Miller Electric 3000 User Manual

Millerfi

March1993

Form:

OM-160518

~.

r.~1~Ic4...1

-



1

~.w











OWNERS

MANUAL

Effective

~_

~



I











With

Serial

No.

KD398640

coven

5/92ASt-161



Read

safety

Have



install,

Call



the

477













and

follow

blocks

trained

only

operate,

distributor

your

directions.

Gold

CC/DC

Welding

For

SMAW

90

Amperes,

1.2

kVA/kW

CH5+

Kohler

these

or

Low

and

service

if

you

Optional

carefully.

SealTM

Generator

Welding

VoltsDCAt

25

DC

Auxiliary

Air-Cooled,

Pressure

Oil

instructions

qualified

unit.

this

do

understand

not

60%

Power

Four-Cycle,

Shutdown

and

all

persons

Model

Duty

With

Overload

Gasoline

Switch

Cycle

3000

Protection

Engine



Give



For



or:

1079,

this

manualtothe

call

help,

MILLER

Appleton,

your

ELECTRIC

WI

operator.

distributor

Mfg.

54912

P.O.

Co.,

414-734-9821

PRINTEDIN~SA

Box

s

a

u

LIMITED

Co.,

MIg.

MILLER

in

tects
RANT?

IMPLIED,

NESS.

Within
ranted
MILLER

which

followed.

MILLER

event

start

on

and

are

1.

5

*

3

2.

*





*

2

3.



I

4.

*

*

*



*



*





*

5.

6

90

6.

*

*

*

the

pans

lime

of

MILLERS

This

limited

WARRANTY

Appleton.

equipment

material

IS

INCLUDING

must

shall
suchafailure

the

as

Yearn

Yearn

YearsPans

Year

Months

Days



Wisconsin,

sold

end

workmanship

EXPRESSLY

periods

warranty

or

components

notified

be

will

MILLER

honor

warranty

date

that

the

follows:

Pans3

main

Original



Pans

Transformer/Rectifier

Arc

Plasma
Semi-Automatic

Robots

Driven

Engine
(NOTE:

Engines



Pans

and

Driven

Motor

Controllers

Process

Coolant

Water

HF

Units

Grids

Welders

Spot

Banks

Load
SDX

Transformers

Gear/Trailers

Running

Fietd

Options

Field

(NOTE:

period

warranty



one

yaar



Batteries



Pans

Guns/TIG

MIS

Plasma

Cutting

Remote

Controls

warranty

Subject

sfter

the

IN

LIEU

THE

WARRANTIES

listed

that

in

writing

instructions

provide

claimsonwarranted

within

the

equipment

Years

Labor

power

and

Labor

Power

Cutting

and

and

Labor

Welding

are

Labor

Guns

Systems

options

ol

the

whichever

and

Labor

Torches

Torches

supersedes

the

to

terms

wsrrsnts

effective

at

the

OF

ALL

below,

tall

duetosuch

within

warranty

was

rectifiers

Power

Automatic

Generators

warranted

covered

are

product

is

greater.)

(Equipment

end

its

to

dateofthis

timeitis

OTHER

OF

MILLER

(30)

thiny

the

on

time

delivered

Sources

Sources

Wire

separately

under

they

TRUE

all

conditions

originsl

detectsinmaterial

periods.

Feeders

are

MILLER

previous

below,

retell

limited

warranty

shipped

MILLER.

by

WARRANTIES.

MERCHANTABILITY

will

repair

of

such

days

claim

warranty

equipment

All

warranty

the

to

original

the

by

angina

BIuenM

True

installed

in,

with

a

MILLER

purchsser

EXPRESS

or

replace

or

workmanship.

defect

procadurea

listed

retail

manufacturer.)

for

the

for

a

or

BLUETM

Effective

number

serial

endisexclusive

warranties

Electric

that

new

of

de

is

tree

WAR

THIS

OR

FIT

AND

war

any

at

failure,

or

be

to

in

the

below

lime

periods

purchaser,

remaining

of

minimum

January

MILLERS

1.

2.

3.

MILLER

CIALJINDUSTRIAL

THE USE

In
shall

writing

ment

chase

goods

will

vice

TO

ARE

TRACT,

ANY

THEORY

LIMITED

1992

1,

of

preface

withnoother

*

Accessory

*

Replacement

True

Items

furnished

trade

accessories.

any.

Consumabla

and

relays.

Equipment

that

ment

based

upon

and

necessary

of

outside

PRODUCTS

AND

01

the

avant

MILLERS

at

ba,

MILLER

by

authorized

alan

(lass

price

customers

at

ba

FOB.,

Factory

as

facility

for

went

transportation

THE

EXTENT

THE

SOLE

FOR

LIABLE

DAMAGES

RANTY,

REMEDY

OPERATION

CLUDING
FOR
FURNISHED

Some

lasts,

the

citic

In

or

waived.

Warranty

vary

EXPRESS

PARTICULAR

slates

or

above

legal

Canada,

remedies

Irom

DIRECT,

(INCLUDING

TORT

GUARANTY

FOR

WHICH.

ANY

in

the

esciusion

liwitatlon

rights,

legislation

other

Ihe

limitations

provides

province

WARRANTY

KC

or

newer)

Kits

Pans

Limited

MILLER,

by

These

has

bean

been

improperly

standards,

maintenance,

ARE

INTENDED

AND

claim

option:

(1)

appropriate

MILLER

depracialion

risk

and

expense.

atAppleton,

of

costs

EXCLUSIVE

INDIRECT,

LOSS

OTHER

NOT

OR

REPRESENTATION

OF

FOR

THIS

CUSTOM

WARRANTY

EXCLUDED

IS

do

not

of

incidental,

exclusion

other

rights

in

some

and

exclusions

legal

province.

or

Warranty

items

modilied

service

any

WITH

provinces

guerantees

BiuanM

components;

that

has

industry

the

spacifications

USERS

MAINTENANCE

a

warranty

in

reasonable

determinedbyMILLER.

PERMITTED

AND

ANY

OR

WARRANTY

BREACH

BUT

OF

LAW.

IMPLIED

PURPOSE.

BY

MILLER

the

U.S.A.

or

and

thanasstaled

specific

to

warranties

shall

but

manufactured

coveredbythe

are

such

contact

as

by

any

installed,

or

aquipmenl

or

equipment

br

the

equipment.

FOR

PURCHASE

PERSONS

OF

WELDING

covaradbythis

repair;or(2)

the

cases.

(3)

station;

based

MILLERS

Wisconsin,

Therefore

kind

will

BY

THE

LAW,

REMEDIES.INNO

INCIDENTAL

SPECIAL.

OF

PROFIT).

LEGAL

THEORY.

PROVIDED

CONTRACT

PROVISION,

TRADE

OF

OF

RESPECT

AND

allow

limitations

indirect,

special

not

apply

may

be

available,

may

provides

and

herein,

set

out

and

other

rights,

or

eapressed

not

to:

apply

others,

by

manufacturers

tips,

cutting

other

party

improperly

which

which

han

AND

TRAINED

AND

EOUIPMENT

warranty,

replacement;

reasonabia

or

(4)

payment

actual

upon

optionofrepair

P.0.6.

at

or

a

no

compensation

be

allowed.

REMEDIES

EVENT

WHETHER

HEREIN

AND

AS

TO

PERFORMANCE,

TORT

DR

MIGHT

ARISE

OR

COURSE

MERCHANTABILITY

ANY

TO

DISCLAIMED

of

how

or

consequential

This

to

you.

but

may

br

certain

to

the

astant

above

may

rights

may

Implied.

nozzles,

than

operated

has

not

bean

USE

the

where

or,

cost

oforcredit

usa)

MILLER

PROVIDED

OR

ANY

ANY

AND

an

long

warranty

vary

additional

that

not

be

such

MILLER.

EXPERIENCED

eacluniva

of

SHALL

CONSEOUENTIAL
BASED

BY

OF

ALL

BY

from

apply.

available,

as

anginea

warranty,

conlaclorn

or

equip

misused

or

had

reasonable

used

for

operation

BY

COMMER

remedies

authorized

repairorreplace

for

the

return

or

replacement

authorized

raimburse

or

HEREIN

MILLER

ON

IMPLIED

AND

OTHER

IMPLICATION,

DEALING.

OR

FITNESS

EOUIPMENT

MILLER.

implied

warranty

damages,

provides

stale

to

warranties

they

may

This

but

of

CON

WAR

LEGAL

stale.

not

Limited

upon

or

it

IN

in

pur

the

ser

BE

ANY

IN

ao

spa

ba

may

I

_____________________________

Before

with

the

Transportation

When

the

USe

or

namep(ate.

unpacking

delivering

Department.

requesting

following

equ(pment,

carrier.

infDrmation

to

spaces

Model

Serial

DateofPurchase

check

Assistance

about

record

__________

or

Style

carton

this

Model

for

any

for

or

filing

equipment,

Designation

No.

RECEIVING-HANDLING

damage

settling

always

and

that

provide

Serial

may

claims

or

have

may

Mode)

Style

occurred

be

obtained

Designation

Number

of

during

from

your

Shipment.

distributor

and

Serial

The

unit.

File

and/or

or

Sty(e

information

claims

any

equipment

Number.

is

located

for

loss

manufacturers

the

on

or

damage

rating

label

miller

r

I

5192

March

1

993

Form:

OM-160

518

1~oIsfi

OWNERS

MANUAL

Effective

(jJOJ1

With

Serial

cI~j\r~J~

No.

KD398640

cover

8/92



ST-161

PAW



CC/DC

Welding



For

SMAW

U

90

Amperes,

U

1.2

kVAJkW



Kohler

CH5+



Optional

U

Read

and

follow

blocks

safety

Have

U

U

477

only

install,

operate,

Callyourdistributorifyoudonotunderstand

the

directions.

these

carefully.

trained

or

and

service

Generator

Welding

VoltsDCAt

25

DC

Auxiliary

Air-Cooled,

Low

Oil

Pressure

instructions

qualified

this

unit.

Power

Four-Cycle,

and

persons

60%

With

Shutdown

all

100

Duty Cycle

Overload

Gasoline

Switch



rt~i

Protection

Engine

U

Give

U

For

U

or:

1079,

this

manualtothe

call

help,

MILLER

Appleton,

distributor

your

ELECTRIC

WI

operator.

Mfg.

54912

P.O.

Co.,

414-734-9821

PRINTED

Box

IN

~SA

PROTECT

AWAY.
In

welding,

information

safety

Safety

HAVE

Standards

ALL

QUALIFIED

1.

Do

not

Wear

2.

Insulate

3.

mats

4.

Disconnect

servicing

a

YOURSELF

PACEMAKER

in

as

INSTALLATION,

PEOPLE.

ELECTRIC

Touching

severe

or

electrically

power

when

live

wire

welding,

all

and

electrically

grounded

live

touch

hole-free

dry,

yourself

covers.

or

input

this

equipment.

ARC

WARNING

most

jobs,

given

listed

live

burns.

live

circuit

power

metal

live.

equipment

electrical

insulating

from

power

WELDING

AND

WEARERS

exposure

below

the

on

SHOCK

electrical

The

whenever

and

machine

is

on.

the

wire,

parts

Incorrectly

parts.

gloves

work

and

or

stop

OTHERS

KEEP

is

only

next

page.

OPERATION,

can

can

parts

electrode

the

output

internal

In

semiautomatic

wire

reel,

installed

hazard.

a

and

ground

engine

the

body

touching

is

FROM

AWAY

certain

to

a

summary

Read

kill.

cause

work

and

is

circuits

drive

welding

or

protection.

using

dry

before

SAFETY

POSSIBLE

UNTIL

hazards

of

the

and

follow

MAINTENANCE,

fatal

shocks

is

circuit

The

on.

input

also

are

automatic

or

roll

housing,

wire

are

improperly

insulating

installing

or

SERIOUS

CONSULTING

occurs.
more

Welding

complete

all

Safety

AND

5.

Properly

Owners

When

6.
conductor

7.

Turn

Do

8.
cables.

Do

9.

Ground

10.

11.Donot

12.

Use

damaged

Wear

13.

14.

Keep

PRECAUTIONS

ARC

WELDING

Standards.

REPAIR

install

Manual

making

off

all

not

use

not

wrap

the

touch

only

a

safety

all

panels

INJURY

YOUR

is

safety

first.

equipment

cables

workpiece

well-maintained

parts

DOCTOR.

safe

information

WORK

and

and

input

worn,

electrode

at

once.

harness

and

OR

when

ground

national,

connections,

when

damaged,

around

to

a

if

in

if

working

covers

be

can

DEATH.

hazardous.

KEEP

precautions

will

that

PERFORMED

this

equipment

and

attach

use.

body.

electrical

with

the

floor

above

local

(earth)

Repair

state,

in

not

undersized,

your

good

contact

equipment.

securelyinplace.

CHILDREN

taken.

are

be

found

ONLY

according

codes.

proper

or

poorly

ground.

work

or

level.

The

in

the

BY

to

grounding

spliced

ground.

or

replace

its

1.

Use

1.

Keep

If

2.

inside,

remove

If

ventilation

3.

4.

Read
manufacturers

and

1.

Protect

Do

2.
Remove

3.

this

4.

Be

approved

your

ventilate

welding

the

cleaners.

yourself

weld

not

all

not

is

alert

that

through

RAYS

ARC
NOISE

Arc

heat
and

rays

and

skin.

can

from

strong

Noise

hearing.

ear

plugs

FUMES

to

your

produces

Welding

fumes

and

out

head

the

fumes

is

poor,

Material

instruction

WELDING

and

Sparks

sparks

flying

workpiece,

Accidental

burns.

metal

to

fire.

possible,

and

where

flying

flammables

welding

small

objects

tightly

FLYING

cause

Chipping

cool,

injury.

and

they

can

damage

the

welding

ultraviolet

from

or

ear

AND

GASES

health.

fumes

can

gases

of

fumes.

the

and/or

area

and

gases.

use

an

approved

Data

Safety

for

can

spatter

and

and

hot

contactofelectrode

can

from

others

sparks

within

cover

and

sparks

cracks

SPARKS

grinding

throw

can

burn

hearing.

process

rays

some

processes

muffsifnoise

can

and

be

hazardous

Do

not

use

air-supplied

Sheets

consumables,

metals,

cause

off

from

fly

hot

metal,

equipment

cause

sparks,

flying

strike

can

ft

35

(10.7

them

with

hot

materials

and

openings

AND

cause

off

slag.

eyes

that

be

gases.

breathe

exhaust

(MSDS5)

fire

the

weld

can

sparks

flammable

of

m)

approved

HOT

flying

and

produce

burn

can

can

damage

level

is

high.

hazardous

Breathing

health.

to

your

the

fumes.

the

at

respirator.

and

coatings,

or

explosion.

arc.

welding

spatter,

fires

cause

orwelding

overheating,

and

hot

material.

the

welding

covers.

from

welding

to

adjacent

METAL

As

metal.

skin;

intense

eyes

these

arc

the

The

hot

and

wire

metal.

arc.

can

areas

can

welds

RAYS

ARC

2.

Wear

a

ANSI

Z49.

when

eyes

Wear

3.

4.

5.

5.

Use

protective

and

glare;

Wear
material

Work

approved

protective

in

wearing

welding
breathing

Do

weldinlocations

not

6.

operations.

form

to

7.

Do

not

cadmium
weld

highly

area,

wearing

containing

for

Watch

5.

Be

6.

aware

can

cause

weld

Do

not

7.

or

8.

Connect

practical

unknown

Do

9.

not

use

Remove

10.

If

11.

1.

2.

contact

Wear

shirt,

Wear

Wear

oil-free

cuffless

approved

recommended.

proper

helmet

welding

listed

1

welding

safety

screens

others

warn

and

(wool

confined

a

an

air-supplied

can

displace

air

is

safe.

The

heat

toxic

weld

tip

coated

on

steel,

plated

the

area

an

air-supplied

these

and

fire,

that

welding

fire

on

closed

on

work

cable

to

prevent

and

paths

welder

stick

electrode

when

protective

trousers,

body

in

Safety

or

clothing

leather)

space

and

elements

keep

the

to

welding

causing

to

not

face

protection

with

fitted

Standards)

watching.

glasses.

barriers

or

watch

not

to

made

and

only

respirator.

air

causing

near

degreasing,

and

of

rays

irritating

gases.

metals,

unless

the

is

well

ventilated,

respirator.

can

give

fire

a

extinguisher

a

on

ceiling,

hidden

side.

containers

workasclosetothe

the

current

electric

frozen

thaw

from

in

holder

use.

garments

shoes,

high

shield

or

to

a

proper

to

Side

shields

to

protect

the

arc.

from

durable,

foot

protection.

if

itiswell

Shielding

or

injury

the

arc

can

such

as

coating

and

The

coatings

off

toxic

floor,

suchastanks

from

traveling

shock

pipes.

cut

or

such

as

and

a

safety

goggles.

skin.

protect

shadeoffilter

protect

your

recommended.

others

from

flame-resistant

ventilated,

gases

death.

Be

react

or

with

cleaning,

galvanized,

is

removed

if

necessary,

and

any

if

fumes

nearby.

bulkhead,

or

or

drums.

welding

long,

and

fire

hazards.

off

welding

leather

gloves,

cap.

Side

(see

face

and

flash

while

or

for

used

the

sure

spraying

to

vapors

or

lead,

from

the

while

metals

welded.

partition

area

as

possibly

wire

at

heavy

shields

srI

9/92

IL~c

Protect

mechanical

2.

Install

and

them

to

prevent

CYLINDERS

Shielding

pressure.
gas

process,

compressed

shocks,

secure

a

stationary

gas

If

damaged,

cylinders

be

sure

gas

and

cylinders

support

arcs.

fallingortipping.

can

explode

cylinders

a

cylinder

are

normally

to

treat

cylinders

in

an

upright

or

equipment

contain

them

from

if

damaged.

under

gas

can

explode.

of

the

part

carefully.

excessive

position

by

cylinder

high

Since

welding

heat,

chaining

to

rack

3.

Keep

circuits.
Never

4.

Use

5.

fittings

associated
Turn

6.

7.

in

8.

associated

cylinders

allow

only

designed

face

protective

Keep

use

or

Read

and

Standards.

a

welding

correct

shielding

for

parts

from

away

cap

connected

follow

equipment,

from

away

electrode

the

specific

in

good

valve

in

place

for

use.

instructions

and

any

to

cylinders,

gas

application;

condition.

outlet

when

over

on

CGA

publication

welding

touch

any

regulators,

opening

valve

except

compressed

other

or

cylinder.

maintain

cylinder

when

gas

P-i

listed

electrical

and

hoses,

and

them

valve.

cylinder

cylinders.

in

Safety

is

1.

securely

2.

Keep

Stop

a

ENGINE

Engines

ENGINE

explosion.

Engine

MOVING

Moving

cut

fingers

all

doors,

in

place.

before

me

en

SPARKS

TO

burn

Batteries

gases.

WARNING

EXHAUST

produce

fuel

parts,

panels,

EXPLODE;

eyes

harmful

FUEL

is

PARTS

and

highly

such

hands

covers,

can

flammable.

can

as

fans,

and

installingorconnecting

cause

can

BATTERY

skin,

and

contain

acid

GASES

exhaust

cause

cause

rotors,

catch loose

and

guards

BATTERY

and

generate

can

gases.

injury.

and

closed

unit.

ACID

kill.

fire

or

belts

can

clothing.

and

GASES

can

explosive

1.

Use

If

2.

away

1.

Stop

2.

Do

open
Allow

3.

fuel

Do

4.

Do

5.

engine.

Have

3.
maintenance

To

4.

negative

5.

Keep

parts.

Reinstall

6.
finished

1.

Always

2.

Stop

cables.

Do

3.

4.

Do
Observe

5.

ENGINES

equipment

in

used

from

engine

add

not

flames.

engine

cold

to

overfill

not

not

spill

only

prevent

hands,

and

wear

engine

allow

not

not

use

outside

closed

a

building

any

before

while

fuel

cool

to

engine

tankallow

fuel.Iffuel

qualified

and

troubleshooting

accidental

battery

()

loose

hair,

or

panels

before

face

a

before

tools

to

welder

correct

polarity

be

in

air

open,

vent

intakes.

hazardous.

or

can

area,

checking

smoking

before

fueling.

before

beginning

room

is

spilled,

remove

people

starting

from

cable

clothing,

and

guards

starting

engine.

when

shield

disconnecting

cause

sparks

charge

(+

batteries

and

to

well-ventilated

exhaust

engine

fuel.

adding

if

unit

is

or

near

If

possible,

job.

for

fuel

to

clean

up

guards

as

necessary.

during

servicing,

battery.

and

tools

close

doors

on

working

or

connecting

when

working

or

iump

batteries.

on

)

areas.

any

check

expand.

before

or

away

when

a

battery.

start

and

outside

sparks

and add

starting

covers

disconnect

from

moving

servicing

battery

on

a

battery.

vehicles.

or

for

is

4

~

(.~

~

.

~

The

SafetyinWelding
Welding

Safety

dent

D.C.

Recommended

Cutting

can

ciety,

National
tection

Sri

Society,

and

of

Documents,

20402.

of

Welding

550

Electrical

Association,

9/92

Health

Safe

Containers

Society

N.W.

LeJeune

STEAM
COOLANT

skin.

coolant

under

pressure.

and

Cutting,

N.W.

550

Standards,

U.S.

Practices

That

Standard

Rd,

Code,

Batterymarch

AND

can

in

the

ANSI

LeJeune

OSHA

Government

for

Have

Held

AWS

Miami,

NFPA

Standard

PRESSURIZED

burn

radiator

Standard

MiamiFL33126

Rd,

CFR

29

Printing

the

Preparation

Hazardous

from

F4.i

FL

33126

70,

Park,

Quincy,

face,

eyes,

be

can

very

PRINCIPAL

from

Z49.1,

from

1910,

Office,

Washington,

for

Welding

Substances,

American

from

National

MA

Welding

02269.

HOT

and

h

and

ot

SAFETY

American

Superinten

and

Ameri

So

Fire

Pro

1.

Do

cool.

to

2.

Wear

Allow

3.

STANDARDS

Safe

Handling

from

P-i,

Suite

way,

for

Code

Canadian

levard,

Safe

tion,

Institute,

Cutting

Fire

Safety

Rexdale,

Practices

ANSI

1430

And

Protection

not

remove

and

gloves

pressure

of

Compressed

Compressed

501,

Arlington,

in

Standards

Welding

Association,

Ontario,

ForOccupationAnd

Standard

Broadway.

Processes,

Welding

Association,

radiator

a

put

to

escape

Gas

Association,

VA

and

Canada

Z87.1,

New

Batterymarch

when

cap

over

rag

before

Gases

22202.

Cutting,

Standards

M9W

Educational

from

York,

NFPA

engine

area

cap

completely

in

Cylinders,

1235

CSA

Sales,

1R3.

American

NY

10018.

Standard

Park,

is

hot.

when

removing

Jefferson

Standard

178

And

Eye

National

51

Quincy,

Allow

engine

removing

CGA

Pamphlet

Davis

Wi

17.2,

Rexdale

Face

Standards

from

B,

MA

cap.

cap.

High

from

Bou

Protec

National

02269.

22334566

SECTION

SECTION

2-1.
2-2.

2-3.

2-4.

SECTION

3-1.

3-2.
3-3.
3-4.

SECTION

SECTION

5-1.

5-2.

-

1

SAFETY

2

SPECIFICATIONS

Volt-Ampere

Cycle

Duty

Fuel

Consumption

DC

Auxiliary

3INSTALLATION

Selecting

Engine

A

Prestart

Grounding

Connecting

4OPERATING

OPERATING

5

Auxiliary
Auxiliary

Power

Equipment

SIGNAL

Curves

Power

Location

Checks

The

Generator

Weld

To

DC

TABLE

WORDS

Curve

And

Output

THE

WELDING

AUXILIARY

Receptacle

Operation

OF

.

Moving

Auxiliary

Welding

Terminals

GENERATOR

EOUIPMENT

CONTENTS

Generator

Power

System

1

7

10
10

SECTION

6-1.

6-2.

6-3.

6-4.

6-5.
6-6.
6-7.

6-8.

SECTION

SECTION

8-1.
8-2.

SECTION

Figure
Figure

Figure

MAINTENANCE

6

Routine

Changing

Adjusting

Air

Clean

Drive

Overload

Maintenance

Cleaner

Air

Belt

Engine

Engine

Service

Intake

Adjustment

Protection

Troubleshooting

7

ELECTRICAL

WELDING

8-

Shielded

Welding

PARTS

9

Main

9-1.
9-2.

Panel,

9-3.

Panel,

METHODS

Arc

Metal

Troubleshooting

LIST

Assembly

Front

Control

&

TROUBLESHOOTING

Oil

Speed

And

Cooling

And

Replacement

DIAGRAMS

&

TROUBLESHOOTING

Welding

(SMAW)

w/Components

w/Components

Areas

11

12
13
13

14
14
15

16

18

20
25

28

31

32

OM.160

518

3)93



Read



Obey



Learn

SECTION

all

safety

messages

all

safety

messages

the

meaning

of

WARNING



1

throughout

avoid

to

injury.

and

SAFETY

this

manual.

CAUTION.

SIGNAL

WORDS

rnodl.1

2/93

1

2

L~

/

5

6

NOTE

7H

;

ELECTRIC

I

Do

I

Disconnect

installingorservicing.

SHOCK

touch

live

not

input

~

kill

can

electrical

parts.

power

betore~

Off

switch

Turn

SECTION

3

_______________

~

READ

Section

when

using

Figure

2

2

\

a

CAUTION



1-1.

SAFETY

3-1

high

Safety

MOVING





before

frequency.

Keep

away
all

Keep

panels

when

operating.

BLOCKS

proceeding

Information

PARTS

from

SPECIFICATIONS

______________

at

can

moving

and

start

parts,

covers

of

injure.

closed

I

I

I

1

Safety

2

Signal

WARNING

serious

or

CAUTION

or

injury

happen.

Statement

3

Result

4

Safety

Hazard

Hazard

5

6

Safety

Read

safety

bol

shown.

7

NOTE

Special



ation

Alert

Word

means

injury

means

equipment

Of

Instructions

Symbol

Banner

blocks

instructions

related

not

Symbol

possible

can

happen.

possible

damage

Hazard

(If

for

for

to

safety.

death

minor

can

And

To

Avoid

Available)

each

sym

best

oper

Specification

TypeOfOutput

Rated

Weld

Output

Amperage

Maximum

Welding

Auxiliary

Engine

Engine

Fuel

Engine

Drive

Overall

Weight

Options

Range

Open-Circuit

Process

Power

Speed

Tank

Capacity

Oil

Capacity

Belt

Size

Dimensions

Rating

(No

Load)

Voltage

Constant

90

Amperes,

40

To

Volts

75

Shielded

Welding

1.2

kW,

Kohler

1800

rpm

2.3

U.S.

22.4

oz

.343x32.3

1/2

x

See

Figure

Net:

101

See

Rear

Table

Current/Direct

25

A

100

DC

(See

Metal

Arc

(GTAW)

120

Volts

CH5+

Air-Cooled,

Idle

Speed;

(8.7L)

gal

(0.66L)

3-2

lb

(46

Cover

2-1.

Volts

Section

Welding

Possible

DC,

Cogged

kg);

Welding

Current

DC

At

60%

2-1)

(SMAW);

With

10

Amperes

One-Cylinder,

4150

rpm

113

Ship:

Generator

(CC/DC)

Duty

Cycle

Flux

Appropriate

Four-Cycle

Weld

And

lb

(51

kg)

Description

Section

(See

Cored

Arc

Process

Power

Welding

Options

Gasoline

Speed

2-2)

Engine

(FCAW)

And

Gas

Tungsten

Arc

OM-160

518

Page

1

2-1.

Volt-Ampere

Curves

Cl)

0

>

0

100

90

80

60

50

40

30

70

20

10

The

volt-ampere

minimum
and

amperage

of

the

welding

other

curves

and

generator.

settings

shown.

maximum

output

fall

curves

capabilities

between

show

voltage

Curves

the

of

the

0

0

25

50

DC

75

AMPERES

Figure

100

2-1.

Volt-Ampere

125

150

Curves

rsDl.1

10/91



SB-152

541

2-2.

EXCEEDING



Do

Duty

not

exceed

U)

w

a

<

Cycle

a

DUTY

indicated

300

250

200

150

100

75

50-

CAUTION

CYCLE

duty

cycles.

-

-

.

.

RATINGS

RATED

will

damage

OUTPUT

---

unit.

~......,

warn7.1

2/92

is

Duty

cycle

operate

without

how

within

causing

ten

a

unit

the

long

minute

period

overheating

can

or

damage.

unit

This

allowing

every

--

is

welding

10

minutes.

rated

at

6

60%

minutes

duty

cycle

out

of

OM-160

518

Page

10

2

15

20

%

25

DUTY

Figure

30

40

CYCLE

2-2.

50

Duty

60

Cycle

7080

100

Chart

sbl.2

10/91

SB-152

540

2-3.

Fuel

Consumption

The

fuel

typical

loads.

er

consumption

fuel

under

use

curve

weld

shows

or

pow

~

ci,

w

I-

1.89

1

.66

1.42

1

0.95

0.71

0.47

0.23

.18

-J

Q~

0.42

0.37

0.31

0.26

0.21

0.16

0.10

0.05

_j

ci

0.50

0.44

0.38

0.31

0.25

0.19

0.12

0.06

~

DC

-IDLE

0

0

15

DC

0.2

30

WELD

0.4
DC

Figure

AMPERES

0.6

POWER

2-3.

45

(25

KW

Fuel

60

0.8

Consumption

AUX

VOLTS)

POWER

75

1.0

90

1.2

Curve

rsb2.I

10/91SB-153

250

2-4.

DC

Auxiliary

~80

0

>

Q60

140

40

20

Power

Curve

The

dc

iliary

the

120

power

power

in

volt

shows

curve

amperes

dc

receptacle.

the

aux

available

at

0

0

2.5

5.0

DC

7.5

AMPERES

10

12.5

15

SB.152

758

Figure

2-4.

DC

Power

Curve

For

120

Volt

Receptacle

OM-160

518

Page

3

SECTION

3INSTALLATION

3-1.

Selecting

a

ENGINE



Do



Use
outside

ENGINE

fire.



Use

arrestor

laws.



A

spark

and

California,

state



Properly



Stop

before



Service

A

Location

WARNING

EXHAUST

breathe

not

in

open,

and

EXHAUST

U.S.

only

and

arrestor

in

grass,

Oregon,

and

local

maintain

engine

servicing

spark

And

GASES

exhaust

fumes.

well-ventilated

from

away

Forestry

comply

and

arrestor

building

SPARKS

Department

with

is

mandatory

or

brush,

and

authorities

the

spark

allow

exhaust

arrestor.

spark

away

Moving

can

or

areas,

air

intakes.

local,

in

in

other

arrestor.

system

from

Keep

leaks

approved

state,

all

National

covered

areas.

flammables.

unit
and

all

forest

Washington.

kill.

vent

can

and

Check

to

cool

level

possible

Welding

exhaust

cause

spark

federal

Forests

lands

in

with

down



tilting

fire

Generator

can

cause

or

engine

2

HOT

PIPE



FALLING

serious

damage.









fuel

and

damage.

2

ENGINE

can

exhaust

Keep

Lift

Unit

Have

two

Move

unit

adequate

It

using

before

skid

oil

EXHAUST

cause

fires.

and

EQUIPMENT

personal

handlesonends

at

persons

with

hand

capacity.

lift

fork

a

vehicle,

transporting.

1

2

Lift

centerof

and

3

Keep

haust

pipe

away

injury

of

adequate

cart

secure

in

18

(457

All

On

Sides

Handles

Lifting

unit

with

handles.

transport

Exhaust

flammables

outlet.

AND

from

and

of

base.

strength

similar

or

mm)

hands

unit.

Outlet

EXHAUST

flammables.

can

cause

equipment

lift

unit.

device

unit

a

on

rwarnl.1

Space

Open

positioned

Obtain

help

from

away

proper

12/91

to

ex

of

in

lift

OM-160

518

Page

Figure

3-1.

Location

~<

And

Movement

Of

The

Welding

5T-161

Generator

4771

ST-151

Inches

A

19

B

14-5/8

C

28-3/4

C

5T.161

Ref.

556/

Millimeters

483

371

730

478

>.-.~<

3-2.

Figure

4

Overall

Dimensions

200

200

Maximum
lubrication.

Keep

tilted.

Do

room

out

Do

let

fuel

leak

not

from

cap

during

tilting.

fuel

cap

overfill

not

for

expansion

causing

tilting

at

leaks.

angles

highest

fuel

tank

nd

a

for

proper

when

point



leave

with

tilting

S-0702

3-2.

.~

Engine

ENGINE

explosion.







Prestart

a

Stop

Do

not

not

Do

Checks

WARNING

FUEL

before

engine

fuel

while

overfill

tank;

Figure

can

fueling.

smoking

clean

3-3.

or

up

cause

near

any

Maximum

sparks

spilled

fire

or

fuel.

flames.

Welding

or

Generator

Tilt

REMOVE

SPRAY

under



Rotate
before

Angles

FUEL

may

pressure.

fuel

cap

removing

CAP

cause

slowly

cap.

Check

be

cold

Add

injury;

and

all

and

fresh

engine

Figure

6-1).

I

Fuel

Fill

fuel

tanktowithin

of

bottomoffiller

for

space

2

Fill

Oil

Fill

Oil

3

Remove

Reinsert

rests

cap

thread

cap

stick

and

If

oil

is

not

(see

Figure

oil

to

raise

F.

L

to

SLOWLY;

FUEL

wait

until

fluids

daily.

level

on

a

fuel

the

Cap

dipstick
dipstick

check

before

first

neck

expansion.

Cap/Dipstick

Tube

and

in

tube

to

up

6-1).

level

tube.

oil

full

Add

collar.

level.

on

on

onto

oil

may

hissing

rwarn3

Engine

surface.

time

in

1

(25

to

wipe

tube

so

Remove

mark,

4

oz

dipstick

FUEL

be

stops

1

9191

must

starting

(see

mm)

provide

off

oil.

fill

oil

Do

not

dip

add

oil

(0.12

L)

from

Figure

3-4.

Checking

Fluid

Levels

rsb4,1

OM-160

11/92ST-16l

518

Page

479

5

3-3.

Grounding

The

Generator

Auxiliary

Power

System

1

Equipment

Terminal

Grounding

The

power

to

3-4.

.~

generator

neutralisconnected

the

machine

Tools

Needed:

-.~

Connecting

.

auxiliary

frame.

a

ELECTRIC



Always



Do

not



Stop

engine



Read

To

Weld

WARNING

SHOCK

wear

dry

touch

live

before

Precautions

Safety

Figure

Output

can

insulating

electrical

gloves.

parts.

making

at

3-5.

Terminals

kill.

weld

any

beginning

Equipment

connections.

output

of

this

manual.

Grounding

Connection

rsb5.1

1/93



ST-i

Ret.

~7

863-A/Ret.

ST-I

rwarnl3,l

81

479

2/92

OM-160

518

Page

I

DC

1

2

~

Receptacle

2

DC

Negative

Positive

()

(+)

Weld

Weld

Output

Output

Receptacle

For

Direct

Current

~

~

tive

(DCEP).



Work

receptacle

cable

to

Electrode

For

Direct

tive

connections.

3

4

Align

receptacle.

rotate

Current

(DCEN),

Weld

Output

Connector

keyways

clockwise

connect

Receptacle

on

Insert

Electrode

and

+

Electrode

reverse

connector
connector

until

Posi

work

cable

electrode

receptacle.

Nega

cable

and
and

tight

to

in

receptacle.

~-

Ret.

ST-I57863-A/ST-161

Weld

Figure

6

3-6.

Output

Connections

480

SECTION

4-

OPERATING

THE

WELDING

GENERATOR

a

ELECTRIC



Do

not



Always



Insulate



Stop



Keep

WELDING



Do

not



Watch



Do

not



Do

not



Allow

ARC

NOISE



Wear



Wear

FUMES



Keep



Ventilate

=~!t?



Read

manufacturers

WARNING

SHOCK

touch

live

wear

dry

yourself

before

engine

all

panels

can

weld

near

for

fire;

keep

unit

locate

weldonclosed

and

work

RAYS

can

damage

welding

correct

AND

head

your

area,

Material

can

helmet

eye,

GASES

or

Safety

kill.

can

electrical

insulating

from

work

parts.

gloves.

and

ground.

installingorservicing.

and

covers

securely

cause

equipment

fire

flammable

extinguisher

combustible

over

containers.

to

burn

or

material.

nearby.

cool

eyes

hearing.

with

correct

and

ear,

out

of

the

use

breathing

Data

instructions

body

can

fumes.

Sheets

for

protection

be

device.

material

in

place

explosion.

surfaces.

before

handling.

and

skin;

of

shade

filter.

hazardous.

(MSDS5)

used.

and

!

~

~_.

,~

I

\

E

NGINE



Do

not



in

Use

outside

ENGINE

sion.



Stop



Do

not



Do

not

MOVING



Keep

and

rotors.



Keep

and

securely

MAGNETIC

RENTS



Pacemaker



Wearers

near

See

Safety

sic

welding

EXHAUST

breathe

open,

and

FUEL

engine

fuel

overfill

PARTS

away

all

doors,

can

should

welding

any

Precautions

safety

exhaust

well-ventilated

from

away

can

before

fueling.

while

smoking

clean

tank;

can

from

moving

panels,

in

place.

FIELDS

affect

pacemaker

wearers

keep

consult

operations.

at

information.

GASES

fumes.

areas,

building

any

cause

or

near

up

any

cause

such

parts

and

covers,

FROM

away.

their

doctor

beginning

kill.

can

vent

or

air

intakes.

fire

or

or

sparks

fuel.

spilled

injury.

as

fans,

guards

HIGH

operation.

before

of

manual

~

exhaust

explo

flames.

belts.

closed

CUR

going

for

ba

110/91

4

2

U

Figure

_______

1

Amperage

2

Engine

Low

3

4

Throttle

5

6

4-1.

Controls

3

_______

~LE~1

______

4

Choke

6

Fuel

1

Insulating

2

Safety

Shields

3

Welding

4

Hand

Wear

dry

glasses
welding

correct

a

Control

Hour

Oil

Level

Control

Control

Shutoff

Valve

ST-161

Gloves

Glasses

Helmet

Shield

insulating

with

side

helmet

or

shadeoffilter

Z49.1).

Meter

(Optional)

(Optional)

Light

Lever

477/Rel.ST-161

With

gloves,

shields,

shield

hand

(see

Side

safety

and

with

ANSI

sb3.110/91

479

a

Figure

4-2.

Safety

Equipment

OM-160

518

Page

7

Figure

4-3.

Work

Tools

Clamp

Needed:

1

Work

Clamp

Connect

work

paint-free

close

as

Use

clean

chipping

after

to

wire

metal

hammer

welding.

clamp

location

weld

brush

weld

at

on

area as

or

sandpaper

joint

to

to

a

clean,

workpiece,

possible.

area.

remove

sb4.1

to

Use

slag

2/93

Figure

4-4.

Amperage

3

Control

1

2

1

Amperage

Use

control

Engine

age.

weld/power

weld

output.

while

justed

2

Electrode

Scale

shows

trode

diameter

3

Amperage

Numbers

amperes.

Control

select

to

must

speed

Control

welding.

Scale

recommended

for

Scale

scale

in

weld

weld

be

running

to

may

amperage.

are

Ret.

amper

attain

be

welding

ST-157

at

full

ad

elec

883-A

OM-160

518

Page

1

Open

Close

or

2

Use

and

engine,

3

Use

air/fuel

to

engine.Ifstarting

move

4

Pull

smooth

After

levertoleft.

Keep

auxiliary

for

Stop

4-5.

Figure

8

Engine

Controls

Fuel

valve

valve

during

Throttle

lever

select

Choke

lever

right

choke

Starter

starter

engine

throttle

idle

speed.

unit

Shutoff

before

when

transport.

Control

to

start

engine

levertoRun.

move

Control

to

regulate

mixture.

on)

(choke

levertoleft

Handle

handle

motion.

warms,

lever

power.

by

moving

S-0690

Valve

starting

unit

Lever

and

speed.

Lever

Move

if

starting

a

warm

move

in

Run

Move

lever

Ret.

/

engine.

is

in

not

stop

engine

To

carburetor

choke

a

engine,

(choke

with

quick,

choke

for

lever

to

to

ST-161

use

start

lever

cold

off).

weld/

Idle

Stop.

478

6

1

Use

hours

erates

Engine

meter

(see

only

Hour

check

to

Section

when

Meter

total

This

6).

engine

operating

meter

op

is

running.

rsb6.1

2/92

Figure

Install

&

Connect

EquIpment~)

)

________________

_____

)

________________

_____

Insert

Electrode

Into_Holder

Select

Electrode

Begin

_________________

Figure

4-6.

Engine

Hour

1

Q~

LOW

4-7.

_____ _____

Weldin~

OIL

Automatic

Put

Personal

Equipment

On

Safety

Low

I

~~JJ

I

Meter

(Optional)

Shutdown

ControI~~)

(Optional)

Start

________________

_____

Oil

Set

Low

I

flickers

Light

pulled

automatic

Engine

is

added

oil

Fill

engine

stick

(see

Eng~~Uia~)__..)

Oil

Level

when

if

does

engine

low

not

to

with

has

oil

engine.

oil

Figure

~g~pmen~,~

Light

starter

stopped

level

start

F

to

3-4).

handle

shutdown.

until

sufficient

mark

Ref.

ST-157

rSbO.1

due

on

is

to

dip

863

~-

9/92

Figure

4-8.

Sequence

Of

Shielded

Metal

Arc

Welding

(SMAW)

OM-160

518

Page

9

SECTION

5-

OPERATING

AUXILIARY

EQUIPMENT

5-1.

a

ELECTRIC



Do



Stop

reconnection.



Ground

national,



Connect

earth



Do

normally

ELECTRIC



If

using

disconnect
electrode

hazards.



Watch



Keep

use

The

weld

when

the

Auxiliary

WARNING

SHOCK

touch

not

engine

generator

state,

equipment

ground.

not

connect

supplied

SPARKS

auxiliary

both

from

fire.

for

fire

a

extinguisher

it.

output

engine

Power

live

electrical

before

and

to

any

by

welding

causing

terminals

is

running.

DC

making

according

local

grounding

power

kill.

can

parts.

internal

inspection

all

to

codes.

terminal

electrical

utility

distribution

power.

can

cause

and

only

cables

electric

and

nearby,

are

electrically

to

shock

not

know

Receptacle

applicable

to

a

proper

system

fire.

welding,

prevent

and

how

energized

or

live

fire

to

,~-.

X

~

~

cii

0

MOVING

injury.



Keep

away

and

rotors.



DC

electrical
incorrect





Essentially

motors.

duty
speed

This

auxiliary

lights

AC/DC

power

all

Keep

and

securely

AUXILIARY

DC

Use

rated

tools

Do

not

use

equipment,

However,

tools

may

tools

unit

provides

power.

and

portable

DC

or

AC-only

any

PARTS

from

moving

doors,

panels,

in

place.

POWER

equipment

operation.

only

output

for

DC.

DC

to

power

induction

or

all

hand

tools

the

damaged

run

only

1200

DC

power

power

rated

switches

This

be

will

ratings.

can

cause

such

parts

covers,

for

incandescent

AC

motors,

motors.

are

powered

on

DC

by

full

at

speed

of

watts

is

suitable

with

tools

must

power

equipment.

serious

as

fans,

belts,

and

can

and

inexpensive/light

power,

on

direct

for

115or120

closed

guards

damage

cause

lights

transformer

universal

by

and

variable

DC.

current

incandescent

be

used

not

rwarn8.1

and

(DC)

volt

10/92

to

Figure

5-1.

Auxiliary

Power

DC

Receptacle

1

120V

Maximum

1.2

kW.

able

only

DC

power

cent

lights

tools

with

DC

ratings.

2

pensive/light
damaged

able

speed

speed

Use

DC

cent

lights

Do

not

AC-only

transformer

tors,

duction

2

lOAFuseFi

Fl

protects

load

or

tacle.IfFl

continues

at

put

is

still

available.

fuse

replacement.

And

Circuit

Protection

1OA

output

Full

auxiliary

when

is

suitable
and

115

The

DC

by

tools

DC.

on

output

and

DC

use

rated

motors.

generator

circuits

short

opens,

to

run

the

receptacle.

DC

Receptacle

RUN

at

power

not

welding.

for

incandes

portable

120

volt

or

duty

only

tools

AC/DC

switchesoninex

tools

power,

will

run

only

for

incandes

rated

to

power

equipment,

equipment,

from

dc

on

the

generator

but

there

Weld

See

Section

Ret.

ST.157

speed

is

avail

power

may

and

at

for

run

AC

recep

is

no

output

6-7

vari

or

over

863-A

full

DC.
any

mo

out

is

or

be

in

for

5-2.

OM-160

Auxiliary

)

518

Page

10

Equipment

)

Figure

Operation

OnA

lnstat&Co~n~ct~)

5-2.

SequenceOfAuxiliary

)Turn

Equipment

liarY))

Operation

Begin

Ope~on

SECTION

6

MAINTENANCE

&

TROUBLESHOOTING

6-1.

The

Routine

maintenance

a

ELECTRIC



Do

not



Always



Insulate



Stop

engine



Keep

ENGINE



Do

not



in

Use

outside

Maintenance

label

WARNING

SHOCK

touch

live

wear

dry

from

yourself

before

all

breathe

open,

panels

EXHAUST

well-ventilated

and

away

is

located

and

exhaust

can

electrical

insulating

parts.

gloves.

work

installing

covers

GASES

fumes.

from

any

the

on

kill.

and

ground.

or

servicing.

securely

can

or

areas,

building

fuel

in

vent

air

tank

place.

kill.

exhaust

intakes.

above

the

throttle

ENGINE

sion.







MOVING





HOT





Maintenance

sons.

control

FUEL

Stop

engine

Do

fuel

not

while

Do

overfill

not

PARTS

hands,

Keep

parts

moving

tors.

all

Keep

and

doors,

securelyinplace.

PARTS

Allow

cooling

Wear

protective

hot

on

a

engine.

to

lever

(see

can

before

smoking

tank;

loose

such

panels,

can

period

gloves

be

performed

Figure

cause

fueling.

or

clean

up

can

cause

clothing,

as

pulleys,

covers,

cause

before

and

6-3).

fire

or

explo

near

any

sparks

spilled

flames.

or

fuel

injury.

and

tools

away

belts,

guards

burns.

when

rwarn9.I

and

closed

working

fans,

and

severe

servicing.
clothing

onlybyqualified

from

ro

per

10/91

Recommended

Check

Oil

Oil

~

.2

~5

STOP

Oil-API

Below

Above

oil

daily

Capacity
Change

Air

Filter

Air

filter

Engine

32F

32F

Service

element

RPM

~

(4

Service

(0C)

(0C)

Add

oz.

22.4

Normal

100

.

... .

Classification

SAE

5W-20,

SAE

1OW-30,

to

Full

oz.

(0.66L)

conditions

hours

or

Kohler

1506306

Miller

067101

-

IDLE

1800

RUN

(Weld&Power)

~

SF-SG/CC-CD

SAE

SAE

on

dipstick)

100

less-See

Figure

5W-30

1OW-40

hours

Manual

-

6-1.

4150

4

R~J

Maintenance

Drive
Drive

Spark
Spark

*Resistor

Fuel

Capacity

Fuel

grade

least

at

If

equipped

service

L$~

Label

Belt

Belt

plug
Plug

Spark

87

per

Inspection

Resistor

gap

Plug

U.S.

2.3

Regular



octane

with

spark

Manual

KOHLER

SPEED

100

Miller

&

Std

Champion

Mandatory

Gal

Unleaded

or

+

(RON

arrestor,

or

supplied

CH5+

CONTROL

hours

150412

.030

RCI2YC*

in

(8.7L)

MON)

inspect

instructions.

ENGiNE



See

in.

Canada

Vented

2

(.76

and

S.146

Manual

mm)

cap

281-A

OM-160

518

Page

11

Stop

engine

before

maintaining.

not

throw



take

25

~-

Do

fluids

center.

~JJ

~y~

6-4~J

away

to

area

Hours

engine

recycling

Air

Clean

Cleaner

Foam

Element

Hours

500

ED

Check

Valve

hours

Clearance

havealferna

slip

rings,

FactoryAu

by

Station.

oil

bear

shut

engInes

manual

Every200

for

brushes,

and

ings

down

thorized

optional/ow

checked

Service

6-2.

Changing

Engine

Oil

Figure

6-2.

Maintenance

Tools

Schedule

Needed:

3/8

Stop

Change

in

gine

1

Use

room

2

Remove

draining

3

Remove
for

plug.

4

Fill

mark

and

in

specifications.

Reinstall

engine.

engine

Figure

is

still

Support

blocks

for

oil

Fill

Oil

oil.

Drain

Oil

oiltodrain

Maintenance

crankcase

on

dipstick.

grade

oil

Change

warm.

Block

large

pan.

at

enough

6-1.

Cap/Dipstick

fill

oil

cap/dipstick

Plug

Allow

plug.

completely.

Label

with

new

Use

of

oil.

See

fill

oil

cap/dipstick.

interval

while

oil

to

enough

Reinstall

oil

correct

Figure

ST-I

listed

en

provide

before

time

F

to

type

6-1

for

61

481

OM-160

518

Page

Figure

12

6-3.

Changing

Engine

Oil

6-3.

Adjusting

Engine

Speed

Moving

Have
before

Parts

belt

guard

running

Hazard.

in

place

engine.

READ

Section

SAFETY

before

6

Tools

BLOCKS

Needed:

~

at

proceeding.

and

Start

1

Move

2

3

Loosen

adjustment

engine

screws.

4

If

stop

(see

5

Turn

two

and
control

plate

speed

securing

3/8,

Throttle

levertoRun.

Speed

Securing

Belt

engine

engine

Section

Speed

screw

full

start

lever

left

(see

9/32

run

Control

Adjustment

securing

plate

runs

Guard

does

and

Adjustment

out

turns.

engine.

and

or

items

screws

in

start

of

load.

at

screws

4150

remove

Lever

right

rpm.

reach

no

Plate

and

move

left

or

Tighten

4150rpm,

belt

guard

engine

Screw

at

not

6-6).

Screw

(counterclockwise)

Reinstall

right

Move

speed

to

2

and

and

belt

guard

throttle

adjustment

engine

adjust

3).

Tighten

stop

engine.

ST-161

Ref.

until

482

6-4.

Air

Cleaner

2

Service

3

Figure

4

Figure

6-4.

6-5.

Engine

Air

Cleaner

Speed

Adjustment

READ

Section6before

Maintenance

SAFETY

BLOCKS

at

proceeding.

Stop

engine.

Air

1

2

Retaining

Loosen

air

move

3

Wing

Remove

4

Foam

Wash

element

detergent.

element

Saturate

oil.

gine

Reinstall

element.

5

Paper

Replace

with

a

new

element

dirty
pressed

Reinstall

start

Cleaner

Screw

retaining

cleaner

Nut

shown.

as

Element

in

Rinse

and

allow

element

Squeeze

element

Element

or

dirty

element.

or

air.

air

cleaner

OM-160

of

Cover

screw

cover.

(Precleaner)

water

warm

all

detergent

to

air-dry.

with

clean

out

excess

on

damaged

clean

Do

cover.

518

not

with

5T-151

and

with

from

en

paper

element

wash

com

Page

re

oil.

839

13

6-5.

Clean

Air

Intake

And

Cooling

Figure

6-6.

Areas

Air

Intake

And

Cooling

Areas

6-6.

Stop

1

Remove

Remove

2

Readjust

cracked

3

Drive

Tools

Needed:

~

9/16,5/8

engine.

Guard

Belt

five

screws

guard

Drive

Belt

belt

tension

belt.

Tensioning

Belt

Adjustment

in

in

7/16

securing

and

inspect

if

necessary.

Screw

I

belt.

~

belt

Replace

guard.

And

Replacement

4

Securing

To

replace

and

loosen

Install

screws.

Check
between

pressure

to

sure

belt,

securing

belt

new

Reinstall

belt

tension

pulleys.

to

a

used

a

Screw

remove

and

tensioning

by

Apply

belt

new

belt.

READ

Section

tensioning

screw,

pressing

about

lb

5.5

or

When

Remove

belt

lb

8.5

(2.5

properly

screws.

hand-tighten

SAFETY

screw

belt.

securing

midway

kg)

(3.9

kg)

pres-

ten-

before

6

sioned,

BLOCKS

proceeding.

belt

deflects

at

inward

start

about

of

Ref.

ST-161

1/8

482

in

(3

mm).

Adjust

screw

obtained.

Reinstall

unit.

Stop

in

or

belt

Remove

out

until

guard

and

belt

by

proper

run

guard

turning

belt

unit

ten

and

tensioning

tension

is

minutes.

readjust

tension

belt

belttensionifnecessary.Replacebeltguard.

OM-160

518

Page

Drive

Figure

14

6-7.

Belt

Adjustment

and

Replacement

6-7.

Overload

Protection

a

~

120V

WARNING

CAUTION

TOOLS

NOT

USE

CONSULT

1OA

AND

:DC

AC

OWNERS

LIGHTS

ONLY

DC

POWER

ONLY!DO

RATED

MANUAL!

FOR

TOOLS.

10

0

-~-

Fl

READ

Section

Replacement

or

greater,

10

fuse

amperes

A

SAFETY

6

rating:

maximum.

before

volts

125

BLOCKS

at

proceeding.

Stop

engine.

1

Fuse

2

lOAFuseFl

Fuse

Fl

overload

120V

dc

the

engine

there

is

Weld

output

Turn

fuse

to

remove

fuse

holder.

and

panel

If

fuse

Factory

tion.

start

Holder

protects

short

or

receptacle.

continues

no

output

still

is

holder

counterclockwise

fuse.

Push

clockwise

turn

continues

Authorized

of

the

circuit

If

Fl

to

the

at

receptacle.

available.

Put

new

fuse

holder

to

open,

Service

unit

to

from

on

is

open

run

fuse

into

secure.

contact

Sta

the

but

In

Figure

6-8.

Location

OfFlFuse

Ret,

ST-151

~86/Ret.

ST-157

883-A

OM-160

518

Page

15

6-8.

Troubleshooting

Do

not

Always

Insulate

Stop

engine

Keep

Do

not

in

Use
outside

PARTS

Allow

Wear

hot

on

a

power

WARNING

SHOCK

touch

live

wear

yourself

all

breathe

open,

and

cooling

protective

dry

from

before

and

panels

EXHAUST

exhaust

well-ventilated

away

can

period

gloves

engine.

output.

insulating

kill.

can

electrical

parts.

gloves.

work

and

ground.

installingorservicing.

severe

can

in

vent

or

air

when

from

cause

covers

GASES

before

securely

fumes.

areas,

building

any

servicing.

and

clothing

Table



-~

Have
brushes

Broken

place

kill.

exhaust

intakes.

burns.

working

6-1.

Factory

and

drive

Welding

Authorized

slip

rings.

belt.

Trouble

Remedy

Service

ENGINE

FUEL

sion.



Stop



Do



Do

MOVING



Keep

and



Keep

and

not

not

engine

fuel

while

overfill

PARTS

away

rotors.

all

doors,

securely

before

from

Troubleshooting

persons.

Station

check

can

fueling.

smoking

clean

tank;

can

moving

panels,

in

place.

be

to

performed

generator

cause

or

up

cause

parts

covers,

---~

-..

near

any

such

fire

sparks

spilled

injury.

as

and

guards

only

rwarnhl.1

Section

or

explo

or

fuel.

fans,

by

qualified

--

6-6

flames.

belts,

closed

11/91

AA

ELECTRIC











ENGINE





HOT





Trouble

No

weld

or

auxiliary

Low

Low

Erratic

weld

or

high

welding

output.

weld

arc.

output.



-~

Have

Check

er

(see

Check

Check

Have

Factory

and

adjust

engine

weld

cable

internal

Factory

Authorized

engine

manual).

size

and

external

Authorized

Service

speed.

and

Service

Station

Tune-up

length.

weld

output

Station

check

generator.

forfull

engine

connections.

check

brushes

horsepow

and

slip

-~

-~

--

-~

-a

6.3

rings.

horse

--

-~

-~

-a

-a

-~

---

6-6

6-3

--

--

6-3

--

Check

Check

Check

power

Check

Change

Check

Check

Amperage

drive

belt

and

adjust

(see

engine

governor

to

proper

and

adjust

governor

control

tension.

engine

manual).

(see

engine

electrode

engine

(see

engine

settings

speed.

manual).

polarity.

speed.

manual).

connections.

and

Tune

up

engine

for

full

Weld

OM-160

output

518

Page

uncontrollable.

16

 

-~

Have

control.

Factory

Authorized

Service

Station

check

Amperage





-~





Table

6-2.

Auxiliary

Power

Trouble

No

auxiliary

Erratic

Low

auxiliary

Trouble

power.

auxiliary

power.

power.

Remedy

-~

Check

Have

and

replace

Factory

fuse

Authorized

Fl.

Service

Station

check

brushes

and

Slip

-~

-~

Section

6-7



-

rings.

Have

Factory

Authorized

Service

Station

check

brushes

and

slip

--a

--

rings.

Check

drive

belt

and

Check

horsepower

throttle

Move

and

Check

necessary

Check

drive

Have

Factory

adjust

(see

lever

adjust

to

achieve

belt

Authorized

tension.

engine

engine

Run

to

engine

full

tension.

speed.

Tune-up

manual).

position.

Perform

speed.

horsepower

Service

Station

(see

engine

engine

engine

check

to

achieve

maintenance

manual).

generator.

full

as

-~

-~

6-6

6-3

Engine

Engine

will

runs

not

rough

Trouble

start.

or

stalls.

6-3.

Table

fuel

Open

oil

Check

fuel

Check

throttle

Move

See

engine

--

Dirt

Have

water

or

Factory

Tune-up

shutoff

level.

level

control

manual.

in

Authorized

engine

Engine

Check

in

fuet.

(see

valve.

optional

tank.

levertoRun

Replace

engine

Trouble

Remedy

oil

fuel.

Service

manual).

shutdown

level

position.

Station

check

switch.

fuel

filter.

Section

---~

-..

--~

--~

---

Figure

Figure

Figure

Figure
Figure

4-5

3-4,

4-7

3-4

4-5

OM-160

518

Page

17

U)

m

C)

0

z

m

r

-I

m

C)

a

r

a

C)

Cl)

WELD

POSITIVE

OUTPUT

DC

NEGATIVE

(POS)

25

RC2

539-A

7

B

POWER

15-I25VDC

AUX

I

58-152

PLG3/RC3

Generator

Welding

For

PLG2

IIRC2

1161

1/1/ti

11

kJltlJdl2hl

1~

13312

17

16

15

PLG2/RC2

I

41ttP/PtttPLG2

123456789

313

_~jA-_~-~_-~46

I

RC3

I

I

23456789

ttl\ttttttPLc3

1/31331351391241

1

~4)4

>1>

PLG3/RC3

E!~i~IIj

>2>

PLG3/RC3

METER

RUNNING

(OPTIONAL)

HOUR



rJJ3

-a

I

ENG

GNO

OIL

LEVEL

Diagram

Circuit

7-1.

Figure

-

TAB

ENGINE

EXCITATION

0

-u

0)

0

0)

C,

0,

I,

CD

(0

IGNITION

KILL

OIL

SHUTOOWN

LOW

I

L

SP4

860-B

ST-153

Generator

-,

ALTERNATOR

HOUSING

I

I

Welding

For

Diagram

OUTPUT

NEGATIVE

Wiring

7-2.

Figure

~

BLK

r(~~

I

silo

GR~W

L

r

L

SECTION

8-

WELDING

METHODS

&

TROUBLESHOOTING

mcd5.~

9192

a

ELECTRIC



Always



Insulate



Do

not



Keep

FUMES

to

your



Keep



Ventilate



Read
manufacturers

WELDING



Do

not



Watch



Do

not



Do

not



Allow

ARC
NOISE



Wear



Wear

WARNING

SHOCK

wear

dry

yourself

touch

live

all

panels

AND

GASES

health.

head

your

or

area,

Material

can

weld

near

for

fire;

keep

unit

locate

weldonclosed

work

and

RAYS

can

damage

welding

correct

can

helmet

eye,

can

insulating

from

work

electrical

and

covers

of

the

out

use

breathing

Data

Safety

instructions

cause

flammable

extinguisher

combustible

over

containers.

equipment

burn

hearing.

with

and

ear,

kill.

gloves.

and

parts.

securely

can

fumes.

Sheets

for

fire

material.

to

cool

eyes

correct

body

ground.

in

be

hazardous

device.

(MSDSs)

material

or

used.

explosion.

nearby.

surfaces.

before

and

shade

protection.

and

handling

skin;

of

filter.

4

MOVING



Keep

and

rotors.



Keep

and

securely

HOT

PARTS



Allow



Wear

MAGNETIC
RENTS



Pacemaker



Wearers

near

arc

tions.

WELDING

tronic



Disconnect

vehicle.



Place

See

Safety

welding

PARTS

from

away

all

doors,

in

can

period

cooling

protective

FIELDS

affect

can

wearers

should

welding,

CURRENT

in

parts

both

work

clamp

Rules

information.

safety

can

moving

panels,

place.

cause

before

gloves

pacemaker

keep

consult

gouging,

vehicles.

battery

close

as

at

beginning

cause

parts

covers,

touching

and

clothing.

FROM

away.

their

or

can

cables

to

such

and

severe

doctor

spot

damage

before

the

of

weld

manual

injury.

as

fans,

belts,

closed

guards

burns.

welded

metal.

HIGH

CUR

operation.

before

opera

elec

welding

as

possible.

for

going

basic

welding

a

on

8-1.

Tools

Shielded

N

OTE

Needed:

~

Metal

2

Arc

Welding

7

Welding

current

4

~

(SMAW)

starts

soon

as

electrode

as

touches

the

workpiece.

1

Workpiece

Make

fore

welding.

2

Work

Place

ble.

3

Electrode

A

small

quires

Follow

one.

electrode

ting
Figure

4

Insulated

5

Electrode

6

Arc

Arc

length

electrode

with

arc

a

sharp,

7

Slag

Use

a

brush

and

slag
making

sure

workpiece

Clamp

close

as

diameter

less

current

recommendations

manufacturer

weld

8-2).

Length

is

the

to

the

correct

crackling

chipping

to

remove

check

another

is

the

weld

to

electrode

than

amperage

Electrode

Holder

Position

distance

workpiece.

amperage

sound.

hammer

slag.

weld

bead

weld

pass.

clean

as

a

when

Holder

from

A

will

and

Remove

ST-151

be

possi

large

set

(see

the

short

give

wire

before

593

re

of

OM-160

518

Page

Shielded

Figure

20

8-1.

Metal

Arc

Welding

(SMAW)

Procedure

6010

&

6011

w

w

a

0

w

It
I

w

0

w

-J

w

a

-~L

5/32

o

0
Lt)

0

o

U)

I-

-

ow

uJz

0

0

0

0

0

0

LI)

0

ClJ

C\i

C~ C~

LI)

0

0

LI)

~

6013

7014

7018

7024

Ni-Cl

308L

5/32

9115

7,93

1/4

3/32

115

3/IS

7193

1/8

5/32

1115

1132

1/4

5/32

I/IA

I

3132

3/16

~1/8

5/32

M

6010

6011

6013

7014

7018

7024

NI-CL

308L

*EP

EN

uJ

a

0

I

0

w

-J

w

EP

EP

E~EN

EP,EN

ER

EP,EN

ER

ER

=

ELECTRODE

=

ELECTRODE







U

z

0

I
C,)

0

0~

ALL

ALL

ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL

ALL

POSITIVE

NEGATIVE



2

0

It
I

w

2

uJ
0~

DEEP

DEEP

LOW

MED

LOW

LOW

LOW
LOW

(REVERSE

(STRAIGHT

MIN.

HIGH

SMOOTH,

LOW

SMOOTH,

CAST

STAINLESS

PREP,

SPATTER

GENERAL

FAST

HYDROGEN,

STRONG

FASTER

IRON

POLARITY)

POLARITY)

ROUGH

EASY,

EASY,

-

Ref.

S-087

985-A



0

a

v

v

y

v

/

v
/

Figure

8-2.

Electrode

And

Amperage

Selection

Chart

OM-160

518

Page

21

1

Electrode

2

Workpiece

3

Arc

electrode

2

Drag

like

striking

after

slightly

out

goes

If

high.

use

piece,

a

match;

touching

electrode

electrode

a

quick

across

lift

work.

was

sticks
twist

workpiece

electrode

If

arc

lifted

to

work-

to

it.

to

free

S-0049

Figure

Figure

8-3.

Ii

8-4.

Striking

Striking

An

Arc

An

3



Arc

Scratch

2



Tapping

Start

Technique

Technique

1

Electrode

2

Workpiece

3

Arc

electrode

Bring

workpiece;

If

arc.

arc

lifted

too

workpiece,

the

high.

electrode.

then

goes

use

straight

lift

slightly

electrode

out,

If

electrode

a

quick

twist

down

to

sticks

to

to

start

was

to

free

S.0050

OM-160

End

518

View

Page

0

1O0~3O0

\

300

10~\~

~-

<~

View

Of

Of

Work

22

Angle

GROOVE

Side

WELDS

Electrode

Figure

Angle

8-5.

Positioning

End

Electrode

ViewOfWork

Holder

Angle

FILLET

Side

WELDS

View

~-

Of

Electrode

Angle

S-0660

POOR

WELD

BEAD

34~

1

2

3

4

5

Large

Spatter

Rough,

Crater

Slight

Welding

Bad

Overlap

Poor

Penetration

uneven

Deposits

bead

During

NOTE

______________________

Angle

Too

~

Small

WELD

GOOD

Figure

Weld

bead

thicknessofbase

8-6.

shape

BEAD

4

Weld

Bead

Characteristics

affectedbyelectrode

is

metal.

Correct

Angle

5

5

angle,

arc

1

Fine

Uniform

2

Moderate

3

Welding

Weld

a

new

in

1/8

(3.2

welded.

being

No

4

Overlap

Good

5

Metal

length,

Spatter

Bead

Crater

bead

thickness

mm)

Penetration

travel

Too

Angle

During

or

layer

Into

speed,

Large

S-0053.A

for

in

Base

S-0052-B

and

each

metals

Too

H

Li

Short

Slow

Figure

8-7.

ELECTRODE

Conditions

Drag

ARC

TRAVEL

That

ANGLE

L_]

Normal

LENGTH

Normal

SPEED

Affect

Weld

Bead

Shape

Too

Long

Fast

OM160

Spatter

518

S-066

Page

1

23

NOTE

~

Normally,

however,

multiple

stringer

a

single

for

wide

stringer

groove

beads

work

bead

is

satisfactory

weld

jointsorbridging

better.

for

most

across

narrow

gaps,

groove

a

weave

weld

joints;

bead

or

1

Stringer

Movement

2

Weave

Movement

3

Weave

Use

weave

wide

area

trode.

Do

ceed

https://manualmachine.com/3

Ele

Figure

I

8-8.

ctrode

L

Mov

/

$~

~

~

~~I~f

4jI~t~-

ement

2

/

During

Welding

/

2-1/2

electrode.

1

Tack

Prevent

edges

ing

together

tack

welding

tior,

before

2

Square

Good

for

thick.

(5

mm)

3

Single

Good

for

in

3/4

(5-19

with

oxyacetylene

equipment.

ting

from

material

alsobeused

ercan

els.

Create

30

materials

4

Double

Good

for

3/l6in(5mm).

Bead

Along

Bead

Along

Patterns

patterns

in

one

let

not

times

Welds

ahead

the

final

Groove

materials

V-Groove

materials

mm)

after

degree

in

V-groove

V-Groove

materials



Steady

Seam



SideToSide

Seam

to

of

pass

weave

diameter

of

joint

of

electrode

materials

weld.

Weld

up

Weld

3/16

thick.

or

plasma

Remove

cutting.

to

prepare

angle

welding.

thicker

the

width

from

to

Cut

of

Weld

cover

elec

ex

S-0054A

draw

in

posi

3/16

through

bevel

cut

scale

A

grind

bev

bevel

than

9-0662

a

of

by

in

on

2To3in

(51-76

(6.4

OM-160

1/4in

mm4

mm)

518

~

Page

0

24

I

4..

8-9.

Butt

Weld

Joints

Test

1

Vise

2

Weld

Joint

Hammer

3

weld

joint

bends

in

direction

over

shown.

but

S-0057-B

does

Strike

weld

A

good

not

break.

1

Figure

2

1

Figure

8-10.

1

Electrode

2

Fillet

arc

Keep

rate

of

speed.

shown

corner.

surface.

For

maximum

sides

of

3

Multi-Layer

Weld

second

a

fillet

er

weaving

8-8.

Figure

making

Weld

short

to

provide

Square

upright

is

needed.

patterns

Remove

another

S-0060

and

move

Hold

fusion

edge

strength

section.

Deposits

when

layer

Use

weld

S-0058-A

/

definite

at

electrode

into

of

the

weld

a

any

shown

before

slag

pass.

/

weld

both

heavi

of

S-OO61

as

the

the

in

8-2.

2

Single-Layer

Welding

Fillet

Weld

Troubleshooting

Figure

3

Multi-Layer

Figure

8-11.

8-12.

Tee

Fillet

Lap

Joint

Weld

Joint

300

1

Less

Or

1

Electrode

2

Single-Layer

Move

electrode

3

Multi-Layer

Weld

second

a

filletisneeded.

er

fore

making

Weld

both sides

mum

strength.

Fillet

in

Fillet

layer

Remove

another

of

Weld

circular

Weld

when

weld

joint

S~oo63

motion.

heavi

a

slag

pass.

for

maxi

be

/S-0064

Arc

length

electrode.

Damp

Workpiece

Possible

too

long.

dirty.

Causes

Table

8-1.

Porosity



small

Porosity

from

and

gas

dirt

~

Corrective

Reduce

arc

length.

Use

electrode.

dry

Remove

.

welding.

all

grease,

oil,

moisture,

rust,

paint,

Actions

coatings,

slag,

pockets

work

from

cavitiesorholes

in

weld

metal.

surface

before

OM-160

resulting

518

Page

25

Table

8-2.

Excessive

Spatter

Amperage

Arc

length

Insufficient

Possible

too

high

too

long

Possible

heat

Causes

for

or

Causes

input.

~.....

~

electrode.

voltage

too

high

.

.





~~-

Decrease

Reduce

amperage

arc

length

Table

select

or

or

voltage.

8-3.

Incomplete

\

hr11

Increase

amperage.

Select

larger

larger

Corrective

electrode.

Fusion

Corrective

electrode

and

Actions

Actions

increase

Excessive

metal

particles

weld

bead.

Incomplete

fuse

to

completely

preceeding

amperage.



Spatter

Fusionfailure

weld

that

cool

bead.

scattering

to

with

solid

base

of

molten

form

near

of

weld

metal

metal

or

a

Improper

Workpiece

Improper

Improper

Insufficient

technique.

welding

dirty.

LackofPenetration

Possible

joint

preparation.

weld

technique.

heat

input.

Causes

Place

stringer

work

Adjust

Momentarily

arc

Keep

Remove

on

all

welding.

Table

Material

too

arc

Keep

Increase

on

amperage.

bead

angle

hold

leading

grease,

8-4.

thick.

leading

or

arc

Joint

in

proper

widen

on

edge

oil,

edge

Select

Lack

location(s)

to

groove

side

groove

weld

of

puddle.

moisture,

Good

rust,

Of

Penetration

Penetration

preparation

weld

of

puddle.

electrode

larger

at

access

walls

paint,

Corrective

and

design

during

joint

bottom

when

using

coatings,

must

increase

and

welding.

during

weaving

slag,

Actions

provide

welding.

technique.

dirt

and

Of

Lack

tween

access

amperage.

from

Penetration

weld

metal

to

bottom

work

surface



and

of

shallow

base

groove.

before

fusion

metal.

be

OM-160

518

Page

Reduce

travel

speed.

26

Table

8-5.

Excessive

Penetration

Excessive

Excessive

Excessive

Possible

heat

input.

Possible

heat

input.

Causes

Causes

~.

Penetration

Select

Increase

Select

Increase

lower

and/or

lower

and/or

amperage.

maintain

Table

amperage.

maintain



Good

Penetration

Use

smaller

steady

8-6.

Burn-Through

Use

smaller

steady

travel

travel

Corrective

electrode.

speed.

Corrective

electrode.

speed.

Actions

Actions

Excessive

ing

derneath

through

weld

Penetration

base

Burn-Through

pletely

through

holes

wherenometal



metal

weld

base



weld

and

metal

metal

remains.

metal

hanging

melting

resulting

melt

un

com

in

Unsteady

Excessive

Possible

hand.

Possible

heat

input.

Causes

Causes

Use

two

restraint

Use

Make

Select

Increase

tack

lower

Table

hands.

welds

travel

8-7.

Practice

Table

(clamp)

along

amperage

speed.

Waviness

technique.

8-8.

to

hold

joint

for

electrode.

Distortion

Base

metal

in

the

direction

the

weld

base

metal

before

starting

Bead

Of

Corrective

moves

of

bead.

Corrective

in

position.

welding

Waviness

parallel

base

Actions

Distortioncontraction

ing

welding

move.

Actions

operation.

and

metal.

Of

Beadweld

does

that

not

forces

cover

of

metal

joint

weld

base

that

formed

metal

metal

is

not

by

dur

to

Weld

in

small

segments

and

allow

cooling

between

welds.

OM-160

518

Page

27

SECTION

9

PARTS

LIST

OM-160

518

Page

ST-162

841

9-1.

Figure

28

Main

Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Figure

9-1.

Main

Description

Assembly

Quantity

1

..

2

..

3

.

4

..

5

..

6

.

7

..

8

..

9

..

10

..

11

..

12

..

13

.

14

.

15

..

16

..

17

..

18

..

19

..

20

..

21

..

22

23

24

25
26

27

28
29
30
31
32

.

.

33

.

.

34

.

.

35

. .

36

. .

37

.

.

38

. .

39

. .

40

.

.

41

.

.

42

.

.

43

.

.

44

.

.

. . .

.

. . . .

. . .

...

. .

. ...

PLG2,3

RC2

SR3

RC3

..

..

..

..

.

..

.

.

147

020

+148

+148

601

602 213
602 243

602 215

+157

..

..

601

721

150

150

720

279

150

123

152

756
975

152

452

146

994

148976

412

150
146

280

151

209
971
965

148

966

217

150

135

134

113

633

150708

135

133

114066

150

496

150497
150

498

150

502

503

150
150

506
155063
148

965

9-3

Fig

155

797

906

150

567
150

216
150344
150

127

026

947

150

128

150

130

127

596
135

133

114

066

9-2

Fig

157

907

129

527

600

681

010

521

600

325

040 234

tank

CAP,

. .

HOSE,
CLAMP,
BRACKET,

. .

BRACKET,

. .

CLAMP,

.

.

MOUNT,

. .

BRACKET,

.

.

BRACKET,

. .

HANGER,

. .

LABEL,

. .

. .

PULLEY,Vsglgrv6.75Odiax6.000Px.625

BELT,

. .

LABEL,

. .

LABEL,

. .

GUARD,

. .

SCREW,

.

.

WASHER,

. .

WASHER,

.

.

RETAINER,

.

.

SCREW,

.

.

WASHER,

. .

CONNECTOR,

. .

CONNECTOR,

. .

GENERATOR,

. .

CONNECTOR,

.

..

CONNECTOR,

. .

.

PULLEY,

. . .

SPACER,fan

.

..

FAN,

. . .

BEARING,

. . .

BEARING,

. . .

BRUSH

.

..

BASE

..

SCREEN,

. .

PANEL,

. .

LABEL,

.

.

HANDLE,

. .

RECTIFIER,

. .

BRACKET,

..

.

INSULATOR,

.

..

RECTIFIER,

.

..

STAND-OFF,

.

..

RECTIFIER,

.

..

TUBING,

.

.

WASHER,

.

.

CONNECTOR,

. .

CONNECTOR,

. .

PANEL,

. .

CABLE,

. .

CONNECTOR,

.

..

SPLICE,

.

..

WIRE,

.

..

CABLE,

.

..

AF-2

.

..

screw-on

(see

engine

(see

control

tank

stl

cush

stud

sgl

mtg

adjustment

cable

warning

V

cogged

warning

warning

belt

.375-16

lock

flat

adjuster

.437-14

lock

V

generator

HOLDER

handle

control

caution

front/rear

stl

.625

flat

front

w/electrode

prl

tie

weld

HOLDER,

w/vent

list)

parts

list)

engine

parts

idle

fuel

.75Odia

1.000dia

x

.281

.312-18

hole

eng/gen

alternator

2.750Ig.625dia

can

moving

.500

general
engine

drive

sti

stl

x

std

parts

widex.343

precautionary

exhaust

.

1.000

hexhd

.375

split

.375

sparks

belt

4.000

x

sti

split

rect

rect

(consisting

rectgP/S

rect

sgl

grv

hexhd

.437

9P/S

pin

plug

20-1

4ga

Amp

Amp

of)

Amp

rcpt

skt

20-l4ga

3.75Odiax3.500Px.670

6.469dia

ball

roller

ASSEMBLY,

base

w/components

use

positive/negative

mtg

rectifier

negative

insul

positive

stl

rect
rect

hooks

no

rectifier

half

.250-20

half

OD

x

l2ga

ID

.344

9P/S

skt

20-l4ga

or

(consisting

3

phase

1

x

3

phase

wallx1.125

1.500

x

Amp

rcpt

slings

.000

Amp

w/components

holder

(consisting

insul

male

No.

200A

6

(orderbyft)

4

twlk

wire

cop

strd

electrode

nyl

cause

deep

Amp

generator

OD

(Dinse

.750

stud

serious

32.300

x

can

350720-1

350218-1

1-641765-0

350536-1

of)

full

wave

.31

x

Ig

full

wave

.l25thk

x

1-614765-0

350536-1

of)

type)

high

bore

cause

2thd

50

injury

Ig

bore

Series

fire

1

.

1

.

1

.

1

1

.

1

.

4

1

.

1

.

1

.

....

1

.

1

.

1
1

1
1
1
1

2

1
1
1
2

9

1
1

9

1
1
1

1

1

1
1
1

1
2

2

1
1
1
1

2

1

2
2

1

9

1

1

.

1

2

2

2Oft

1

OM-160

518

Page

29

Item

No.

Dia.

Mkgs.

Part

No.

Figure

9-1.

Main

Description

Assembly

Quantity

(Continued)

+When

Part

BE

45
46

47

48

49
50

51

52

53

54
55

56

57

of

SURE

Si

ordering

042

769

TO

PROVIDE

157908

010368
026843

600325
010521
600681

129527

134746
147552

067101

+154656

..

147544
152460
152583

137690

a

component

Optional

150126

Automatic

MODEL

CABLE,

CLAMP,
INSULATOR,

CABLE,
WIRE,

SPLICE,
CONNECTOR,

WRENCH,

ENGINE,

AIRFILTER

SWITCH,

TANK,

VALVE,

BUSHING,tankfuel

MOUNT,

AUTO

originally

Low

AND

displaying

SERIAL

w/g

tie

fuel

dual

ARC,

Oil

round

ground

vinyl

weld

cop

4

prl

hex

5mm

Kohler

oil

low

2.3gal

2

fuel

stud

hand-held

a

Shutdown

NUMBER

clamp

200A

wire

twlk

gas

level

(consisting

No.

insul

6

male

strd

short

(consisting

(consisting

w/micron

way

.625dia

precautionary

Kit.

.250-20

shield

WHEN

of)

(orderbyft)

(Dinse

of)

of)

filter

stud

the

label,

ORDERING

50

type)

.625

high

label

should

REPLACEMENT

series

also

be

PARTS.

1
1

2

2Oft

1
1
1
1

1

1
1

1

1
1

6

1

ordered.

OM-160

518

Page

30

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

WW25W

str

armd

twlk

.250-20

brs

.250

ASSEMBLY

mintr

1OA

cer

lens

(order

4-4OVDC

Front

dx

2P3W

insul

250V

low

by

2

w/Components

ohm

10/40

stud

.500

2P3W

grd

iSA

fern

(Dinse

jam

hvy

ID

.625

x

oil

level

model

and

3

125V

iSA

P

125V

&S5266DF

type)

ODx.O3lthk

serial

4

(Fig

50/70

number)

9-2.

str

grd

brs

hex

flat

fuse

mintr

.250-20x1.750

brs

pointer

md

red

hour

Panel,

push-on-type

Figure

Neg,Pos

. . .

Ri

.

.

CS

..

RC1

.

C3,4

.

Fl

. .

HM.154

..

..

..

..

..

.

154

*012

154

150765

154663
152537

654

604

176

073

690

129

525

601

836

010

915

131

646

046 432

655

063030
097

924

653

081

RHEOSTAT,

.

.

PANEL,front

. .

CAPACITOR

.

.

NUT,

. .

. .

.

.

. .

. .

. .

. .

. .

. .

. .

. .

. .

speed

RECEPTACLE,

PLUG,
RECEPTACLE,

NUT,

WASHER,

CAPACITOR

HOLDER,

FUSE,
STUD,

KNOB,

LIGHT,

NAMEPLATE,

METER,

. .

1

..

2

..

3

..

4

..

5

..

6

..

...

7

..

8

..

9

..

.

10

..

11

..

12

..

13

..

14

..

15

..

16

..

9-1

series

Item

38)

..

1

1
1
1

1

2
3

2

1
1

1

1

1

1

1

1

5

16

13

*Recommended

Part

of

042

Part

BE

of

SURE

042

TO

Spare

769

781

PROVIDE

Parts.

Optional

Optional

MODEL

12

Automatic

Running

AND

11

Figure

Low

Hour

SERIAL

9-2.

Oil

Meter.

10

Panel,

Shutdown

NUMBER

Front

w/Components

Kit.

WHEN

ORDERING

9

REPLACEMENT

PARTS.

6

7

8

ST-162

642

OM-160

518

Page

31

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

9-3.

Figure

1

..

2



.

3

.

4

..

5

.

6

..

7

..

8

..

01,2

.

...

SRi



..

R3,4,VR1,2.

.

.

R2

R3

,2,4

....

....

...

.

148

967

137

198

111

087

149

243

035 704

151

530

149244

152

534

153

064

COVER,

. .

NUT,

. . .

CLAMP,

 .

CAPACITOR,

 .

RECTIFIER,

. .

SUPPRESSOR

. .

.

.

RESISTOR,WWadj25W3ohm

PANEL,

. .

RESISTOR,

. .

Panel,

(consisting

insert

capacitor

mtg

components

WW

10-24

elctlt

integ

adj

Control

of)

1

.375dia

950uf

800V

40A

lOW1ohm

w/Components

clip

100VAC

(Fig

26)

Item

9-1

1

3

2

2

3

2

1

1
1

-1

BE

SURE

TO

PROVIDE

7

6

MODEL

5

Figure

AND

4

9-3.

SERIAL

(

Panel,

NUMBER

Control

WHEN

w/Components

ORDERING

2

3

REPLACEMENT

PARTS.

ST.151

475

OM-160

518

Page

32