Page 1
March1993
Form:
OM-160518
Effective
With
Serial
No.
KD398640
OWNERS
MANUAL
Read
and
follow
these
instructions
and
all
Give
this
manualtothe
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Millerfi
~.
r.~1~Ic4...1
-
~_
~
I
1
~.w
Gold
SealTM
Model
3000
CC/DC
Welding
Generator
For
SMAW
Welding
90
Amperes,
25
VoltsDCAt
60%
Duty
Cycle
1.2
kVA/kW
DC
Auxiliary
Power
With
Overload
Protection
Kohler
CH5+
Air-Cooled,
Four-Cycle,
Gasoline
Engine
Optional
Low
Oil
Pressure
Shutdown
Switch
coven
5/92ASt-161
477
PRINTEDIN~SA
Page 2
Page 3
s
a
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
endisexclusive
withnoother
guerantees
or
warranties
eapressed
or
Implied.
u
LIMITED
WARRANTY
Subject
to
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
dateofthis
limited
warranty
is
tree
of
de
tects
in
material
end
workmanship
at
the
timeitis
shipped
by
MILLER.
THIS
WAR
RANT?
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
pans
or
components
that
tall
duetosuch
detectsinmaterial
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
to
be
followed.
MILLER
shall
honor
warranty
claimsonwarranted
equipment
listed
below
in
the
event
of
suchafailure
within
the
warranty
time
periods.
All
warranty
lime
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
follows:
1.
5
Yearn
Pans3
Years
Labor
*
Original
main
power
rectifiers
2.
3
Yearn
Pans
and
Labor
*
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
*
Robots
3.
2
YearsPans
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
angina
manufacturer.)
4.
I
Year
Pans
and
Labor
*
Motor
Driven
Guns
*
Process
Controllers
*
Water
Coolant
Systems
HF
Units
*
Grids
Spot
Welders
*
Load
Banks
SDX
Transformers
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
yaar
whichever
is
greater.)
5.
6
Months
Batteries
6.
90
Days
Pans
and
Labor
*
MIS
Guns/TIG
Torches
*
Plasma
Cutting
Torches
*
Remote
Controls
*
Accessory
Kits
*
Replacement
Pans
MILLERS
True
BiuanM
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
anginea
or
trade
accessories.
These
items
are
coveredbythe
manufacturers
warranty,
it
any.
2.
Consumabla
components;
such
as
contact
tips,
cutting
nozzles,
conlaclorn
and
relays.
3.
Equipment
that
has
bean
modilied
by
any
party
other
than
MILLER.
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
aquipmenl
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
han
bean
used
for
operation
outside
of
the
spacifications
br
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIALJINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
In
the
avant
01
a
warranty
claim
covaradbythis
warranty,
the
eacluniva
remedies
shall
ba,
at
MILLERS
option:
(1)
repair;or(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonabia
cost
of
repairorreplace
ment
alan
authorized
MILLER
service
station;
or
(4)
payment
oforcredit
for
the
pur
chase
price
(lass
reasonable
depracialion
based
upon
actual
usa)
upon
return
of
the
goods
at
customers
risk
and
expense.
MILLERS
optionofrepair
or
replacement
will
ba
FOB.,
Factory
atAppleton,
Wisconsin,
or
P.0.6.
at
a
MILLER
authorized
ser
vice
facility
as
determinedbyMILLER.
Therefore
no
compensation
or
raimburse
went
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.INNO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL.
INCIDENTAL
OR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
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
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.
Some
slates
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
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
citic
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
stale
to
stale.
In
Canada,
legislation
in
some
provinces
provides
br
certain
additional
warranties
or
remedies
other
thanasstaled
herein,
and
to
the
astant
that
they
may
not
ba
waived.
Ihe
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
Irom
province
to
province.
I
r
_____________________________
I
RECEIVING-HANDLING
Before
unpacking
equ(pment,
check
carton
for
any
damage
that
may
have
occurred
during
Shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
infDrmation
about
this
equipment,
always
provide
Mode)
Designation
and
Serial
or
Sty(e
Number.
USe
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
namep(ate.
Model
__________
Serial
or
Style
No.
DateofPurchase
miller
5192
Page 4
Page 5
March
1
993
Form:
OM-160
518
Effective
With
Serial
No.
KD398640
OWNERS
MANUAL
U
Read
and
follow
these
instructions
and
all
U
Give
this
manualtothe
operator.
U
U
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Callyourdistributorifyoudonotunderstand
the
directions.
rt~i
U
U
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
1079,
Appleton,
WI
54912
Co.,
P.O.
Box
414-734-9821
1~oIsfi
(jJOJ1
cI~j\r~J~
PAW
100
CC/DC
Welding
Generator
For
SMAW
Welding
U
90
Amperes,
25
VoltsDCAt
60%
Duty Cycle
U
1.2
kVAJkW
DC
Auxiliary
Power
With
Overload
Protection
Kohler
CH5+
Air-Cooled,
Four-Cycle,
Gasoline
Engine
Optional
Low
Oil
Pressure
Shutdown
Switch
cover
8/92
ST-161
477
PRINTED
IN
~SA
Page 6
Page 7
ARC
WELDING
SAFETY
PRECAUTIONS
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
When
making
input
connections,
attach
proper
grounding
conductor
first.
7.
Turn
off
all
equipment
when
not
in
use.
8.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
9.
Do
not
wrap
cables
around
your
body.
10.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
11.Donot
touch
electrode
if
in
contact
with
the
work
or
ground.
12.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
13.
Wear
a
safety
harness
if
working
above
floor
level.
14.
Keep
all
panels
and
covers
securelyinplace.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
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
hearing.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shadeoffilter
(see
ANSI
Z49.
1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
3.
Wear
approved
safety
glasses.
Side
shields
recommended.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
and
cleaners.
5.
Work
in
a
confined
space
only
if
itiswell
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
weldinlocations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
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.
WELDING
can
cause
fire
or
explosion.
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
contactofelectrode
orwelding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
through
small
cracks
and
openings
to
adjacent
areas
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
suchastanks
or
drums.
Connect
work
cable
to
the
workasclosetothe
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
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.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
1.
Use
approved
ear
plugs
or
ear
muffsifnoise
level
is
high.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
srI
9/92
Page 8
Page 9
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
Stop
en
me
before
installingorconnecting
unit.
SafetyinWelding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
MiamiFL33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.i
from
American
Welding
So
ciety,
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.
ENGINES
can
be
hazardous.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
1.
Stop
engine
before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and add
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tankallow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.Iffuel
is
spilled,
clean
up
before
starting
engine.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
finished
and
before
starting
engine.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
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.
IL~c
CYLINDERS
can
explode
if
damaged.
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.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
fallingortipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
ENGINE
FUEL
can
cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on
a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop
engine
before
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
Batteries
contain
acid
and
generate
explosive
gases.
3.
4.
5.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
iump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
4
~
.
(.~
~
~
STEAM
AND
COOLANT
can
skin.
The
coolant
in
the
under
pressure.
PRESSURIZED
burn
face,
eyes,
radiator
can
be
very
h
HOT
and
ot
and
1.
2.
3.
Do
not
remove
radiator
cap
when
engine
is
hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
Allow
pressure
to
escape
before
completely
removing
cap.
PRINCIPAL
SAFETY
STANDARDS
Sri
9/92
Page 10
Page 11
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
SIGNAL
WORDS
.
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
2-3.
Fuel
Consumption
2-4.
DC
Auxiliary
Power
Curve
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Generator
3-2.
Engine
Prestart
Checks
3-3.
Grounding
The
Generator
Auxiliary
Power
System
3-4.
Connecting
To
Weld
Output
Terminals
SECTION
4OPERATING
THE
WELDING
GENERATOR
SECTION
5
OPERATING
AUXILIARY
EOUIPMENT
5-1.
Auxiliary
Power
DC
Receptacle
5-2.
Auxiliary
Equipment
Operation
1
11
12
13
13
14
14
15
16
22334566
7
10
10
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
6-2.
Changing
Engine
Oil
6-3.
Adjusting
Engine
Speed
6-4.
Air
Cleaner
Service
6-5.
Clean
Air
Intake
And
Cooling
Areas
6-6.
Drive
Belt
Adjustment
And
Replacement
6-7.
Overload
Protection
6-8.
Troubleshooting
SECTION
7
ELECTRICAL
DIAGRAMS
SECTION
8-
WELDING
METHODS
&
TROUBLESHOOTING
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
8-2.
Welding
Troubleshooting
SECTION
9
PARTS
LIST
Figure
9-1.
Main
Assembly
Figure
9-2.
Panel,
Front
w/Components
Figure
9-3.
Panel,
Control
w/Components
18
20
25
28
31
32
OM.160
518
3)93
Page 12
Page 13
SECTION
1
SAFETY
SIGNAL
WORDS
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Generator
rnodl.1
2/93
1
2
2
\
a
CAUTION
/
;
3
_______________
______________
ELECTRIC
SHOCK
can
kill
MOVING
PARTS
can
injure.
L~
I
Disconnect
input
power
betore~
~
Keep
all
panels
and
covers
closed
I
I
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts,
I
installingorservicing.
when
operating.
I
5
READ
SAFETY
BLOCKS
at
start
of
6
Section
3-1
before
proceeding
7H
NOTE
~
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
Turn
Off
switch
when
using
high
frequency.
Specification
TypeOfOutput
Rated
Weld
Output
Amperage
Range
Maximum
Open-Circuit
Voltage
Welding
Process
Description
Auxiliary
Power
Rating
Engine
Engine
Speed
(No
Load)
Fuel
Tank
Capacity
Engine
Oil
Capacity
Drive
Belt
Size
Overall
Dimensions
Weight
Options
Constant
Current/Direct
Current
(CC/DC)
90
Amperes,
25
Volts
DC
At
60%
Duty
Cycle
(See
Section
2-2)
40
To
100
A
75
Volts
DC
(See
Section
2-1)
Shielded
Metal
Arc
Welding
(SMAW);
Flux
Cored
Arc
Welding
(FCAW)
And
Gas
Tungsten
Arc
Welding
(GTAW)
Possible
With
Appropriate
Process
Options
1.2
kW,
120
Volts
DC,
10
Amperes
Kohler
CH5+
Air-Cooled,
One-Cylinder,
Four-Cycle
Gasoline
Engine
1800
rpm
Idle
Speed;
4150
rpm
Weld
And
Power
Speed
2.3
U.S.
gal
(8.7L)
22.4
oz
(0.66L)
1/2
x
.343x32.3
Cogged
See
Figure
3-2
Net:
101
lb
(46
kg);
Ship:
113
lb
(51
kg)
See
Rear
Cover
OM-160
518
Page
1
Page 14
Page 15
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
a
CAUTION
300
-
250
-
200
U)
150
w
a
<
100
.
75
.
Figure
2-2.
Duty
Cycle
Chart
Cl)
0
>
0
100
90
80
70
60
50
40
30
20
10
0
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
generator.
Curves
of
other
settings
fall
between
the
curves
shown.
rsDl.1
10/91
SB-152
541
0
25
50
75
100
125
150
DC
AMPERES
EXCEEDING
DUTY
CYCLE
RATINGS
will
damage
unit.
Do
not
exceed
indicated
duty
cycles.
warn7.1
2/92
This
unit
is
rated
at
60%
duty
cycle
allowing
welding
6
minutes
out
of
every
10
minutes.
RATED
OUTPUT
~......,
50-
---
--
10
15
20
25
30
40
50
60
7080
100
Duty
cycle
is
how
long
the
unit
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
%
DUTY
CYCLE
sbl.2
10/91
SB-152
540
OM-160
518
Page
2
Page 16
Page 17
2-3.
Fuel
Consumption
The
fuel
consumption
curve
shows
typical
fuel
use
under
weld
or
pow
er
loads.
~
-J
_j
ci,
w
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
DC
AUX
POWER
0.95
0.21
0.25
0.71
0.16
0.19
0.47
0.10
0.12
-IDLE
0.23
0.05
0.06
0
0
15
30
45
60
75
90
DC
WELD
AMPERES
(25
VOLTS)
0.2
0.4
0.6
0.8
1.0
1.2
DC
POWER
KW
rsb2.I
10/91SB-153
250
Figure
2-3.
Fuel
Consumption
Curve
2-4.
DC
Auxiliary
Power
Curve
The
dc
power
curve
shows
the
aux
iliary
power
in
amperes
available
at
140
the
120
volt
dc
receptacle.
~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
Page 18
Page 19
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Generator
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
Do
not
breathe
exhaust
fumes.
Use
in
open,
well-ventilated
areas,
or
vent
exhaust
outside
and
away
from
building
air
intakes.
ENGINE
EXHAUST
SPARKS
can
cause
fire.
Use
only
U.S.
Forestry
Department
approved
spark
arrestor
and
comply
with
all
local,
state,
and
federal
laws.
A
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.
Properly
maintain
the
spark
arrestor.
Stop
engine
and
allow
exhaust
system
to
cool
down
before
servicing
spark
arrestor.
Service
spark
arrestor
away
from
flammables.
HOT
ENGINE
EXHAUST
AND
EXHAUST
PIPE
can
cause
fires.
Keep
exhaust
and
pipe
away
from
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
Lift
Unit
at
handlesonends
of
base.
Have
two
persons
of
adequate
strength
lift
unit.
Move
unit
with
hand
cart
or
similar
device
of
adequate
capacity.
It
using
a
fork
lift
vehicle,
secure
unit
on
a
proper
skid
before
transporting.
rwarnl.1
12/91
Keep
unit
level
tilting
can
cause
fuel
and
oil
leaks
and
possible
fire
or
engine
damage.
2
2
1
18
in
(457
mm)
Open
Space
On
All
Sides
2
Lifting
Handles
Lift
unit
with
hands
positioned
in
centerof
handles.
Obtain
help
to
lift
and
transport
unit.
3
Exhaust
Outlet
Keep
flammables
away
from
ex
haust
outlet.
Figure
3-1.
Location
And
Movement
Of
The
Welding
Generator
5T-161
4771
ST-151
556/
Ref.
5T.161
478
~<
Inches
Millimeters
A
B
C
19
14-5/8
28-3/4
483
371
730
C
>.-.~<
Figure
3-2.
Overall
Dimensions
OM-160
518
Page
4
Page 20
Page 21
200
200
Maximum
tilting
angles
for
proper
lubrication.
Keep
fuel
cap
at
highest
point
when
tilted.
Do
not
let
fuel
leak
from
cap
during
tilting.
S-0702
Do
not
overfill
fuel
room
for
expansion
a
tank
leave
nd
tilting
with
out
causing
leaks.
Figure
3-3.
Maximum
Welding
Generator
Tilt
Angles
3-2.
Engine
Prestart
Checks
a
WARNING
.~
ENGINE
FUEL
can
cause
fire
or
explosion.
Stop
engine
before
fueling.
Do
not
fuel
while
smoking
or
near
sparks
or
flames.
Do
not
overfill
tank;
clean
up
any
spilled
fuel.
REMOVE
FUEL
CAP
SLOWLY;
FUEL
SPRAY
may
cause
injury;
FUEL
may
be
under
pressure.
Rotate
fuel
cap
slowly
and
wait
until
hissing
stops
before
removing
cap.
rwarn3
1
9191
Check
all
fluids
daily.
Engine
must
be
cold
and
on
a
level
surface.
Add
fresh
fuel
before
starting
engine
the
first
time
(see
Figure
6-1).
I
Fuel
Cap
Fill
fuel
tanktowithin
1
in
(25
mm)
of
bottomoffiller
neck
to
provide
space
for
expansion.
2
Oil
Fill
Cap/Dipstick
3
Oil
Fill
Tube
Remove
dipstick
and
wipe
off
oil.
Reinsert
dipstick
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
11/92ST-16l
479
Figure
3-4.
Checking
Fluid
Levels
OM-160
518
Page
5
Page 22
Page 23
3-3.
Grounding
The
Generator
Auxiliary
Power
System
3-4.
Connecting
To
Weld
Output
Terminals
a
WARNING
~-
1
Equipment
Grounding
Terminal
The
generator
auxiliary
power
neutralisconnected
to
the
machine
frame.
Tools
Needed:
-.~
rsb5.1
1/93
Ret.
ST-i
~7
863-A/Ret.
ST-I
81
479
Figure
3-5.
Equipment
Grounding
Connection
.
.~
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Do
not
touch
live
electrical
parts.
Stop
engine
before
making
any
weld
output
connections.
Read
Safety
Precautions
at
beginning
of
this
manual.
rwarnl3,l
2/92
1
~
~
2
~
I
DC
Negative
()
Weld
Output
Receptacle
2
DC
Positive
(+)
Weld
Output
Receptacle
For
Direct
Current
Electrode
Posi
tive
(DCEP).
connect
work
cable
to
Work
receptacle
and
electrode
cable
to
Electrode
+
receptacle.
For
Direct
Current
Electrode
Nega
tive
(DCEN),
reverse
cable
connections.
3
Weld
Output
Receptacle
4
Connector
Align
keyways
on
connector
and
receptacle.
Insert
connector
and
rotate
clockwise
until
tight
in
receptacle.
Figure
3-6.
Weld
Output
Connections
Ret.
ST-I57863-A/ST-161
480
OM-160
518
Page
6
Page 24
Page 25
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Stop
engine
before
installingorservicing.
Keep
all
panels
and
covers
securely
in
place
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weldonclosed
containers.
Allow
work
and
equipment
to
cool
before
handling.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection
FUMES
AND
GASES
can
be
hazardous.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
Figure
4-2.
Safety
Equipment
E
NGINE
EXHAUST
GASES
can
kill.
Do
not
breathe
exhaust
fumes.
Use
in
open,
well-ventilated
areas,
or
vent
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
explo
sion.
!
Stop
engine
before
fueling.
Do
not
fuel
while
smoking
or
near
sparks
or
flames.
Do
not
overfill
tank;
clean
up
any
spilled
fuel.
=~!t?
,~
~
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans,
belts.
and
rotors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
I
\
~_.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
any
welding
operations.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
~
110/91
4
1
Amperage
Control
2
Engine
Hour
Meter
(Optional)
3
Low
Oil
Level
Light
(Optional)
4
Throttle
Control
Lever
6
5
Choke
Control
6
Fuel
Shutoff
Valve
ST-161
477/Rel.ST-161
479
Figure
4-1.
Controls
2
3
4
1
Insulating
Gloves
2
Safety
Glasses
With
Side
_______
Shields
3
Welding
Helmet
~LE~1
U
welding
helmet
or
hand
shield
with
_______
______
4
Hand
Shield
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
a
correct
shadeoffilter
(see
ANSI
Z49.1).
sb3.110/91
OM-160
518
Page
7
Page 26
Page 27
1
Work
Clamp
Tools
Needed:
Connect
work
clamp
to
a
clean,
paint-free
location
on
workpiece,
as
close
to
weld
area as
possible.
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Use
chipping
hammer
to
remove
slag
after
welding.
sb4.1
2/93
Figure
4-3.
Work
Clamp
1
Amperage
Control
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
2
Electrode
Scale
Scale
shows
recommended
elec
trode
diameter
for
weld
amperage.
3
Amperage
Scale
Numbers
in
scale
are
welding
amperes.
2
3
Ret.
ST-157
883-A
Figure
4-4.
Amperage
Control
1
Fuel
Shutoff
Valve
Open
valve
before
starting
engine.
Close
valve
when
unit
is
not
in
use
or
during
transport.
2
Throttle
Control
Lever
Use
lever
to
start
and
stop
engine
and
select
engine
speed.
To
start
engine,
move
levertoRun.
3
Choke
Control
Lever
Use
lever
to
regulate
carburetor
air/fuel
mixture.
Move
choke
lever
to
right
(choke
on)
if
starting
a
cold
engine.Ifstarting
a
warm
engine,
move
choke
levertoleft
(choke
off).
4
Starter
Handle
Pull
starter
handle
with
quick,
smooth
motion.
After
engine
warms,
move
choke
levertoleft.
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
4-5.
Engine
Controls
OM-160
518
Page
8
Page 28
Page 29
1
Engine
Hour
Meter
Use
meter
to
check
total
operating
6
hours
(see
Section
6).
This
meter
op
erates
only
when
engine
is
running.
rsb6.1
2/92
Figure
4-6.
Engine
Hour
Meter
(Optional)
I
Low
Oil
Level
Light
Q~
1
Light
flickers
when
starter
handle
is
pulled
if
engine
has
stopped
due
to
automatic
low
oil
level
shutdown.
LOW
OIL
Engine
does
not
start
until
sufficient
oil
is
added
to
engine.
Fill
engine
with
oil
to
F
mark
on
dip
stick
(see
Figure
3-4).
Ref.
ST-157
863
Figure
4-7.
Automatic
Low
Oil
Shutdown
(Optional)
Install
&
Connect
)
EquIpment~)
Electrode
Personal
Safety
I
I
Set
ControI~~)
Start
Eng~~Uia~)__..)
Select
Put
On
________________
________________
Equipment
~~JJ
________________
_____
_____
_____ _____
_____
~g~pmen~,~
~-
)
Insert
Begin
Weldin~
Electrode
Into_Holder
_________________
Figure
4-8.
Sequence
Of
Shielded
Metal
Arc
Welding
(SMAW)
rSbO.1
9/92
OM-160
518
Page
9
Page 30
Page 31
SECTION
5-
OPERATING
AUXILIARY
EQUIPMENT
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine
before
making
internal
inspection
or
reconnection.
Ground
generator
according
to
all
applicable
national,
state,
and
local
codes.
Connect
equipment
grounding
terminal
to
a
proper
earth
ground.
Do
not
connect
to
any
electrical
distribution
system
normally
supplied
by
utility
power.
ELECTRIC
SPARKS
can
cause
fire.
If
using
auxiliary
power
only
and
not
welding,
disconnect
both
welding
cables
to
prevent
live
electrode
from
causing
electric
shock
and
fire
hazards.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
The
weld
output
terminals
are
electrically
energized
when
the
engine
is
running.
DC
AUXILIARY
POWER
electrical
equipment
incorrect
operation.
Use
DC
output
only
for
incandescent
lights
and
tools
rated
for
DC.
Do
not
use
DC
to
power
AC
motors,
transformer
equipment,
or
induction
motors.
Essentially
all
hand
tools
are
powered
by
universal
motors.
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.
This
unit
provides
1200
watts
of
direct
current
(DC)
auxiliary
power.
DC
power
is
suitable
for
incandescent
lights
and
portable
power
tools
with
115or120
volt
AC/DC
or
DC
ratings.
This
power
must
not
be
used
to
power
any
AC-only
rated
equipment.
rwarn8.1
10/92
Figure
5-1.
Auxiliary
Power
DC
Receptacle
And
Circuit
Protection
5-2.
Auxiliary
Equipment
Operation
)
)
lnstat&Co~n~ct~)
)Turn
OnA
liarY))
Begin
Ope~on
Figure
5-2.
SequenceOfAuxiliary
Equipment
Operation
,~-.
~
X
~
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
can
damage
and
cause
cii
0
5-1.
Auxiliary
Power
DC
Receptacle
1
120V
1OA
DC
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
DC
ratings.
The
switchesoninex
pensive/light
duty
tools
may
be
2
damaged
by
DC
power,
and
vari
able
speed
tools
will
run
only
at
full
speed
on
DC.
Use
DC
output
only
for
incandes
cent
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.
2
lOAFuseFi
Fl
protects
generator
from
over
load
or
short
circuits
on
dc
recep
tacle.IfFl
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
replacement.
Ret.
ST.157
863-A
OM-160
518
Page
10
Page 32
Page 33
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Stop
engine
before
installing
or
servicing.
Keep
all
panels
and
covers
securely
in
place.
ENGINE
EXHAUST
GASES
can
kill.
Do
not
breathe
exhaust
fumes.
Use
in
open,
well-ventilated
areas,
or
vent
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
explo
sion.
Stop
engine
before
fueling.
Do
not
fuel
while
smoking
or
near
sparks
or
flames.
Do
not
overfill
tank;
clean
up
any
spilled
fuel
MOVING
PARTS
can
cause
injury.
Keep
hands,
loose
clothing,
and
tools
away
from
moving
parts
such
as
pulleys,
fans,
belts,
and
ro
tors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securelyinplace.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
Maintenancetobe
performed
onlybyqualified
per
sons.
rwarn9.I
10/91
6-1.
Routine
Maintenance
The
maintenance
label
is
located
on
the
fuel
tank
above
the
throttle
control
lever
(see
Figure
6-3).
Recommended
Oil-API
Service
Classification
SF-SG/CC-CD
Below
32F
(0C)
SAE
5W-20,
SAE
5W-30
Above
32F
(0C)
SAE
1OW-30,
SAE
1OW-40
Check
oil
daily
(4
oz.
Add
to
Full
on
dipstick)
Oil
Capacity
22.4
oz.
(0.66L)
Oil
Change
Normal
conditions
100
hours
Drive
Belt
Inspection
100
hours
See
Manual
Drive
Belt
Miller
150412
4
Spark
plug
gap
Resistor
&
Std
.030
in.
(.76
mm)
Spark
Plug
Champion
RCI2YC*
*Resistor
Spark
Plug
Mandatory
in
Canada
Air
filter
element
.
Kohler
1506306
~
Air
Filter
Service
100
hours
or
less-See
Manual
.2
Miller
067101
Fuel
grade
Regular
or
Unleaded
Fuel
Capacity
2.3
U.S.
Gal
(8.7L)
Vented
cap
at
least
87
octane
(RON
+
MON)
2
~5
Engine
RPM
... .
IDLE
-
1800
RUN
(Weld&Power)
-
4150
If
equipped
with
spark
arrestor,
inspect
and
service
per
Manual
or
supplied
instructions.
KOHLER
CH5+
ENGiNE
STOP
~
~
R~J
L$~
SPEED
CONTROL
S.146
281-A
Figure
6-1.
Maintenance
Label
a
WARNING
OM-160
518
Page
11
Page 34
Page 35
Stop
engine
before
maintaining.
Do
not
throw
away
engine
fluids
take
to
area
recycling
~-
center.
~JJ
25
Hours
ED
500
Hours
~y~
Clean
Air
Cleaner
Foam
Element
6-4~J
Check
engInes
Clearance
Valve
manual
Every200
hours
havealferna
for
brushes,
slip
rings,
bear
ings
and
optional/ow
oil
shut
down
checked
by
FactoryAu
thorized
Service
Station.
6-2.
Changing
Engine
Oil
Figure
6-2.
Maintenance
Schedule
Stop
engine.
Change
engine
oil
at
interval
listed
in
Figure
6-1.
Change
oil
while
en
gine
is
still
warm.
1
Support
Block
Use
blocks
large
enough
to
provide
room
for
oil
pan.
2
Oil
Fill
Cap/Dipstick
Remove
oil
fill
cap/dipstick
before
draining
oil.
3
Oil
Drain
Plug
Remove
plug.
Allow
enough
time
for
oiltodrain
completely.
Reinstall
plug.
4
Maintenance
Label
Fill
crankcase
with
new
oil
to
F
mark
on
dipstick.
Use
correct
type
and
grade
of
oil.
See
Figure
6-1
for
specifications.
Reinstall
oil
fill
cap/dipstick.
ST-I
61
481
Tools
Needed:
3/8
in
Figure
6-3.
Changing
Engine
Oil
OM-160
518
Page
12
Page 36
Page 37
6-3.
Adjusting
Engine
Speed
Start
and
run
engine
at
no
load.
1
Throttle
Control
Lever
Move
levertoRun.
2
Speed
Adjustment
Plate
3
Securing
Screw
Loosen
securing
screws
and
move
adjustment
plate
right
or
left
until
engine
runs
at
4150
rpm.
Tighten
screws.
4
Belt
Guard
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.
6-4.
Air
Cleaner
Service
Figure
6-4.
Engine
Speed
Adjustment
Stop
engine.
1
Air
Cleaner
Cover
2
Retaining
Screw
Loosen
retaining
screw
and
re
move
air
cleaner
cover.
3
Wing
Nut
Remove
as
shown.
4
Foam
Element
(Precleaner)
Wash
element
in
warm
water
with
detergent.
Rinse
all
detergent
from
element
and
allow
to
air-dry.
Saturate
element
with
clean
en
gine
oil.
Squeeze
out
excess
oil.
Reinstall
element
on
paper
element.
5
Paper
Element
Replace
dirty
or
damaged
element
with
a
new
element.
Do
not
wash
dirty
element
or
clean
with
com
pressed
air.
Reinstall
air
cleaner
cover.
5T-151
839
READ
SAFETY
BLOCKS
at
start
of
Section
6
before
proceeding.
Moving
Parts
Hazard.
Have
belt
guard
in
place
before
running
engine.
Tools
Needed:
~
3/8,
9/32
in
Ref.
ST-161
482
READ
SAFETY
BLOCKS
at
start
of
Section6before
proceeding.
4
2
3
Figure
6-5.
Air
Cleaner
Maintenance
OM-160
518
Page
13
Page 38
Page 39
6-5.
Clean
Air
Intake
And
Cooling
Areas
6-6.
Drive
Belt
Adjustment
And
Replacement
I
~
READ
SAFETY
BLOCKS
at
start
of
Section
6
before
proceeding.
Figure
6-7.
Drive
Belt
Adjustment
and
Replacement
Figure
6-6.
Air
Intake
And
Cooling
Areas
Tools
Needed:
~
9/16,5/8
in
7/16
in
Ref.
ST-161
482
Stop
engine.
4
Securing
Screw
sioned,
belt
deflects
inward
about
1/8
in
(3
mm).
1
Belt
Guard
To
replace
belt,
remove
tensioning
screw
Remove
five
screws
securing
belt
guard.
and
loosen
securing
screws.
Remove
belt.
Adjust
belt
tension
by
turning
tensioning
Remove
guard
and
inspect
belt.
Install
new
belt
and
hand-tighten
securing
screw
in
or
out
until
proper
belt
tension
is
screws.
Reinstall
tensioning
screw,
obtained.
2
Drive
Belt
Check
belt
tension
by
pressing
belt
midway
Readjust
belt
tension
if
necessary.
Replace
between
pulleys.
Apply
about
8.5
lb
(3.9
kg)
Reinstall
belt
guard
and
run
unit
ten
minutes.
cracked
belt.
pressure
to
a
new
belt
or
5.5
lb
(2.5
kg)
pres-
Stop
unit.
Remove
belt
guard
and
readjust
3
Tensioning
Screw
suretoa
used
belt.
When
properly
ten-
belttensionifnecessary.Replacebeltguard.
OM-160
518
Page
14
Page 40
Page 41
6-7.
Overload
Protection
a
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
6
before
proceeding.
Figure
6-8.
Location
OfFlFuse
~
CAUTION
:DC
POWER
FOR
TOOLS
AND
LIGHTS
ONLY!DO
NOT
USE
AC
ONLY
RATED
TOOLS.
CONSULT
OWNERS
MANUAL!
Stop
engine.
1
Fuse
Holder
2
lOAFuseFl
Replacement
fuse
rating:
125
volts
or
greater,
10
amperes
maximum.
10
A
Fuse
Fl
protects
the
unit
from
overload
or
short
circuit
on
the
120V
dc
receptacle.
If
Fl
is
open
the
engine
continues
to
run
but
there
is
no
output
at
the
receptacle.
Weld
output
is
still
available.
120V
1OA
DC
0
Turn
fuse
holder
counterclockwise
to
remove
fuse.
Put
new
fuse
In
fuse
holder.
Push
fuse
holder
into
panel
and
turn
clockwise
to
secure.
-~-
Fl
If
fuse
continues
to
open,
contact
Factory
Authorized
Service
Sta
tion.
Ret,
ST-151
~86/Ret.
ST-157
883-A
OM-160
518
Page
15
Page 42
Page 43
6-8.
Troubleshooting
AA
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Stop
engine
before
installingorservicing.
Keep
all
panels
and
covers
securely
in
place
ENGINE
EXHAUST
GASES
can
kill.
Do
not
breathe
exhaust
fumes.
Use
in
open,
well-ventilated
areas,
or
vent
exhaust
outside
and
away
from
any
building
air
intakes.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
ENGINE
FUEL
can
cause
fire
or
explo
sion.
Stop
engine
before
fueling.
Do
not
fuel
while
smoking
or
near
sparks
or
flames.
Do
not
overfill
tank;
clean
up
any
spilled
fuel.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
Troubleshooting
to
be
performed
only
by
qualified
persons.
rwarnhl.1
11/91
Table
6-1.
Welding
Trouble
Trouble
No
weld
or
auxiliary
power
output.
-~
Remedy
Low
weld
output.
Broken
drive
belt.
Have
Factory
Authorized
Service
Station
check
generator
brushes
and
slip
rings.
-~
Section
---~
--
-..
6-6
Have
Factory
Authorized
Service
Station
check
generator.
-~
-~
6.3
Check
and
adjust
engine
speed.
Tune-up
engine
forfull
horsepow
er
(see
engine
manual).
Check
weld
cable
size
and
length.
Check
internal
and
external
weld
output
connections.
Have
Factory
Authorized
Service
Station
check
brushes
and
slip
rings.
Check
Amperage
control
settings
and
connections.
--
-~
Check
drive
belt
tension.
Low
or
high
weld
output.
-a
--
-~
6-6
Erratic
welding
arc.
Check
and
adjust
engine
speed.
Tune
up
engine
for
full
horse
power
(see
engine
manual).
Check
governor
(see
engine
manual).
Change
to
proper
electrode
polarity.
-~
6-3
-a
--
Check
and
adjust
engine
speed.
Weld
output
uncontrollable.
Check
governor
(see
engine
manual).
-a
--
-~
6-3
---
--
-~
Have
Factory
Authorized
Service
Station
check
Amperage
-~
control.
OM-160
518
Page
16
Page 44
Page 45
Table
6-2.
Auxiliary
Power
Trouble
Move
throttle
lever
to
Run
position.
--
Table
6-3.
Engine
Trouble
Tune-up
engine
(see
engine
manual).
Trouble
No
auxiliary
power.
-~
Remedy
Check
and
replace
fuse
Fl.
Erratic
auxiliary
power.
Have
Factory
Authorized
Service
Station
check
brushes
and
Slip
rings.
Have
Factory
Authorized
Service
Station
check
brushes
and
slip
rings.
Check
drive
belt
tension.
Check
and
adjust
engine
speed.
Tune-up
engine
to
achieve
full
horsepower
(see
engine
manual).
Section
-~
6-7
-
-~
--a
--
-~
6-6
-~
6-3
Low
auxiliary
power.
Check
and
adjust
engine
speed.
Perform
engine
maintenance
as
necessary
to
achieve
full
horsepower
(see
engine
manual).
Check
drive
belt
tension.
Have
Factory
Authorized
Service
Station
check
generator.
Trouble
Engine
will
not
start.
Open
fuel
shutoff
valve.
Remedy
Check
oil
level.
Check
optional
oil
level
shutdown
switch.
Check
fuel
level
in
tank.
Move
throttle
control
levertoRun
position.
See
engine
manual.
Engine
runs
rough
or
stalls.
---~
-..
--~
--~
---
Section
Figure
4-5
Figure
3-4,
Figure
4-7
Figure
3-4
Figure
4-5
Dirt
or
water
in
fuet.
Replace
fuel.
Have
Factory
Authorized
Service
Station
check
fuel
filter.
OM-160
518
Page
17
Page 46
Page 47
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16
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13312
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-
EXCITATION
PLG2/RC2
PLG3/RC3
_~jA-_~-~_-~46
E!~i~IIj
>1>
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>2>
RUNNING
PLG3/RC3
HOUR
METER
(OPTIONAL)
-a
rJJ3
IGNITION
KILL
TAB
I
I
LOW
OIL
SHUTOOWN
OIL
ENG
LEVEL
GNO
L
PLG2
RC2
POSITIVE
DC
WELD
OUTPUT
NEGATIVE
7
58-152
539-A
25
(POS)
PLG3/RC3
B
I
15-I25VDC
AUX
POWER
Figure
7-1.
Circuit
Diagram
For
Welding
Generator
Page 48
Page 49
r(~~
~
-,
I
BLK
L
r
L
I
ALTERNATOR
I
HOUSING
SP4
GR~W
silo
NEGATIVE
OUTPUT
ST-153
860-B
Figure
7-2.
Wiring
Diagram
For
Welding
Generator
Page 50
Page 51
SECTION
8-
WELDING
METHODS
&
TROUBLESHOOTING
mcd5.~
9192
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weldonclosed
containers.
Allow
work
and
equipment
to
cool
before
handling
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
touching
welded
metal.
Wear
protective
gloves
and
clothing.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Rules
at
beginning
of
manual
for
basic
welding
safety
information.
N
OTE
~
Welding
current
starts
as
soon
as
electrode
touches
the
workpiece.
1
Workpiece
Make
sure
workpiece
is
clean
be
fore
welding.
2
Work
Clamp
Place
as
close
to
the
weld
as
possi
ble.
3
Electrode
A
small
diameter
electrode
re
quires
less
current
than
a
large
one.
Follow
recommendations
of
electrode
manufacturer
when
set
ting
weld
amperage
(see
Figure
8-2).
4
Insulated
Electrode
Holder
5
Electrode
Holder
Position
6
Arc
Length
Arc
length
is
the
distance
from
the
electrode
to
the
workpiece.
A
short
arc
with
correct
amperage
will
give
a
sharp,
crackling
sound.
7
Slag
Use
a
chipping
hammer
and
wire
~
brush
to
remove
slag.
Remove
slag
and
check
weld
bead
before
making
another
weld
pass.
ST-151
593
4
4
2
7
Tools
Needed:
Figure
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
Procedure
OM-160
518
Page
20
Page 52
Page 53
w
a
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It
I
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w
-J
w
w
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a
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ow
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6010
&
6011
o
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0
0
LI)
0
0
0
0
LI)
0
LI)
I-
-
ClJ
C\i
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~
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
308L
3/16
U
~1/8
5/32
uJ
a
0
I
0
w
-J
w
a
0
z
0
I
C,)
0
0~
2
0
It
I
w
2
uJ
0~
6010
EP
ALL
DEEP
6011
EP
v
ALL
DEEP
MIN.
PREP,
ROUGH
HIGH
SPATTER
6013
E~EN
v
ALL
LOW
GENERAL
7014
EP,EN
y
ALL
MED
SMOOTH,
EASY,
FAST
7018
ER
v
ALL
LOW
LOW
HYDROGEN,
STRONG
7024
EP,EN
/
FLAT
HORIZ
FILLET
LOW
SMOOTH,
EASY,
FASTER
NI-CL
ER
ER
v
ALL
LOW
CAST
IRON
308L
/
ALL
LOW
STAINLESS
*EP
=
ELECTRODE
POSITIVE
(REVERSE
POLARITY)
EN
=
ELECTRODE
NEGATIVE
(STRAIGHT
POLARITY)
-
Figure
8-2.
Electrode
And
Amperage
Selection
Chart
Ref.
S-087
985-A
OM-160
518
Page
21
Page 54
Page 55
1
Electrode
Figure
8-3.
Striking
An
Arc
Scratch
Start
Technique
Figure
8-4.
Striking
An
Arc
Tapping
Technique
~-
<~
Figure
8-5.
Positioning
Electrode
Holder
~-
2
Workpiece
3
Arc
2
Drag
electrode
across
workpiece
like
striking
a
match;
lift
electrode
slightly
after
touching
work.
If
arc
goes
out
electrode
was
lifted
to
high.
If
electrode
sticks
to
work-
piece,
use
a
quick
twist
to
free
it.
S-0049
Ii
2
1
Electrode
2
Workpiece
3
Arc
Bring
electrode
straight
down
to
workpiece;
then
lift
slightly
to
start
arc.
If
arc
goes
out,
electrode
was
lifted
too
high.
If
electrode
sticks
to
workpiece,
use
a
quick
twist
to
free
the
electrode.
S.0050
3
1O0~3O0
\
End
View
Of
Work
Angle
Side
View
Of
Electrode
Angle
GROOVE
WELDS
0
300
10~\~
End
ViewOfWork
Angle
Side
View
Of
Electrode
Angle
FILLET
WELDS
S-0660
OM-160
518
Page
22
Page 56
Page 57
POOR
WELD
BEAD
1
Large
Spatter
Deposits
Figure
8-6.
Weld
Bead
Characteristics
Figure
8-7.
Conditions
That
Affect
Weld
Bead
Shape
2
Rough,
uneven
bead
3
Slight
Crater
During
Welding
4
Bad
Overlap
34~
5
Poor
Penetration
5
GOOD
WELD
BEAD
1
Fine
Spatter
S-0053.A
4
2
Uniform
Bead
3
Moderate
Crater
During
Welding
Weld
a
new
bead
or
layer
for
each
5
1/8
in
(3.2
mm)
thickness
in
metals
being
welded.
4
No
Overlap
5
Good
Penetration
Into
Base
Metal
S-0052-B
Angle
Too
Small
H
NOTE
~
Weld
bead
shape
is
affectedbyelectrode
angle,
arc
length,
travel
speed,
and
______________________
thicknessofbase
metal.
Correct
Angle
Angle
Too
Large
Drag
ELECTRODE
ANGLE
Li
L_]
Spatter
Too
Short
Normal
Too
Long
ARC
LENGTH
Slow
Normal
Fast
TRAVEL
SPEED
S-066
1
OM160
518
Page
23
Page 58
Page 59
1
Stringer
Bead
Steady
Movement
Along
Seam
2
Weave
Bead
SideToSide
Movement
Along
Seam
3
Weave
Patterns
Use
weave
patterns
to
cover
a
wide
area
in
one
pass
of
the
elec
trode.
Do
not
let
weave
width
ex
ceed
2-1/2
times
diameter
of
electrode.
S-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
$~
~
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
alsobeused
to
prepare
bev
els.
/
~
Create
30
degree
angle
of
bevel
on
materials
in
V-groove
welding.
4
Double
V-Groove
Weld
Good
for
materials
thicker
than
3/l6in(5mm).
9-0662
L
~~I~f
4jI~t~-
NOTE
~
Normally,
a
single
stringer
bead
is
satisfactory
for
most
narrow
groove
weld
joints;
however,
for
wide
groove
weld
jointsorbridging
across
gaps,
a
weave
bead
or
multiple
stringer
beads
work
better.
https://manualmachine.com/3
I
Figure
8-9.
Butt
Joints
I
2To3in
(51-76
mm)
~
4..
1/4in
0
(6.4
mm4
2
1
1
Vise
2
Weld
Joint
3
Hammer
Strike
weld
joint
in
direction
shown.
A
good
weld
bends
over
but
does
not
break.
1
S-0057-B
Figure
8-10.
Weld
Test
OM-160
518
Page
24
Page 60
Page 61
1
Electrode
Figure
8-11.
Tee
Joint
Figure
8-12.
Lap
Joint
8-2.
Welding
Troubleshooting
Table
8-1.
Porosity
~
Porosity
small
cavitiesorholes
resulting
from
gas
pockets
in
weld
metal.
Possible
Causes
Corrective
Actions
Arc
length
too
long.
Reduce
arc
length.
Damp
electrode.
Use
dry
electrode.
Workpiece
dirty.
.
Remove
all
grease,
oil,
moisture,
rust,
paint,
coatings,
slag,
and
dirt
from
work
surface
before
welding.
2
Fillet
Weld
Keep
arc
short
and
move
at
definite
rate
of
speed.
Hold
electrode
as
shown
to
provide
fusion
into
the
corner.
Square
edge
of
the
weld
surface.
For
maximum
strength
weld
both
sides
of
upright
section.
3
Multi-Layer
Deposits
Weld
a
second
layer
when
a
heavi
er
fillet
is
needed.
Use
any
of
the
weaving
patterns
shown
in
Figure
8-8.
Remove
slag
before
making
another
weld
pass.
S-0060
/
S-0058-A
/
S-OO61
2
1
Electrode
300
Or
Less
2
Single-Layer
Fillet
Weld
Move
electrode
in
circular
motion.
3
Multi-Layer
Fillet
Weld
1
Weld
a
second
layer
when
a
heavi
er
filletisneeded.
Remove
slag
be
fore
making
another
weld
pass.
Weld
both sides
of
joint
for
maxi
mum
strength.
Single-Layer
Fillet
Weld
Multi-Layer
Fillet
Weld
S~oo63
/S-0064
3
OM-160
518
Page
25
Page 62
Page 63
Table
8-2.
Excessive
Spatter
.
.
~.....
~
~~-
Excessive
Spatter
scattering
of
molten
metal
particles
that
cool
to
solid
form
near
weld
bead.
Possible
Causes
Corrective
Actions
Amperage
too
high
for
electrode.
Decrease
amperage
or
select
larger
electrode.
Arc
length
too
long
or
voltage
too
high
Reduce
arc
length
or
voltage.
Table
8-3.
Incomplete
Fusion
Incomplete
Fusionfailure
of
weld
metal
\
to
fuse
completely
with
base
metal
or
a
preceeding
weld
bead.
hr11
Possible
Causes
Corrective
Actions
Insufficient
heat
input.
Increase
amperage.
Select
larger
electrode
and
increase
amperage.
Improper
welding
technique.
Place
stringer
bead
in
proper
location(s)
at
joint
during
welding.
Adjust
work
angle
or
widen
groove
to
access
bottom
during
welding.
Momentarily
hold
arc
on
groove
side
walls
when
using
weaving
technique.
Keep
arc
on
leading
edge
of
weld
puddle.
Workpiece
dirty.
Remove
all
grease,
oil,
moisture,
rust,
paint,
coatings,
slag,
and
dirt
from
work
surface
before
welding.
Table
8-4.
Lack
Of
Penetration
Lack
Of
Penetration
shallow
fusion
be
tween
weld
metal
and
base
metal.
LackofPenetration
Good
Penetration
Possible
Causes
Corrective
Actions
Improper
joint
preparation.
Material
too
thick.
Joint
preparation
and
design
must
provide
access
to
bottom
of
groove.
Improper
weld
technique.
Keep
arc
on
leading
edge
of
weld
puddle.
Insufficient
heat
input.
Increase
amperage.
Select
larger
electrode
and
increase
amperage.
Reduce
travel
speed.
OM-160
518
Page
26
Page 64
Page 65
Table
8-5.
Excessive
Penetration
~.
Excessive
Penetration
weld
metal
melt
ing
through
base
metal
and
hanging
un
derneath
weld
Excessive
Penetration
Good
Penetration
Possible
Causes
Corrective
Actions
Excessive
heat
input.
Select
lower
amperage.
Use
smaller
electrode.
Increase
and/or
maintain
steady
travel
speed.
Table
8-6.
Burn-Through
Possible
Causes
Corrective
Actions
Excessive
heat
input.
Select
lower
amperage.
Use
smaller
electrode.
Increase
and/or
maintain
steady
travel
speed.
Table
8-7.
Waviness
Of
Bead
Waviness
Of
Beadweld
metal
that
is
not
parallel
and
does
not
cover
joint
formed
by
base
metal.
Possible
Causes
Corrective
Actions
Unsteady
hand.
Use
two
hands.
Practice
technique.
Table
8-8.
Distortion
Distortioncontraction
of
weld
metal
dur
ing
welding
that
forces
base
metal
to
move.
Possible
Causes
Corrective
Actions
Excessive
heat
input.
Use
restraint
(clamp)
to
hold
base
metal
in
position.
Make
tack
welds
along
joint
before
starting
welding
operation.
Select
lower
amperage
for
electrode.
Increase
travel
speed.
Weld
in
small
segments
and
allow
cooling
between
welds.
Base
metal
moves
in
the
direction
of
the
weld
bead.
Burn-Through
weld
metal
melting
com
pletely
through
base
metal
resulting
in
holes
wherenometal
remains.
OM-160
518
Page
27
Page 66
Page 67
SECTION
9
PARTS
LIST
Figure
9-1.
Main
Assembly
ST-162
841
OM-160
518
Page
28
Page 68
Page 69
Item
Dia.
Part
No.
Mkgs.
No.
Description
Figure
9-1.
Main
Assembly
Quantity
..
1
147
601
. .
CAP,
tank
screw-on
w/vent
.
1
..
2
HOSE,
(see
engine
parts
list)
.
1
.
3
CLAMP,
(see
engine
parts
list)
.
1
..
4
150
721
. .
BRACKET,
control
idle
1
..
5
150
720
. .
BRACKET,
tank
fuel
.
1
020
279
.
.
CLAMP,
stl
cush
.75Odia
x
.281
hole
.
1
.
6
. . .
..
150
123
. .
MOUNT,
sgl
stud
1.000dia
.312-18
stud
.750
high
4
..
7
.
. .
..
152
756
.
.
BRACKET,
mtg
eng/gen
.
1
..
8
. . . .
+148
975
. .
BRACKET,
adjustment
alternator
.
1
. ...
152
452
. .
HANGER,
cable
2.750Ig.625dia
nyl
.
1
..
9
. . .
..
146
994
. .
LABEL,
warning
moving
parts
can
cause
serious
injury
....
.
1
..
10
148976
. .
PULLEY,Vsglgrv6.75Odiax6.000Px.625
bore
.
1
..
11
150
412
. .
BELT,
V
cogged
.500
widex.343
deep
x
32.300
Ig
1
..
12
146
280
. .
LABEL,
warning
general
precautionary
1
.
13
151
209
. .
LABEL,
warning
engine
exhaust
sparks
can
cause
fire
1
.
14
+148
971
. .
GUARD,
belt
drive
.
1
..
15
601
965
.
.
SCREW,
.375-16
x
1.000
hexhd
1
..
16
602 213
. .
WASHER,
lock
sti
split
.375
1
..
17
602 243
.
.
WASHER,
flat
stl
std
.375
2
..
18
148
966
.
.
RETAINER,
adjuster
belt
1
..
19
150
217
.
.
SCREW,
.437-14
x
4.000
hexhd
1
..
20
602 215
. .
WASHER,
lock
sti
split
.437
1
..
21
...
PLG2,3
..
135
134
. .
CONNECTOR,
rect
9P/S
plug
Amp
350720-1
2
113
633
. .
CONNECTOR,
rect
pin
20-1
4ga
Amp
350218-1
9
22
150708
. .
GENERATOR,
(consisting
of)
1
23
RC2
.
..
135
133
.
..
CONNECTOR,
rectgP/S
rcpt
Amp
1-641765-0
1
114066
. .
.
CONNECTOR,
rect
skt
20-l4ga
Amp
350536-1
9
150
496
. . .
PULLEY,
V
sgl
grv
3.75Odiax3.500Px.670
bore
1
150497
.
..
SPACER,fan
1
150
498
. . .
FAN,
generator
6.469dia
1
150
502
. . .
BEARING,
ball
1
150
503
. . .
BEARING,
roller
1
150
506
.
..
BRUSH
HOLDER
ASSEMBLY,
generator
1
24
155063
..
BASE
1
25
148
965
. .
SCREEN,
handle
base
1
26
Fig
9-3
. .
PANEL,
control
w/components
1
27
155
797
.
.
LABEL,
caution
use
no
hooks
or
slings
2
28
+157
906
. .
HANDLE,
front/rear
2
29
SR3
.
..
150
567
. .
RECTIFIER,
positive/negative
(consisting
of)
1
30
150
216
.
..
BRACKET,
mtg
rectifier
1
31
150344
.
..
INSULATOR,
rectifier
1
.
.
32
150
127
.
..
RECTIFIER,
negative
half
3
phase
full
wave
1
.
.
33
026
947
.
..
STAND-OFF,
insul
.250-20
x
1
.000
Ig
x
.31
2thd
2
.
.
34
150
128
.
..
RECTIFIER,
positive
half
3
phase
full
wave
1
. .
35
150
130
.
.
TUBING,
stl
.625
OD
x
l2ga
wallx1.125
2
. .
36
127
596
.
.
WASHER,
flat
stl
.344
ID
x
1.500
OD
x
.l25thk
2
.
.
37
RC3
.
..
135
133
. .
CONNECTOR,
rect
9P/S
rcpt
Amp
1-614765-0
1
114
066
. .
CONNECTOR,
rect
skt
20-l4ga
Amp
350536-1
9
. .
38
Fig
9-2
. .
PANEL,
front
w/components
1
. .
39
157
907
. .
CABLE,
w/electrode
holder
(consisting
of)
1
.
.
40
129
527
.
..
CONNECTOR,
twlk
insul
male
(Dinse
type)
50
Series
.
1
.
.
41
600
681
.
..
SPLICE,
prl
4
wire
2
.
.
42
010
521
.
..
WIRE,
tie
2
.
.
43
600
325
.
..
CABLE,
weld
cop
strd
No.
6
(orderbyft)
2Oft
.
.
44
040 234
.
..
AF-2
HOLDER,
electrode
200A
1
OM-160
518
Page
29
Page 70
Page 71
Description
Quantity
Figure
9-1.
Main
Assembly
(Continued)
CABLE,
w/g
round
clamp
(consisting
of)
CLAMP,
ground
200A
INSULATOR,
vinyl
CABLE,
weld
cop
strd
No.
6
(orderbyft)
WIRE,
tie
SPLICE,
prl
4
wire
CONNECTOR,
twlk
insul
male
(Dinse
type)
50
series
WRENCH,
hex
5mm
short
ENGINE,
Kohler
gas
(consisting
of)
AIRFILTER
SWITCH,
oil
low
level
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
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
Part
of
042
769
Optional
Automatic
Low
Oil
Shutdown
Kit.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
No.
Mkgs.
Part
No.
45
157908
46
010368
47
026843
48
600325
49
010521
50
600681
51
129527
134746
52
147552
067101
53
Si
..
+154656
54
147544
55
152460
56
152583
57
150126
137690
1
1
2
2Oft
1
1
1
1
1
1
1
1
1
1
6
1
OM-160
518
Page
30
Page 72
Page 73
ST-162
642
Figure
9-2.
Panel,
Front
w/Components
*Recommended
Spare
Parts.
Part
of
042
769
Optional
Automatic
Low
Oil
Shutdown
Kit.
Part
of
042
781
Optional
Running
Hour
Meter.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Part
No.
Description
No.
Mkgs.
Figure
9-2.
Panel,
Front
w/Components
(Fig
9-1
Item
38)
Quantity
..
1
Ri
.
.
..
150765
.
.
RHEOSTAT,
WW25W
10/40
ohm
1
..
2
154663
. .
PANEL,front
1
..
3
CS
..
..
152537
.
.
CAPACITOR
1
..
4
154
654
. .
NUT,
speed
push-on-type
.500
stud
1
..
5
RC1
.
..
604
176
. .
RECEPTACLE,
str
dx
grd
2P3W
iSA
125V
1
073
690
.
.
PLUG,
str
grd
armd
2P3W
iSA
125V
P
&S5266DF
..
6
...
Neg,Pos
..
129
525
. .
RECEPTACLE,
twlk
insul
fern
(Dinse
type)
50/70
series
..
2
..
7
601
836
. .
NUT,
brs
hex
.250-20
jam
hvy
3
..
8
010
915
. .
WASHER,
flat
brs
.250
ID
x
.625
ODx.O3lthk
2
..
9
.
. . .
C3,4
.
..
131
646
. .
CAPACITOR
ASSEMBLY
1
..
10
046 432
. .
HOLDER,
fuse
mintr
1
..
11
Fl
. .
.
*012
655
. .
FUSE,
mintr
cer
1OA
250V
1
..
12
063030
. .
STUD,
brs
.250-20x1.750
1
..
13
097
924
. .
KNOB,
pointer
1
..
14
154
653
. .
LIGHT,
md
red
lens
low
oil
level
1
..
15
NAMEPLATE,
(order
by
model
and
serial
number)
1
..
16
HM
.
154
081
. .
METER,
hour
4-4OVDC
1
3
2
4
5
16
13
6
7
8
12
11
10
9
OM-160
518
Page
31
Page 74
Page 75
Figure
9-3.
Panel,
Control
w/Components
(Fig
9-1
Item
26)
Figure
9-3.
Panel,
Control
w/Components
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
..
1
148
967
. .
COVER,
(consisting
of)
1
137
198
. . .
NUT,
insert
10-24
3
.
2
087
111
.
CLAMP,
capacitor
1
.375dia
clip
2
.
3
.
...
01,2
...
149
243
.
CAPACITOR,
elctlt
950uf
100VAC
2
..
4
..
SRi
,2,4
.
035 704
. .
RECTIFIER,
integ
40A
800V
3
.
5
.
.
R3,4,VR1,2.
151
530
. .
SUPPRESSOR
2
..
6
R2
....
149244
.
.
RESISTOR,WWadj25W3ohm
1
..
7
152
534
. .
PANEL,
mtg
components
1
..
8
R3
....
153
064
. .
RESISTOR,
WW
adj
lOW1ohm
1
-1
(
7
2
6
5
4
3
ST.151
475
OM-160
518
Page
32
Page 76
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