure 3-3) ~ Normally engine-driven welding generators do hot require grounding. However, this machine has aux- iliary power plant capability; therefore, grounding of the frame and case is recommended, Also, unusual cir- cumstances may require machine grounding. For these reasons a convenient grounding terminal is provided on all weld /powor units. For detailed grounding instructions consult your local or stato codes or the latest issue of the National Electrical Code. if additional information regarding your particular operating circumstances and/or grounding re quirements is needed, consult a qualified electrician or your dealer. After determining the extent to which any grounding requirements apply to your particular situa- tion, follow them explicitly Equipment Grounding "Terminal Figure 3-3. Equipment Grounding Termipal 3-3. WELD OUTPUT CONNECTIONS (Figure 5-1) ~ To obtain the full rated output from this unit, itis 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. The weld output receptacles are elec- trically energized when the engine i running. Ensure that the unit is completely shut down before making weld output connections. Disconnect the welding cables when not welding and do not touch the output receptacles when the engine is running.A. Location ‘The ELECTRODE and WORK AC WELD output recep- tacles are located on the center portion of the front panel. B. Welding Cables If welding cables were not ordered with this unit, the stops listed should be followed to ensure the best welding performance: 1. It is recommended that the welding cables be kept as short as possible, be placed close together, and be of adequate current carrying capacity, The resistance of the welding cables ‘and connections causes a voltage drop which is ‘added to the voltage of the are, Excessive cable rosistance may resutt in overloading os well a3 reducing the maximum current output capability Of this unit. Proper operation is to a great extent dependent on the use of welding cablos and con- nections that are in good condition and of ade- quate size. An insulated electrode holder must bbe used to ensure the operator's safety. 2. Use Table 3-1 as 2 quide for selecting correct cable size for the anticipated maximum weld cur- rent which will be used. Table 3-1 shows total cable length, which includes the electrode and work cable,’ Example: If the electrode holder cable is 75 feat long and the work cable is 25 feet long, select the size cable that is recommended for 100 feet at the maximum weld current that is to be used. 3. Do not use damaged or frayed cables. 4, Follow the electrode holder manufacturer's in- structions for installing the electrode holder onto the wold cable. 5. Use correct lugs on the weld cable to connect the work clamp. 6. Ensure that all connections are clean and tight. Tabio 3-1. Welding Cable Size Frecona [ TOTAU LENGTH OF GABLE GOTPERT WELD RGU fauenesl 60 [100 [iso | 200 | mo] 300 f a80-[ aoo NOTE. ‘A. SO FECT OR LESS. 002 700-8 ee eee in a erates Seater eee C. Jack Plug Installation The supplied red jack plugs are to be connected to the ‘weld cables in order to facilitate connection to the weld output receptactes. Connect the red jack plugs to the ‘wold cables as follows: Remove 3/4 inch of insulation from one end of each welding cable. 2. Clamp the welding cable in a vice with the unin- sulated end protruding upward out of the vise approxmately 1-3/4 inches. 3. Place the steo! tie wire (see item A Figure 3-4) approxmately 1/4 inch from the end of the in- ssulation. 4, Make a half tum around the cable bringing the looped ends of the tie wire together. 5. Insert a rod of approximately 3/8 inch diameter through the two looped ends of the tie wire. 6. Twist the tie wire (B} until the entire tie wire is twisted and is tight around the insulation of the welding cable. 7. Clip off the looped ends of the tie wire, 8, Bend the twisted tie wire over and along the side (C) of the uninsulated portion of the welding cable. 9. Wrap the strip of copper foil tightly around the ‘uningulated end of the welding cable and twisted tie wire (D). OO) ——— Jack Plug Installation 10. Place the jack plug on the end of the welding cable and push in onto the welding cable over the copper foil (D). 111. Insert the 1/4-20 set screws into the center and bottom holes in the jack plug and tighten (E}, 12. Remove the welding cables from the vise and in- sert the jack plug into the insulating sleeve. Slide the insulating sleeve over the jack plug and welding cable until the hole in the insulating sleeve lines up with the remaining hole in the jack plug. OM-410 Poge713, Insert the 8-32 self tapping screw (F) through the hole in the insulating sleeve into the jack plug. Tighten the screw with a screw driver. 14. Connect the weld cables to the appropriate wold output receptacles. 15. Ensure that all connections are clean and tight. —es SECTION 4~ ENGINE PREPARATION seemmmmnensc ‘See the Engine Manufacturer's manual for complete engine care. 4-1. LUBRICATION (Figure 4-1) - This engine was shipped from the factory with the crankcase filled with the correct amount and type of break-in oil unless other- wise ordered. Check the oil level before attempting to operate the engine, It should be up to the full mark on the dipstick. Add a quality brand of detergent oil if the «il level is low. See the oil selection chart (Table 9-1) in Section 9. New engines have very close clearance between the moving parts. Thus, itis recom mended that loading of the engine be kept to @ ‘minimum during the first 10 hours of operation. Be sure to check the oil level several times each day during the engine break-in period. This engine requires ebout 50 hours of running time before becoming fully broken in, andl Figure 4-1. Oil Level indicator (Manual Start Models Illustrated) ‘After about 100 hours of running time, drain the break- in ol. See tho oil selection chart (Table 9-1) in Section 9 for correct oil type and grade to use after the break-in oil is drained. 4-2. FUEL (Figure 42) Never attempt to fil the fuel tank with the engine running. Do not fil the fuel tank completely as cold fuel will expand when exposed to outside temperature in a warm climate or to engine heat. If the tank is too ful, it will overflow causing @ potential fre hazard. Never allow fuel to drain on the engine or other ‘components. Do not mix oil with the gasoline. Use @ good grade of “regular”, “low lead”, or “no lead” ‘gasoline of at least 85 octane for this engine. The “low lead” or “no lead’ fuels lower the pollution factor and reduce combustion chamber deposits if used exclusive- y. Fuels of lower octane rating may cause detonation (knocking) which could result in damage to the engine. if unable to obtain fuel of suitable octane rating, consult the Engine Manufacturer's Service Facilty for suitable ‘ongine modifications. Pages ‘The fuel capacity of the fuel tank is 3.6 gallons (U.S. Measure). To reduce potential fire hazards, inspect for fuel and/or leeks prior to putting the unit into ser- vice. Continue to check for leeks during the break-in period and periodically thereafter. Oil seepage may exist at the main bearing seals beyond the normel breek-in period. had Pas Figure 4-2, Fuel Consumption Chart Figure 4-2 illustrates typical fuel consumption under specific toad 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. 4-3. PREPARING NEW BATTERY FOR SERVICE (Electric Start Models Only) CUSENE “ever attempt to operate the engine without the battery connected. Do not attempt to remove the battery while the engine is running. A. Wet Charged Battery (HELE Connect the negative battery cable to the negative (-Iterminal on the battery. This i all that is re- (quired to put the battery into service providing ithas not discharged during transportation and warehousing. If the battery has enough power to start the engine,-t will charge up while the engine is running. Tho wot charged battery is shipped with the electrolyte solution added and normally in an operational status. However, due to long periods of idleness, the battery ‘may become weak and thus require charging. The bat- tery should have @ specific gravity reading of 1.260 (at 80°F) when fully charged. If the battery requires charg- ing, see Section 4-3B, Step 4. B. Dry Charged Battery This battery is shipped in a dry state, To prepare thenew battery for operation, it will be necessary to obtain electrolyte and proceed as follows: TMI Pur on protective eye cover and clothing prior to pouring the electrolyte solution. 1. Remove the battery from the unit and place it on a level worktable or other suitable area. 2. Fill the battery cells to the required level with electrolyte. 3. Place a battory thermometer in one of the center cells and check the specific gravity of each cell with a battery hydrometer. 4, “Thebattery should have a specific gravity of 1.260 (at 80°F) prior to installation. If this condi tion is not met, charge the battery as follows: Ensure that the battery caps are removed before charging. Failure to do so may cause the battery to explode should overcharging occur. ‘a. Use an automotive type battery charger This battery should be charged at about a 3.5 ampere rate until correct electrolyte con- ditione are met. Lower charging rates can be used; however, the time to obtain the cor- rect electrolyte conditions will be longer. b. When tho battery is charged, disconnect it from the charger and recheck the electrolyte level. Add if necessary. Install the battery caps. 5. Rinse the empty electrolyte containers with water before discarding. Since battery acid is corrosive to metals, do not pour into a metal sink ‘or drain, Rinse and muttilate the empty oloc- trolyte container before discarding. If acid has accidentally spilled on the battery or work area during filing or charging, flush off with clear water and neutralize with soda or ammonia solu- tion. Use the same procedure if acid is spilled on clothing. 6. Reinstall the battery in the unit ensuring that the negative (-) battery cable is connected to the negative (-) battery termina. 4-4. AIR CLEANER - This engine is equipped with e replaceable dry element type air cleaner. The air cleaner requires no initial service. memes SECTION 6 - FUNCTION OF GENERATOR CONTROLS — Range ___ Switch Electrode Output “enaut'_L&) YG) Choke J) Qt san Gl 116 Volts DC. ‘Electric Start Models Only ‘Roplaced By Throttle Control On Manusl Start Models 5-1. RANGE SWITCH (Figure 5-1) - The Range switch provides seven coarse amperage ranges. The range of each switch position is displayed on the scale surrounding the Range switch handle. Do not change the position of the Range switch while welding or under load, as this ‘causes arcing across the contacts of the switch, This arcing causes the contacts to become pitted and even- tually inoperative. 5-2. FINE AMPERAGE CONTROL (Figure 6-1)- Tho FINE AMPERAGE control permits the ‘operator to select a welding current between the ‘Wold/ Power ‘Switch Figure 5-1, Control Panet View For Electric Start Models Receptacle 120 Volts AC Duplex. Receptacle minimum and maximum values of the coarse range selacted by the Range switch. The scale surrounding the control is calibrated from 0-100 percent in in- crements of five. The scale represents a percentage of the coarse range selected, not an actual amperage value, When the welding generator is used to produce aux- iiary power, the FINE AMPERAGE control must be set to 100. The FINE AMPERAGE control may be ad- justed while welding. OM-410 Pages,5-3. 115 VOLTS DC RECEPTACLE (Figure 5-1) - A two-pole, three-wire receptacle, labeled 115, VOLTS DC, is provided as a junction point for connac- ting accessory equipment which requires 115 volts de electrical power. The rated output of the 115 VOLTS. DC receptacle is 1 kva. The engine must be operating at weld rpm whenever the 115 VOLTS DC receptacle is. used. Ensure that the AUTOMATIC IDLE control switch (Electric Start Models Oniy) isin the OFF position when utilizing the 115 VOLTS DC receptacle. 5-4. 120 VOLTS AC DUPLEX RECEPTACLE (Figure 5-1) (For Optional 240 Volts AC Receptacio See Section 5-9) The auxiliary power capability of this welding generator is primarily intended for use with por- table cord-connected accessory equipment (lights, diils, grinders, etc.). Do not connect this unit to any service box, switchboard, panelboard, or other equip- ‘ment normally supplied by other electrical power unfess ‘a-proper transfer switch and grounding procedure is employed (see Section 3-2 for unit grounding informe: tion). ALWAYS consult the local electric utility, local and state codes, and the latest issue of the National Electrical Code for proper installation procedures. Since hazardous voltages are present, itis recommended that the installation be made by a licensed electrician to avoid injury or damage caused by improper or faulty in- stalfation. Up to 5 kva of 120 volts ac, 42 amperes, 60 Hz. power {available at this duplex receptacle: however, the power supplied is dependent on the amount of power boing used from the 120/240 Volts AC terminal strip. In all cases, total ac auxiliary power output cannot exceed unit rating (6 kva). Whenever this receptacle is used, the engine must be operating at power rpm and the WELD/POWER switch must be in the POWER position. (WEEE The automatic idle device (Electric Start ‘Models only) is inoperative when the WELD/POWER ‘switch is in the POWER position. 5-5. WELD/POWER SWITCH (Figure 5-1)- A two-position switch, labeled WELD/POWER, is provid- ‘ed for selecting weld current output or power plant out- put. In order for the welding generator to operate, the WELD/POWER Switch must be in the WELD position when the engine is operating at weld mpm and in the POWER position when the engine is operating at power rpm. If itis desired to change from weid operation to power plant operation or vice versa, observe the follow- ing procedures: ENON Ensure that the engine is shut down before making connections to the weld/power generator for either welding or power applications. MELEE On Manual Start Models the position of the WELD/POWER switch and the THROTTLE con- trol must correspond to obtein proper engine speed and generator output: The THROTTLE control must be pulled out to the WELD position when the Page 10 WELD/POWER switch is in the WELD position and pushed into the POWER position when the WELD/POWER switch is in the POWER position. If the WELD/POWER switch is in the POWER position and the THROTTLE contro! is pulled out the engine will not start. Ifthe engine is running at weld speed (THROTTLE pulled out) and the WELD/POWER switch is placed in the POWER position, the engine wil shut down. ‘A. Changing From Power Plant Operation to Weld Operation 1. Tum off or disconnect all equipment connected to the welding generator. 2. Place the WELD/POWER switch in the WELD position, 3. On Electric Start Models: Place the AUTOMATIC IDLE control switch in the desired position. On Manual Start Models: Pull the THROTTLE control fully out and fock. 4, Make connections to the wold output recep tacles, The weld output receptactes are olac- tically energized when the engine is running. Discon- rect the welding cables when not welding and do not touch the cutput receptacles when the engine is run- ning. B. Changing From Weld Operation to Power Plant Operation When changing from weld operation to power plant operation high voltage may momentarily be resent. Allow engine speed to drop to power mm before operating auxiliary power equipment. 1. Break the are and disconnect the welding cables from the welding generator, 2. On Electric Start Models: Place the AUTOMATIC IDLE contro! switch in the ON position, ‘On Manual Start Models: Push the THROTTLE ‘control fully in and lock. 3. Place the WELD/POWER switch in the POWER positon. 4, Set the FINE AMPERAGE control at the 100 position. &. Make connections to the 120 VOLTS AC duplex, receptacle and/or 120/240 Volts AC torminal strip (or optional 240 VOLTS AC receptacia), 6. Do not turn on the equipment which is con- ected to the power plant until the engine has ‘come up to proper speed.5-6. 120/240 VOLTS AC TERMINAL STRIP (Figure 5-2) KAMUGLIUE The ouxiliory power capability of this welding generator is primarily intended for use with por- table cord-connected accessory equipment lights, drils, grinders, etc.). Do not connect this unit to any service box, switchboard, panelboard, or other equip- ‘ment normally supplied by other electrical power unless a proper transfer switch and grounding procedure is employed (see Saction 3-2 for unit grounding informa- tion). ALWAYS consult the local electric utility, local and state codes, and the latest issue of the National Electrical Code for proper instalation procedures, Since ‘hazardous voltages are present, itis recommended that the installation be made by 2 licensed electrician to avoid injury or damage caused by improper or faulty i stallaton. Ensure that the engine is completely shut down before attempting any connections or examina- tion of components on or near the 120/240 Volts AC terminal stip. EWR Before proceeding with this connec- ion familiarize yourself with the circuit diagram provid- ed in the Troubleshooting Section of this manual. GLE 40 directions, such as loft or right, are with respect to the operator facing the welding gonerator front panel, Retain all hardware removed during this procedure for reinstallation. This welding generator is equipped with a four-pole ter- minal strip 17 located behind the right side panel. The terminal strip serves as a connection point whan aux- iiary power is needed. Because this unit has power plant capability, grounding of the generator frame and ‘case may be required. See Section 3-2 for specific infor- ‘mation on grounding this unit. If there are any questions regarding proper connection to terminal strip 1T and/or correct circuit grounding procedures, consult a qualified electrician. To make connection from an external load to terminal strip 17 proceed as follows 1, Shut down the welding genorator. 2. Remove the right side panel. 3, Insert leads through the strain relief provided on ‘the generator rear panel, Route the leads over to terminal strip 1T (soe Figure 5-2). REALE This unit is shioped with the jumper links on terminal strip 1T positioned for 120 volts (see Figure 5:3), (If the unit is equipped with an optional 240 volts ac receptacle, the jumper links wil be positioned for 240 volts). A total of 5 kva of 60 Hertz auxiliary power (4 kva if the unit is a 60 Hertz Model) is available from this unit. When the unit is inked for 120 volts, fullkva is available at either half of the 120 volts ac duplex receptacle or from terminal strip 1T. Wf the unit is hnked for 240 volts, 1/2 of the total kva of the unit is available at either half of the 120 volts duplex receptacle or full kva can be obtained at the terminal strip. In all ceses, when power is supplied to the duplex receptacle and/or the terminal strip, total ac auxiliary ‘power cannot exceed unit rating. When making lead connections to terminal strip 1 use ring terminals to onsure that proper connections are made, 120/240 Volts AC~ ‘Torminal Strip 120/240 Volts ac Cabt Inout Hole And ‘Strain Rob Figure 5-2. Location Of 120/240 Volts Terminal Strip bo) OO) Lead No. 66 oO gs Ouse Lead No. 58 Oe Q Of lo 0) Figure 5-3. Jumper Link Arrangement For 120 And 240 Volts AC 4, For 120 volts ac auxiliary power: ‘A. Connect one lead to terminal A or B on ter- minal strip 1. B. Connect remaining lead to terminal C or D on terminal strip 1. , Ensure that the jumper links on terminal btrip 17 are positioned for 120 volts ac (see Figure 6-3). D. If the circuit must be grounded, connect a ground lead to the welding generator case using the cap screw on the generator endbell located above and behind the terminal strip. E. Tighten strain reliof on generator rear panel, F, Install right side panel and resume operation, For 240 volts ac auxiliary powor: (OM-610 Page 11‘A, Romove and rétain the jumper links from ter- minal strip 17. B, Move lead No. 68 from terminal B to ter- minal D on thé same side of terminal strip 1. . Position the jumper links on 1T for 240 volts ac (see Figure 6-3). D. Connect line leads to terminals A and D on terminal strip 17. E. If the circuit must be grounded, connect a ground lead to the welding generator case using the cap screw on the generator endbell located above and behind the terminal strip. F. Tighten strain relief on generator rear panel. G. Install right side panel and resume operation. For 120/240 volts ac auxiliary power: ‘A. Remove and retain the jumper links from ter- minal strip 17, Move lead No. 68 from terminal B to ter- minal D on the samo side of terminal strip ks on 1T for 240 volte ac (soe Figure 5-3). D. Connect line leads to terminals A and D on terminal strip 1T. E. Connect neutral lead to terminal 8 on ter- minal strip 17. F. Ifthe power supply neutral must be ground- ed, connect 8 ground lead from terminal C on terminal strip 1T to the welding generator case using the cap screw on the generator endbell located above and behind the ter- rminal strip. G. If the circuit must be grouneded, connect a ground lead to the welding gonerator case Using the cap screw on the generator endbell located above and behind the terminal strip. H. Tighten strain relief on generator rear panel. |. Insta right side panel and resume operation. 5-7. DUTY CYCLE (Figure 5-4) - This welding generator is rated at 100 percent duty cycle. This means that the welding generator can be safely operated at rated load continuously. This unit, however, does not offer output in excess of its rating if the duty cycle is ‘tecreased. Pogo t2 in a i. Figure 5-4. Duty Cycle Char 5 - 8. VOLT-AMPERE CURVES (Figure 5-5) - Tho Volt-Ampere curves show the output voltage and cur- rent of the welding generator available at any point from the minimum to maximum of each coarse current range. Load voltage is predetermined to a large extent by the ‘arc characteristics. With the use of the Volt-Ampere ‘curves itis possible to determine what the weld current will be at a particular arc voltage. The Volt-Ampere curves show the minimum and maximum curves of ‘each coarse current range. 0 50 100 150 200 250 AC AMPERES Figure 6-5. Volt-Ampere Curves 5-9. 240 VOLTS AC OUPLEX RECEPTACLE (Figure 5-1) (Optional) The auxitary power capability of this welding generator is primarily intended for use with por- table cord-connected accessory equipment (lights, dil, grinders, etc.J. Do not connect this unit to any service box, switchboard, panelboard, or other equip- ‘ment normally supplied by other electrical power unless 2 proper trenster switch and grounding procedure is employed (see Section 3-2 for unit grounding informa- tion). ALWAYS consult the local electric utility, local and state codes, and the latest issue of the National Electrical Code for proper installation procedures. Since hazardous voltages are present, it is recommended that the installation be made by a licensed electrician to avoid injury or damage caused by improper or faulty in- stallation, 300 350 This welding generator is equipped with a voltage changeover terminal strip 1T and proper stator to pro- vvide reconnection capability for 240 volts ac. Althoughthe capability for either 120 or 240 volts ac is prosent, an optional kit must be purchased if 240 volts is desired at the front panel. (WEEE The FINE AMPERAGE contro! must be set at 100 when using the 240 VOLTS AC receptacie. Up to 5 kva of 240 volts (21 amperes) 60 Hz, ac power is available at this duplex receptacle. Whenever this receptacle is used, the engine must be operating at power rpm and the WELD/POWER switch must be in the POWER position. Ensure that the engine is completely shut down before attempting any connections or examina- tion of components on or near terminal strip 17. Before proceeding with this installa- on, familiarize yourself with the circuit diagram provid- ed in the Troubleshooting Section of this manual. LE 40 directions, such as left or right, are with respect 10 the operator facing the welding generator front panel. Retain all hardware removed during this procedure for reinstallation, 1. Shut down the wel the right side panel. generator and remove 2. Remove 120 VOLTS AC duplex receptacle RC2 located on the front panel. Remove leads and allow thom to hang free. 3. Connect leads No. 66 and 68 removed from RC2. to the 240 volts ac duplex receptacle (one on ‘each side of receptacle). 4. Install the 240 volts ac duplex receptacle in the front panel. 5. Affix supplied 240 VOLTS AC label over existing 120 VOLTS AC designation for duplex recep- tacle on nameplate, 6. Locate terminal strip 17 on the right side of the ‘generator (see Figure 6-3). Disconnect ‘wo leads No. 57 from terminal strip 1T. Tape up terminals on both leads No. 67 and tie leads into wiring harness. 7. Remove and retain the jumper links from ter- minal strip 1T. 8. Move lead No. 68 from terminal B to terminal D on the same side of terminal strip 1T. 9. Position the jumper links on 1T for 240 volts ac (see Figure 5-3). 10. Install right side panel and resume operation. —ememem SECTION 6 - FUNCTION OF ENGINE CONTROLS sameeren 6-1. CHOKE CONTROL (Figure 5-1) - A CHOKE contrat is provided for varying the fual-air mixture to the engine. When the CHOKE control is pulled fully out, very litte air will be admitted to the engine through the carburetor thereby supplying @ richer mixture of fu This position is required if the engine is cold when started, As the engine warms up it will be necessary to push the CHOKE control inward slowly until itis pushed in as far as it will go. When the CHOKE control is fully in, the engine should be ready for operation. 6 - 2. IGNITION SWITCH (Figure 5-1) A. Electric Start Models Placing the IGNITION switch in the ON position energizes the welding generator ignition circuitry and places the welding generator in a ready-to-start status. Placing the IGNITION switch in tho OFF position shuts ‘the welding generator down. (if lft in the ON position it will discharge the battery) B. Manual Start Models ‘Tho IGNITION switch is a spring-loaded toggle switch which normally remains in the ON position. Place the IGNITION switch in the OFF position and hold until the engine stops running to shut the engine down, 6-3. STARTER SWITCH (Electric Start Models Only) (Figure 6-1) - The Starter switch is a spring loaded toggle switch. Placing the switch in the START. position will engage the starter, The switch must be roleased as soon as the engine has started to prevent damage to the starter. 6-4. AUTOMATIC IDLE CONTROL SWITCH {Electric Start Models Only) (Figure 5-1} - The automatic idiing device saves fuel by allowing the engine to idle when the generator is not loaded. The AUTOMATIC IDLE control switch controls the opera- tion of the device. ‘A. On Position When the AUTOMATIC IDLE control switch is in the ON position the engine will remain at idle rpm (1900 + 100 for 60 Hz. Modols; 1700 x 100 for 50 Hz. Models) until an arcs struck. When an arc is struck, the engine speed will increase to weld rpm (3000). Approx- imately 10 seconds after the arc is broken, the engine will return to dle rpm, ‘The AUTOMATIC IDLE control ON position can be used for Shielded Metal-Arc Welding (SMAW). B. Off Posi When the AUTOMATIC IDLE contro! switch is in the OFF position engine speed remains at weld rpm when the generator is not loaded. OM-410 Page 136-6. THROTTLE CONTROL (Manual Start Models Only) ~ The speed of the engine is controlled by the THROTTLE control located on tho front panel. To obtain weld speed pull the THROTTLE control fully out to the WELD position and rotate clockwise to lock in place. To obtain power speed push the THROTTLE control fully in to the POWER position and lock. To unlock, rotate the THROTTLE control 90 degrees ‘counterciock\ The position of the WELD/POWER ‘Switch and the THROTTLE contro! must correspond to obtain proper engine speed and generator output: The THROTTLE contro! must be pulled out to the WELD position when the WELD/POWER switch is in the WELD position and pushed in to the POWER position when the WELD/ POWER switch isin the POWER post- tion. If the WELD/POWER switch is in the POWER position and the THROTTLE control is pulled out the engine will not start. If the engine is running at weld speed (THROTTLE pullod out) and the WELD/POWER switch is pliced in the POWER pasitian, the engine will shut down. 6-6. STOP SWITCH (Manual Start Models Only) - A Stop push button switch is provided on the engine blower housing for shutting the engine down, To stop the engine, depress the Stop switch and hold until the engine stops running. 6-7. HOUR METER (Optional On Electric Start Models Only) - This unit can be equipped with an hour moter. The meter, labeled TOTAL HOURS, registers the total hours of engine operation. This infor- ‘mation is useful for routine maintenance on the engine. qaoommmmeocenses SECTION 7 - SEQUENCE OF OPERATION 2sssiistammesmammmenaa Never under any circumstances, operate the weld/power generator with any portion of the outer enclosure open or removed. In addition to being a hazard to personnel, weather protection to the internal components of the unit willbe greatly reduced. Warran- 1y is void if the weld/power generator is operated with any portion of the outer enclosure open or removed. The weld output receptacles are elec- tncally energized when the engine is running. Discon nect the welding cables when not welding and do not touch the output receptacles when the engine is run- ning. Figure 7-1, AC Weld Connections 7-1. SHIELDED METAL-ARC WELDING (Figure 1. Prepare the engine for operation as instructed in Section 4. 2, Meke weld output connections as instructed in Section 3-3. 3. Place the Range switch in the desired position, 4, Rotate the FINE AMPERAGE control to the desired setting. 5. Place the WELD/POWER switch in the WELD Position. 6. Connect the work clamp to the object to be ‘welded. Place the desired electrode into the elec trode holder. Pege 4 7. Start the engine as instructed in Section 7-3. 8 On Electric Start Models: Place the AUTOMATIC IDLE control switch in the desired position, On Manual Start Models: Pull the THROTTLE control fully out and lock. Prior to welding, itis imperative that pro- er protective clothing (welding coat and gloves) and ‘eye protection (glasses and welding helmet) be put on. Failure to comply may result in serious and even perme nent body demage. 9. Commence welding. 7-2, POWER PLANT OPERATION 1. Propare the engine for operation as instructed in Section 4, 2. Make connections to the 120/240 Volts AC ter- minal strip and/or 120 VOLTS AC duplex recep- ‘acle as instructed in Section 5-4 and 5-6, 3. Place the WELD/POWER switch in the POWER position, 4. Rotate the FINE AMPERAGE control to the 100 setting. Moke sure all electrical equipment connected to the 120 VOLTS AC receptacle and 720/240 Volts AC terminal strip is turned off before starting or stopping the engine. When starting or stop- ping, the engine has low speed which causes fow voltage at the output receptacle of the generator. This could result in damage to electrical equipment. 5. On Electric Start Models: Place the Automatic Idle control switch in the ON position. On Manual Start Models: Ensure that the Throt- tle control is pushed fully in and locked. 6. Start the engine as instructed in Section 7-3.7. Tur on the auxiliary equipment and commence operation. 7-3. STARTING THE ENGINE oy Make sure all electrical equioment connected 10 the 120 VOLTS AC receptacle and 120/240 Volts AC terminal strip is turned off before starting or stopping the engine. When starting or stop- ping, the engine has low speed which causes low voltage at the output receptacle of the generator. This could result in damage to electrical equipment. 1, Fill the fuel tank and check to ensure that cil evel is adequate, 2, Pull the CHOKE control fully out. Lesser degrees of choking may be required if the engine is warm. 3. On Electric Start Models: Place the AUTOMATIC IDLE control switch in the ON position. (On Manual Start Models: Push the Throttle con: ‘tol fully in and look. 4, The WELD/POWER switch may be in either the WELD or POWER position, (LELEEME The Starter switch must be released ‘a5 soon as the engine has started to prevent damage to the starter, 5, On Blectric Start Models: Place the IGNITION switch in the ON position and the Starter switch in the START position. 6. On Manual Start Models: Give a quick steady pull on the rope, 7. Once the engine has started slowly push the CHOKE control inward. 8. Allow the engine to run for a few minutes before applying a load. This is necessary to enable the ‘engine to properly warm up and ensure proper lubrication. 7-4, STOPPING THE ENGINE 1. Remove all weld and power loads from the welding generator. MURA 00 not operate accessory ‘power ‘equipment from the 120 VOLTS AC receptacle or 120/240 Volts AC terminal strip during the engine shut- down period, 2, On Electric Start Models: Place the AUTOMATIC IDLE contro! switch in the ON position. (On Manual Start Models: Push the THROTTLE control fully in and lock. 3. Operate the engine at idle (or power) speed for 2 ‘minutes to allow internal engine temperature to equalize. , 4, Place the IGNITION switch in the OFF position (or depress the Stop switch if applicable). mens SECTION 8 - GENERATOR MAINTENANCE mecca BEESON 11 any work is to be done on the rotor of the generator, remove the spark plugs from the engine. This vill prevent engine compression from turning the rotor and catching the repairman’s hand between the rotor fan casting and the stationary adapter casting. Also, disconnect the negative (-) battery cable from the ‘battery (if applicable). 8 - 1, GENERAL - Economical operation and trouble- free service of this welding generator are based upon regular inspections and reasonable attention. Occasional blowing out of the unit with clean, dry, com: pressed air is recommended. This should be performed periodically, depending upon the location of the unit and the amount of dust and dirt in the atmosphere. 8 - 2. COLLECTOR RING BRUSHES - The brushes should be inspected periodically to ensure their proper function. The brush life is very good under normal con: ditions, If the generator has been operating in an ex- tremely dust or dirty location, a close check of the brushes for freedom of movement and cleanliness should be made weekly. Under normal use slip rings will discolor to a dark brown. If it should become necessary to clean the slip tings use a 3/0 or finer sandpaper followed by @ crocus cloth, Never use emery cloth as part of the emery will embed itself into the collector rings and in turn destroy the carbon brushes. 8-3. WELDING CABLES - Check connections periodically for tightness. The cables should be in- spacted frequently and all breeks in the insulgtion should be repaired or the cables replaced. mes SECTION 9 - ENGINE MAINTENANCE ===—____0291—~ 9-1. PERIODIC SERVICE - The efficiency of the engine depends a great deal on the care and attention given it. By following a definite schedule of inspection ‘and service, engine failure caused by naglect can be avoided. Service periods are based on hours of running ‘time and are for normal operating conditions. For ex- treme conditions of load, dust, ditt, etc., service more often. 9-2. LUBRICATION - This engine requires at least 50 hours of break-in running time. During this break: pporiod the load on the engine should be kept as light as possible and the oil level maintained at the FULL mark. After the break-in period, drain the break-in oil and fill the crankcase to the FULL mark with a good quality (API) SE oil (gasoline operation only). Table 9-1 gives a list of recommended grades of oil to use to keep oil evel Up during break-in and to use after the break-in oil is drained. If SE oil is not available, SD or SD/CC ofl may be used. (01-410 Page 15Table 92. Pa Engine Maintonance Chart ‘After Each Cycle of Operational Hours ‘Service These Items so [100 [200 | s00 | 1000 Inspect Engine Generally ‘Check Fuel Supply ‘Check Oit Lovet Glean Governor Linkage and Oil Ball Joints] bre ‘Service Air Cleaner x1 ‘Change Crankoate Oi! ict &2| ‘Check Battery Electrolyte Lovel 22 ‘Clean Fuel Filker Change Spark Plugs Replace Oil Filter (if used) Clean Grankcase Breather Inspect Breaker Points ‘Check Valve Clearance Remove Carbon and Lead Deposits Tnapect Valves, Grind If Necessary Perform more often in extremely dusty conditions. 2: Perform at 3 month intervals under conditions of infrequent engine operation, For gaseous operation, use an ashless or low-ash dotergent oil specifically made for gasoous-fuled ‘The oil capacity of electric start engines is 3-1/2 quarts; the oil capacity of manual start engines is 4 quarts. Do not overfil the crankcase. Check the dip stick to ensure ‘that the oil lovel is at the required operating level Table 9-1. Recommendod Engine Oit LOWEST TEMPERATURE AT SAE NO. THE ENGINE OW [Above 90°F (32°C) for Continuous Duty | No. 50 [30°F (-1°C) to 90°F (32°C) No. 30 J0°F (-18°C) to 30°F (-1°C) No. 10W [Below 0°F (-18°C) No. BW {In normal operation, oil should be changed aftor 100 hours of operation, The oil should be drained after the engine has been warmed up to normal operating ‘temperature, thus promoting foreign particle suspen: sion in the oll and thereby removal when the oll is drain- ed. Foreign particles tend to sottle at the bottom of the allowed to cool, thereby 9-3. CLEANING THE ENGINE - This air-cooled engine operates most efficiently when kept clean. Main- tain cleanliness at all times. Wipe oil spilis from engine immediately to avoid accumulation of dust. 9-4. SPARK PLUGS Do not attempt to clean the spark Plug electrode by sandblasting. Particles of abrasive ‘ay stick to the spark plug and thereby enter the éngine and cause damage to the internal engine components, Also, the spark plug gop should be kept at .025”. Page 16 ‘Tho area around the base of the spark plugs should be cleaned prior to removal of the spark plugs to help avoid dirt getting into the ongine. Remove tho plugs periodically and clean the electrode with a wire brush or knife blade. Take care s0 as not to ‘rack the porcelain insulator on the snark plugs. 9-5. FUEL FILTER ~ The fuel filter is located bolow the fuel tank. Check the sediment bow! periodically for water and dirt deposits. How often the filter has to be checked will depend on the quality of gasoline used and. how dusty and dirty the location in which the engine is being used. 9-6. AIR CLEANER - Tho air cleaner is one of the ‘most important parts of the engine from the standp. of engine lfe. If dirty alr gets into the engine, itcan wear ‘out a set of piston rings within a few operating hours. “This engine is equipped with a dry paper type filter ele- ment. Dry paper element type cleaners can be cleaned by removing the element and tapping lightly, causing loose dirt to fall off. The element should be rplaced if dirt does not drop off easily. ‘The paper element should be handled with care to avoid perforations, Removing the dirt with compressed air ‘can rupture the paper olement. Check to ensure that ‘gasket surfaces of the element are not bant or damaged in any way. Gasket surfaces must seat tightly at the top and bottom of the cleaner shell to prevent foreign mat- ter from entering the carburetor, Whenever the air cleaner is removed, cover the air in- take hole to prevent dirt from falling into the carburetor. 9-7, GOVERNOR - The governor has been set at the factory and should not require further adjustment. IfCarburetor dlo Mixture Adjustment Screw Idle Speed Adjustment Screw Ile Speed Adjus Locking Na atti Side View Of Adjustment Nut coal Wold Speed Adjustment Rod Throttle Solonotd Adjustment Locking Bowne Nut ‘Nut Figure 9-1. Engine Speed Adjustments the governor works loose or is disconnected, ad: justments should be made by a factory authorized sor- vice station. If one of the springs attached to the governor arm ‘works loose or is disconnected, reattach the spring ex- actly as illustrated in Figure 9-1 or 9-2. 9-8, ENGINE SPEED ADJUSTMENTS Ensure that the points and plugs are clean and properly gapped and that the engine has reached nor- ‘mal operating temperature before proceeding with the engine speed adjustinents, Also adjust the carburetor as, cutlined in the Engine Owner's Manual The engine speeds have been factory adjusted and will how require frequent readjustment. After tuning the engine, check the speeds with a tachometer. With no load applied, the power speed should be 1860 rpm for 60 Hz. Models (1650 rpm for 60 Hz. Models) and the ‘weld speed 3000 rpm. If necessary adjust the speeds as follows: Start the engine as outlined in Section 7-3. 2. Place the WELD/POWER switcl position, ‘the POWER 3. Rotate the FINE AMPERAGE control to 100. 4, Pull the governor arm away from the carburetor to cause the engine to idle. While holding the arm against spring tension, make the following adjustments: A, Rotate idle speed adjustment screw until the engine runs at 1800 rpm. B, Rotate idle mixture adjustment screw in or ‘out £0 obtain maximum rpm with idle speed adjustment screw against stop (1-1/8: 1/8 tum open). C. Readjust idle speed adjustment screw for 1800 rpm, HIER 1 the engine surges tis running too ean} or spark plugs fou! (is running too rich), especially after long periods of idling, repeat Step 4. Ensure that the idle mixture adjustment scrow is 1-1/8 1/8 turn open. 5. Rolease the governor arm, Back off the idle speed adjustment screw approximately 2 turns ‘to obtain @ 1/8 inch gap between the idle speed adjustment screw and the throttle lever (seo Figure 9-1), 6. Loosen the locking nut on the power speed ad- justment rod and rotate the adjustment nut until the engine runs at 1860 rpm (1650 rpm for 60 Hz, Mocels). Tighten locking nut. If the engine surges (hunts) when running at ‘power speed, move the power speed sensitivity spring ‘out or enrichen the idle mixture slightly by rotating the idle mixture adjustment screw counterclockwise, Repeat Steps 4, 5, and 6. 7 7. Place the WELD/POWER switch in the WELD position. 8. Place the AUTOMATIC IDLE switch (Electric ‘Start Models Oniy} in the OFF position. 9. For Electric Start Models: Loosen the locking nut on the weld speed adjustment red and rotate the adjustment nut until the engine runs at 3000 rpm, Tighten locking nut. For Manual Start Models (see Figure 9-2): (0M-410 Page 17Governor Arm: Locking Nut Side View of Carburetor Throttle Plate Weld Speed Adjustment Screw Figure 9-2. Weld Speed Adjustment On Manual Start Models ‘A. Unlock THROTTLE control. B. Pull throttle plate against spring tension, C. Loosen locking nut and adjust weld speed adjustment screw for 3000 rpm D. Tighten locking nut. 9-9. IDLE CONTROL CIRCUIT PROTECTION (Electric Start Models) - The idle control printed cir- cuit board and the throttle solenoid are protected by a fuse F1 located in the wiring hamess beneath the gas tank on the right side of the engine. Wit becomes necessary to replace this fuse, ensure that a fuse of the proper size is used. 9-10. HIGH-ALTITUDE | CARBURETOR MODIFICATION (Optioant) - The carburetor can be equipped with an adjustable main jet for high-altitude operation (above 6000 ft). Minor adjustment will be necessary for proper operation at a particular altitude. Whenever a carburetor adjustment is deemed necessary, allow the engine to reach normal operating ‘temperature. Rotate the FINE AMPERAGE control to 100. 2. Place the WELD/POWER switch in the WELD position. 3. Place the AUTOMATIC IDLE switch (Electric Start Models Only) in the OFF position. 4, While applying a continuous load to the welding generator, rotate the main adjustment screw for best output. ‘Check weld speed (3000 rpm) and power speed. {1860 rpm for 60 Hz. Models; 1650 rpm for 60 Hz. Models), Readjust if necessary. Page 18 9-11. SPARK ARRESTOR (Optional) The engine exhaust system of this welding generator has not been equipped with a spark arrestor unless it was specifically ordered as an optional accessory. 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. Internal combustion engines operating in a highly com- bustible environment ere a common fire hazard. Glow. ing carbon particles blown out with the exhaust can re- ‘ain sufficient heat to ignite materials. While no prac- ticat spark arresting device will stop all sparks, this device wil minimize fire hazards by removing and trap- ping most solid particles provided that it is properly maintained, ‘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. A. Inspection 1. Visually examine the outside of the device for holes, cracks, or metal corrosion, 2. With the engine stopped, look inside the spark arrestor outlet tube with a flashlight or other ight. source. Visually examine the vanes and the outlet tube for metal or weld failure. The vanes must be firmly attached to the inlet tube and the outlet tube must be completely intact (this is an imgortant factor in maintaining spark arresting efficiency. 3, Check the mounting clamp to ensure that the spark arrestor is socurely mounted.Replace the spark arrestor if inspection reveals any formed over the hole, break it loose with a signs of failure. screwdriver or similar tool, B. Sorvising The Carbon Trap 3, Start the engine and run it at idle rpm to blow collected particles out the cleanout hole. If par IRENE Service the device in an area where there ticles ara slow to discharge, momentarily cover 18 no danger from flying sparks or hot carbon particles. the end of the exhaust stack. ‘1, Stop the engine and allow the exhaust system to 4, Stop the engine. Replace and secure the cool, cleanout plug. 2. Remove the closnout plug from the bottom of the spark arrestor with a wrench. If a crust has commence SECTIONIO- GENERATOR TROUBLESHOOTING sammmemsccommauer [GAMER Hazardous volages are present an the in. _Itis assumed that proper installation has been made, ac- temnal circuitry of the welding gonerator while the cording to Section 3 of this manual, and that’ tha enging is sunning. Shut down the engine before at welding generator has been functioning properly until tempting any inspection or work on the inside of the this trouble developed. unit. Troubleshooting of internal circuitry should be per- formed by qualified personnel only. Uso this chart in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these pro- cadures, the nearest Factory Authorized Service Sta- ‘The following chart is designed to diagnose and provide _ tion should be contacted. In all cases of equipment remadies for some of the troubles that may develop in malfunction, the manufacturer's recommendations ‘this welding generator. should be strictly followed. TROUBLE PROBABLE CAUSE REMEDY Battery discharges botween | IGNITION switch S2 loft in | Ensure IGNITION switch S2 is left in OFF position| uses, (Electric Start Models | ON position, when unit Is shut down. Oniy). | Build-up of acid on top of | Clean battery with soda solution; rinse with clear battery (white-grayish | water. substance). Tafroquent use. Periodically recharge battery (approximately every 3 months), Defective battery. —_‘| Replace battery. ‘No power output at power | WELD/POWER switch $1 | Place WELD/POWER switch S1 in POWER posi- receptactes. in WELD position. tion. Low power output at power | Low setting on FINE | Rotate FINE AMPERAGE control R1 to 100. roceptacles. AMPERAGE contro! R1 Engine running below re- | Check air filter; clean if necessary. quired speed (1860 rpm). Clean and adjust points and plugs. Adjust car- buretor (sae Engine Owner's Manual). “Aajust engine speed (see Section 9-8). Voltage Regulator board PC2 defective. ‘Transformer T1 defective. | Replace T1 Replace PC2, (OM-410 Page 19