Miller Electric HJ134589 User Manual

April

1978

FORM:

OM-457C

Effective

Trailblazer

With

MODEL

Serial

22G

No.

HJ134589

OWN

ERS

MANUAL

MILLER

718S.BOUNDS

APPLETON,

NWSA

ELECTRIC

ST.

WI

CODE

PRINTED

IN

54912

NO.

P.O.

U.S.A.

4579

Box

USA

MFG.

1079

ITIIIIER

CO.

LIMITED

WARRANTY

$

LIMITED

Wisconsin

ton,

Equipment

workmanship

are

by

to

by

sold

engines,

delivery

respect

factured

items

manufacturers,

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engines

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MILLER

useful

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replacement

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defect

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original

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failure,

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user:

WARRANTYMiller

warrants

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4.

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days

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ANY

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BUT

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FITNESS

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MILLER

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USERS

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CONSUMER

EXTEND
EXTEND

CONSUMER.

1978

20,

warranties

expressed

welders,

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EXPRESS

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WARRANTY

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MILLER

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the

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COURSE

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WARRANTY

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implied.

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After

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AMENDMENT

manual

was

TO

printed,

SECTION

refinements

INSTALLATION

3

ERRATA

in

equipment

design

SHEET

occurred.

This

sheet

ex.cenXioi~s.tadata

lists

aooearina

later

in

Amend

Normally

plant

quire

For

Code.

needed,

Section

engine-driven

capability;

machine

detailed

If

additional

consult

quirements

Amend

Figure

3-3.

therefore,

grounding.

grounding

information

a

qualified

to

apply

3-3.

Power

EQUIPMENT

welding

grounding

For

instructions

particular

your

Plant

GROUNDING

generators

of

these

reasons

consult

regarding

electrician

situation,

Connections

the

or

your

your

TERMINAL

do

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frame

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your,

require

and

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local

particular

dealer.

follow

case

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state

operating

After

them

grounding.

recommended.

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grounding

terminal

codes

circumstances

determining

explicitly.

However,

the

and

the

this

Also,

is

provided

latest

and/or

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machine

unusual

circumstances

all

on

issueofthe

grounding

which

to

has

auxiliary

weld/power

National

requirements

grounding

any

power

re

may

units.

Electrical

is

re

Circuit

Jumper

IShipped

AMENDMENT

Amend

Add

CAUTION:

_______

connected

Sections

the

chboard,

and

grounding

electric
cedures.
clantoavoid

-

AMENDMENT

Delete

AMENDMENT

Amend

utility,

Section

Section

Groundingl

Lead

Ungrounded)

TO

SECTION

5-1

and

following

accessory

panelboard,

CAUTION

The

auxiliary

equipment

or

procedure

and

local

Since

hazardous

or

injury

SECTION

TO

6-7.

ELECTRICAL

SECTION

TO

POWER

7-2.

5-9

power

other

is

state

voltages

damage

FUNCTION

5-

blockatthe

capability

(lights,

equipment

employed

codes,

are

caused

6-

FUNCTION

TACHOMETER

SEQUENCE

7-

PLANT

Figure

beginning

of

drills,

normally

Section

(see

the

and

present,

improper

by

OPERATION

3-3.

Power

OF

GENERATOR

of

this

welding

grinders,

supplied

3-3

issueofthe

latest

is

recommended

it

or

OF

ENGINE

(OPTIONAL)

OF

OPERATION

Plant

the

section

generator

etc.).

by

for

unit

faulty

Connections

CONTROLS

is

Do

other

primarily

connect

not

electrical

grounding

National

that the

installation.

CONTROLS

/

intended

this

power

unless

information).

Electrical

Code

installation

unit

be

for

to

a

ALWAYS

for

made

use

any

proper

proper

by

with

portable

service

transfer

consult

installation

licensed

a

TC-000

box,

switch

the

electri

OM-457C

680-B

cord-

swit

local

pro

Page

A

Add

CAUTION

CAUTION.:

we/ding

cables

block

The

when

at

weld

not

beginning

output

we/ding

terminals

and

of

Section

are

do

not

/

electrically

touch

the

energized

output

when

terminals

when

the

engine

the

is

running.

engineisrunning.

Disconnect

-

the~

AMENDMENT

Amend

Weld

speed

Amend

Carburetor

I~1t~

be

must

This

engine

To

ensure

machined

minus

or

plus

a

Delete

Amend

Amend

To

long

obtain

nose

Figure

Section

of

Section

Change

Do

not

centered

is

correct

surface

pliers

Section

Figure

proper

TO

SECTION

GOVERNOR

9-3.

this

engine

9-4.

CARBURETOR

Effective

bend,

between

equipped

fuel

of

throttle

.020

inch.

and

9-2.

Carburetor

IDLE

9-9.

9-7.

IDLE

engine

9-

SERVICE

is

1850

rpm.

With

Serial

or

twist,

with

level

To

bend

apply

and

at

right

a

Teledyne

in

the

(no

body

increaseordecrease

float

the

Float

CONTROL/GOVERNOR

CONTROL/GOVERNOR

idle

and/or

ENGINE

FLOAT

No.

pressure

angles

Walbro

float

chamber,

gasket)

lever

Setting

weld

speed,

MAINTENANCE

SETTING

HJ185451

on

to

carburetor.

with

distance

at

a

point

perform~

the

float

the

machined

check
throttle

closetothe

LINKAGE

LINKAGE

body.

distance

body

from

ADJUSTMENT

the

The

surface,

(dimension

inverted.

top

float

of

the

ADJUSTMENT

following

float

body,

and

must

A,

This

dimension

the

float

body

body.

(Figure

procedures:

when

move

Figure

to

9-7)

viewed

freely

9-1)

should

the

machined

on

from

from

be

the

top

1-1/16

free

the

float

axle.

of

float

inches

surface,

end,

to

use

0M-457C

Page

TCO8O

511

9-7.

Idle

Figure

B

Control/Governor

Linkage

Adjustment

1.

Loosen
Rotate

rotation
rotationofthe

be
&

IMPORTANT

______________

due

the

the

to

sockets

(6&8).

CAUTION

engine.

2.

Recheck

engine

pushed

the

thelinkage

of

necessary

lock

to

8)

linkage

(5

and

fully

linkage

the

linkage

linkage

to

adjust

the

position

Check

socket

&

9)

slightly

Ensure

all

that

-------

adjustments

it

allow

in

at

nuts

socket

the

nuts

body

reach

to

this

&

(6

(9)

socket

socket

the

linkage

of

linkage

&

(5

until

unrestricted

limbs

--------~

made

normal

time.

8)

until

(9)

(9)

the

9)

and

remove

the

will

will

lengthen

itself

linkage

for

(7J

being

clear

are

----

far.

thus

operating

throttle

shorten

obtain

to

sockets

freedom

out

movement

of

-

Place

hardware

the

stop

the

governor

the

governor

the

(5&9).

of

movement

of

proper

fan

the

the

temperature

(10)

(2)

plate

inch

1/32

alignment,

of

the

linkage

and

the

-

CONTROL

IDLE

(about

securing

about

is

linkage

linkage

(7)

(7)

required.)

gap

throughout

loosen

is

(7)

-:~-~

switch

five

motor

minutes).

vacuum

the

linkage

inch

1/32

reduce

and

widen

and

its

entire

the

linkage

restored.

unit

in

from

the

the

Tighten

travel.Ifthe

socket

Tighten

before

-

the

LOCK

Ensure

socket

the

stop

gap;

(In

gap.

the

linkage

nuts

the

starting

OUT

that

the

the

to

(9)

counterclockwise

a

some

(1).

governor.

clockwise

A

cases

socket

is

linkage

&

(6

linkage

or

working

position.

CHOKE

-

and

8)

socket

binding

Start

control

it

nuts

rotate

nuts

on

may

the

the

(6

~.

is

3.

Pull
butt

A.

B.

IMPORTANT

BEFORE

AUTOMA

pivoting

Place

4.

when

will

the

delay

after

vacuum

5.

When

I~EIi11~

the

arm

(3)

against

Rotate

whereas

Rotate

rotate

restricts

more

the

TIC

the

the

the

remain

arc

is

about

Do

the

the

counterclockwise

the

the

the

fuel,

Ensure

throttle

IDLE

vacuum

IDLE

IDLE

idle

at

is

broken,

controlledbythe

ten

line

fitting

the

engine

not

readjust

idle

screw

mixture

the

screw

(20)

flow,

the

that

plate

toward

idle

idle

screw

fuel

making

stop

position.

motor

arm

CONTROL
CONTROL

until

an

time

a

seconds,

going

has

gone

the

front

of

(4)

throughout

obtain

to

(4)

rotationofthe

adjustment

clockwise

making

air-fuel

the

vacuum

butts

(2)

obtain

To

until

(17)

switchinthe

switch

is

arc

established,

will

delay
setting

adjust

into

idle

of

the

the

idle

to

rpm

the

welding

550

screw

until

the

air-fuel

mixture

motor

against

this

condition

screw

AUTOMATIC

isinthe

exist

before

the

time-delay

AUTOMATIC

time-delay

intake

manifoldofthe

adjust

rpm,

(4)

screw

generator

the

following

rpm.

screw

(20)

the

engine

mixture

richer.

idle

screw

the

idle

(16)

which

at

the

screw

screw

when

the

to

adjustments:

Clockwise

(4)

counterclockwise

screw

it

may

butts

time

engine

screw

(A)

rotation

will

decrease

operates

leaner.

butts

(16)

(4)

be

necessary

against

IDLE

position.

IDLE

the

begins

A

for

the

Rotating

priortop/acing

position.
engine

in

engine.~

until

(16)

adjusting

the

idle

position.

of

until

smoothly.

against

the

mounting

Operation

immediately

to

return

Figure

desired

1200

rpm

vacuum

the

engine

the

the

screw

the

to

adjust

When

If

9-7.

time

is

motor

Maintain

screw

(4)

rpm.

engine

Rotating

(20)

vacuum

the

IDLE

screw

plate.

of

the

the

engine

comes

idle

to

rpm.

the

engine

This

delay.

obtained.

idle

pressure

will

begins

the

on

increase

falter

to

screw

counterclockwise

unit

motor

mounting

CONTROL

Check

(16).

deviceisautomatic

idling

is

running,

weld

to

up

The

length

does

not

is

screw

-

rpm.



the

arm

engine

or

clockwise

(20)

switch

by

engine

rpm.

of

to

go

located

to

(3)

rpm,

then

roll;

admits

plate

in

the

manually

rpm

When

this

time

idle

rpm

the

on

IMPORTANT

______________

due

to

then

be

Is~..tU.I

6.

Place

ing

the

Check

7.

ment

A.

B.

C.

the

linkage

necessary

~

~

I

nut

Ensure

the

(11).

securing

the

is

deemed

IF

REGULATION

sitivity

IF

REGULATION

sitivity

IF

ENGINE

sitivity

Check

socket

to

readjust

that

CONTROL

IDLE

Adjust

nut

(11)

governor

necessary,

adjustment

adjustment

SURGES

adjustment

the

(18)

body

linkage

being

the

limbs

(19)

outof

vacuum

switch

the.governor

maintain

to

RANGE

screw

RANGE

screw

(HUNTS)

screw

regulation

loosen

IS

(14)

IS

(14)

(14)

engine

for

proper

clear

are

the

in

speed

the

one

TOO

inward.

TOO

outward.

UNDER

outward.

freedom

alignment

idle

motor

of

the

LOCK

adjustment

governor

by

applying

of

the

two

BROAD

NARROW

LOAD

-~

of

screw

fan

OUT

speed

-

Decrease

-

movement

and

with

(16)

and

the

position.

screw

setting.

removing

locking

Increase

Increase

throughout

the

fixed

and

vacuum

Loosen

until

(12)

the

nuts

(13)

the

governor

the

governor

the

governor

end,

repeat

the

a

engine

and

its

adjust

Steps

motor

governor

high

proceed

spring

spring

spring

entire

unit

idle

load.

4

rpm

with

(15)

travel.

the

and

before

speed

of

If

a

(15)

(15)

-

If

tength

5.

working

adjusting

1850

governor

the

following

tension

tension

tension

the

linkageisbinding

of

the

linkage.

the

on

screw

is

obtained.

sensitivity

instructions:

by

sliding

by

sliding

by

the

the

the

sliding

It

will-

engine.

secur

Tighten

adjust

sen

sen

sen

8.

Tighten

by

repeating

the

two

Step

locking

7.

nuts

(13)

to

maintain

the

desired

governor

sensitivity.

Readjust

the

governor

sensitivity

)

Whenever

Amend

The

ft.).

ment

Loosen

main

screw

Rotating

Whenever

1~

the

Section

Teledyne

Minor

adjustment

is

deemed

the

main

adjustment

counterclockwise

(21)

the

screw

counterclockwise

nut

(22).

IMPORTANT

Delete

Figure

AMENDMENT

Amend

Figure

the

governor

9-10.

HIGH

Walbro

carburetor

will

necessary,

adjustment

screw

(21)

admits

Restricting

9-8.

High-Altitude

TO

SECTION

Circuit

10-1.

governor

(Step

speed

ALTITUDE

be

necessary

see

screw

clockwise

(21)

until

clockwise

more

fuel,

the

Diagram

sensitivity

is

61

CARBURETOR

be

can

equipped

for

Figure

9-7

locking

until

the

engine

restricts

making

fuel

flowtothe

Carburetor

-

10

TROUBLESHOOTING

7)

(Step

adjusted,

with

proper

and

nut

the

operation

proceed

(22).

Apply

engine

operates

the

fuel

the

flow,

air-fuel

point

Adjustment

is

adjusted,

the

governor

MODIFICATION

an

adjustable

follows:

as

near-full

a

begins

smoothly;

making

mixture

where

the

governor

sensitivfty

main

at

a

particular

engine

falter

to

then

continue

air-fuel

the

richer.

the

mixture

(Step

(Optional)

for

jet

altitude.

loadtothe

lose

and

counterclockwise

mixture

Remove

is

too

EOWE3

AC

(Step

speed

MAY

71

(Figure

high-altitude

Whenever

welding

RPM.

Rotate

leaner.

the

engine

lean

,,_-_~___

load.

will-cause

5EU~A4~.

~

S~3ED

MUST

6)

need

readjustment.

9-7)

operation

carburetor

a

generator.

main

the

rotation

Rotating

Tighten

valve

GRCcu~UIC

be

readjusted.

(above

adjust

Rotate

adjustment

of

1/4

the

screw

the

locking

burning.

4000

the

turn.

(21)

*.OTE

33

72

r.._77

No.

REAR

B-081

127

24

VIEW

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23

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CAUTION

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AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-457C

Page

E

p.

6677

OF

CONTENTS

Page

No.

Section

TABLE

No.

SECTION

SECTION

SECTION

SECTION



1

SAFETY

1

-1.

Introduction

-

2.

General

1

-

1

Arc

3.

1-4.

2-1.

2-2.
2-3.

2-4.

3-1.
3-2.

-

3
3-4.
3-

4-1.

-

4

-

4

-

4

4-5.

Welding

Standards

2

INTRODUCTION

General

Receiving-Handling

Description

Safety

INSTALLATION

3

Location

Weld

Output

3.

Equipment

Remote

5.

120/240

4

ENGINE

Lubrication

2.

Coolant

3.

Preparing

Cleaner

Air

4.
Fuel

RULES

Precautions

Booklet

Connections

Grounding

Amperage

Volts

AC

PREPARATION

System

New

Battery

OPERATION

FOR

Index

Terminal

Control

Terminals..

For

Connections

Service

OF

ARC

WELDING

POWER

SOURCE

1

3

4

5

5

5

5

7

8

8
8
9
9

SECTION

SECTION

SECTION

5-1.

-

5
5-3.

5-4.

5-5.

-

5

5-7.

5-8.
5-9.

6-1.
6-2.
6-3.

6-4.

6-5.

6-6.

6-7.

-

6

7-

-

7

-

7

-

7

2.

6.

8.

1.

2.

3.

4.



FUNCTION

5

Volts

120

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Fine

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Remote

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Duty
Polarity

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240

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6

FUNCTION

Choke

Push

Start

Idle

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Engine

Temperature

Pressure

Oil

Electrical

Hour

Total



SEQUENCE

7

Sheilded

Power

Starting

Engine

AC

Amperage

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AC

Control

Button

Switch

Ammeter

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Metal-Arc

Plant

Operation

The

Down

Shut

OF

GENERATOR

Receptacle

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Control

Curves

Duplex

OF

ENGINE

And

Gauge

OF

OPERATION

(SMAW)

Engine

Receptacle

CONTROLS

Switch

Welding

CONTROLS

10

10
10

10

10

11

11
11
11

12
12
12
12
12

12

12
12

13
13

13
13

Section

SECTION

8-1.

-

8

8-

No.



8

General

Collector

2.

3.

Welding

GENERATOR

Cables

Ring

MAINTENANCE

Brushes

Page

No.

14

14
14

SECTION

SECTION

PARTS

9

9-1.

Lubrication

9~

2.

Coolant

9-3.

Governor

9.

4.

Carburetor

9-

5.

Vacuum

9.6.Idle
9-

7.

Carburetor

9-8.Air
9-

Idle

9.

9.10.

High

9.11.

Key

9-12.

Spark

10

LIST

ENGINE

MAINTENANCE

System

Service

Float

Circuit

Control

Cleaner

Control/Governor

Type

TROUBLESHOOTING

Altitude

Ignition

Arrestor

Time

Air

Temperature

Service

Carburetor

Setting

Filter

Air

Delay

Switch

Adjustment

Selector

Linkage

Modification

Lubrication

Adjustment

14

14

15

15

15

15
15
16

17

18
18

18

SECTION

1-SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

1-2.

A.

B.

INTRODUCTION

We

learn

experience,
wasteful,

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ing

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given.

technical

Read

to

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2

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Page

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paragraph

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or

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TIONS
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downstream

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gas.

green

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for

clamps

substitute)

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leaks.

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orifices
for

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less

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right

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open

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cylinder

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regulator

inlet

a

regulator

connections.

smooth

disassemble,

wrench.

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cylinder

to

threads.

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on

from

label

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to

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a

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hammer

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ignition.

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assembling

necessary.

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fuel

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prevents

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persons

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ting

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staging-support

operation;

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with

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rise,

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hot,

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referenced

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with

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severe

PRECAUTIONS.

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long-sleeve

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skin

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12

before

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radiation

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to

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of

entry

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eyes

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welding

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at

source

rope

precautions

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trouble.

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ultraviolet

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compressed

unnecessary

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painful.

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clothing

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of

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shield

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in

index.

in

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and

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equipment.

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face

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GROUND

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line

a

ment

the

to

connection

must

comes

receptacle.

use

a

plug

precautions

engine

monoxide

and

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with

precautions

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cable

connections

strike

an

brittle

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a

rupture

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precautions

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hot

conductors

in

or

shock

a

STAND,

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against

and

body

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power

the

building

ground

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connection.

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single-phase

line.

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-

HOT

a

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with

cord

for

connection

grounded

to

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connected

with

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three-prong

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rated
may

arc

area

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ungrounded,

person

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clothing

insulation

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electrical

currents

the

connect

source,

currents

current

electrical

NOT

wire,

dangerous

check

switchbox.

a

grounded

broken

a

exhaust

kill.

can

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capacity.

overheat

on

a

cylinder

that

later

under

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whose

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without

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dry.

against

rubber

sea

HOT

to

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control,

ground.

safely.

may

conduit,

such

liquid

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If

equipment

connect

the

or

ground

bare

metal

a

ground

to

a

switchbox,

the

to

plug,

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off

in

1-2B.

be

must

in

may

can

in

or

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mat

part

flow

the

condition

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cables

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other

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other

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electrically-HOT

becomes

body

OR

ON,

suitable

protection.

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work

electrical

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moisture

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-

or

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resistance,

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shock,

only

lead

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through

frames

i&ork

Equipment

possibly

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oil

as

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phase

3-phase

to

the

equipment

equipment

for

continuity.

of

equipment

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provided

a

three-prong

receptacle,

prong

connect

ground

prong.

enabling

table,

to

only

that

connect

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fire.

cause

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pressure

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a

TOUCH

in

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shock.

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metal-reduces

dangerous

the

body.

of

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water

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fatally.

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pipe

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requirement

power

two

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frames

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with

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body

unit

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adequate

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NOT

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ANY

of

equip

is

available,

wires

of

lead

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possibly

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at

connec

the

equip

ground

is

added

ground

the

line

cord

mating

a

plug,

lead

can

DO

sur

on

can

and

the

lead

for

lead

air.

a

It

a

as

to

to

or

Trademark

of

Proctor

&

Gamble.

OM-457

Page

3

2.

Electrode

insulated

Fully

holders

use

3.

Connectors

insulated

Fully

welding

4.

Cables

Frequently

IMMEDIATELY

damaged

bared

cable.

resistance

cable

Keep

hot

metal

5.

Terminals

Terminals
have

insulating

6.

Electrode

Electrode

switch

of

trigger

gun

other

HOT

7.

Safety

devices

Safety

not

be

disconnected

Before

installation,

OFF

all

switches)

all

nect

volts

line-cord

Holders

with

cable

lengths.

inspect

insulation

Cables

equivalent

dry,

and

sparks.

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and

covers

Wire

wire

metal-arc

gas

is

pressed.

parts.

Devices

such

power

to

prevent

cables

plu~.

electrode

protruding

lock-type

cables

REPLACE

to

with

to

free

of

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other

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secured

becomes

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es
or

inspection,

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remove

accidental

from

welding

holders

screws.

connectors

for

those

avoid

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original

oil

and

Exposed

parts

before

electrically

welding

equipment

hands

interlocks

shunted

or

line

turning

power

should

wear,

with

areas

cable.

grease,

Parts

of

and

and

out.

service,

fuses

be

used.

should

be

cracks

excessively

-

lethal

be

may

and

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electrical

operation.

HOT

when

is

ON

clear

body

circuit

breakers

of

equipment,

lock

(or

ON

of

power.

and

source,

used

and

shock

taped

units

the

and

of

pull

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to

damage.

worn

to

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all

NOT

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115

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not

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connect

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power

1-4.

STANDARDS

For

or

their

1.

2.

burns,

equipment

all

disconnect

source.

more

latest

ANSI

CUTTING

Society,

ANSI

TION

AND

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emergency,

power

information,

revisions

Standard

2501

Standard

obtainable

Institute,

3.

American

AND

CUTTING

COMBUSTIBLES,

4.

NFPA

Standard

FOR

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National

5.

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Boston,

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6.

CGA

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BOOKLET

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INDEX

the

to

es

SAFETY

from

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American

New

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same

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item

as

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polarity

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Fla.

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IN

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HAVE

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obtainablefrom

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guard

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the

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or

Page

4

SECTION

2-

INTRODUCTION

Rated

Amperes

Output

350

@

100%

Duty

40V

Cycle

Welding

Current

Range

45

475

To

Amps

Welding

Coarse

45-

65-140

100-220

130

220

Current

In

Amperes

Ranges

85

.

300

-475

Ranges

Fine

From

To

Max.

Each

Range

Figure

Range

Mm.

Coarse

Open-Circuit

Voltage

Range

Of

55
DC

2-1.

Specifications

To

Volts

Weight

Power

3kva
Volts

7.5

Power

AC

Hz.

Welding

kva

Volts

Hz.

Plant

120

50/60

90

While

120/240

50/60

As

Dimensions

(Inches)

-

43-1/2

Height

Width

-25

-

Depth

AC

63

(Pounds)

?~i~E

1520

1560

~.

GENERAL

2-1.

This

izing

tenance,
tion

assure

RECEIVING-HANDLING

2-2.

Prior

from

that

or

damage

the

purchaser

and

freight

occasiontofile

When
essential
Serial

2-3.

DESCRIPTION

This
Unit

(SMAW)

output
generator.

ac

output

etc.,

manual

personnel

and

presented

optimum

to

installing

around

have

may

that

bill

requesting

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(or

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will

produce

Welding

of

7.5

A

of

while

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has

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prepared

the

with

troubleshooting

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performance

the

occurred

may

with

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claim

Model

Numbers

generator

kva

duplex

up

design,

should

this

equipment,

unit

and

during

have

the

carrier.

arises.

information

Description

dc

a

when

used

120/240

at

receptacle

3

kva

to

be

of

carefully

occurred

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of

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driven

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120

at

of

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on

Figure

in

equipment.

careful

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clean

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copy

carrier

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for

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Stock

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a

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when

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equipment,

Number

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provide

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instructions,

duplex

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SAFETY

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tenance

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welding

generator

240

volts

optional

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be

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desired,

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receptacle.

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equipment

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definitions

blocks

this

heading,

procedures

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auxiliary

receptacle

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see

delete

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If

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ac

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when

operated

the

power

equipment.

AMMETER

supplied

used

by

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is

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ammeter

to

a

discharge

the

ted
volts

the

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are

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at

volts

ENGINE

6-4.

ENGINE

The

being

also

be

being

is

not

registers

ac

power

VOLTS

120

be

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the

the

from

registers

the

battery

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engine

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(Figure

equivalent

electrical

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low

amount

when

to

or

off

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120

the

which

generator.

of

current

the

generator

is

It

Page

6-2.

6-3.

12

START

START

A

the

on

Rotating

and

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starter

started,

rotate

clockwise

CONTROL

IDLE

This

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standard

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not

loaded,

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trol

panel,

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idling

MATIC

tion

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LOCK

necessary

(1800).

rpm

120

volts

receptacle

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push

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the

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pressing

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to

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7.5

the

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stopping

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6-1)

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120

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the

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IDLE

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6-1)

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rpm.

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indicate

to

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indicates

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(Figure

indicates

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the

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coolant

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6-1)

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0-4000

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the

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personnel,

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generator

enclosure

EAr1

SECTION

ope~he

of

the

to

being

the

to

reduced.

greatly

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operated

or

open

outer

a

internal

removed.

SEQUENCE

7-

welding

enclosure

hazard

com

Warranty

with

any

OF

OPERATION

1.

Ensure

that

the

the

in

in

Section

Section

FINE

engine

instructed

2.

Make

connections

instructed

to

3.

Rotate

counterclockwise)

4.

5.

the

Start

Place

position

the

engine

IDLE

and

as

CONTROL

commence

been

has

4.

the

to

3-5.

AMPERAGE

prepared

120/240

controltothe

setting.

instructedinSection

switch

operation.

volts

in

7-3.

the

for

ac

operation

terminals

100

LOCK

as

as

(full

OUT

7-1.

7-2.

Make

120

minal

The

low
This

SHIELDED

Prior

clothing

(glasses

comply

damage.

1.

Ensure

Section

2.

Make

quired.

3.

Place

4.

Rotate

setting.

5.

If
the

STANDARD

to

switch

6.

Start

7.

Place

and

8.

The

control

POWER

VOLTS

engine,

voltage

could

to

the

Remote

a

REMOTE

be

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the

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FINE

PLANT

all

sure

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when

at

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METAL-ARC

welding,

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and/or

may

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the

4.

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Ignition

the

FINE

place

in

REMOTE

the

engine

IDLE

AMPERAGE

if

used)

electrical

AC

turned

the

welding

result

engine

receptacle

off

starting,

output

in

damage

it

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in

-

has

the

to

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equipment

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serious

in

AMPERAGE

the

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position.

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as

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welding.

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OPERATION

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low

receptacle

electrical

to

(SMAW)

that

gloves)

_________________________

been

weld

OFF

the

CONTROL

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a

switch

control

connected

starting

rpm

of

the

volts

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120/240

equipment.

WELDING

proper

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eye

be

on.

put

or

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prepared

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position.

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is

not

to

Amperage

AMPERAGE

7-3.

the

desired

in

(or

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while

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the

to

ac

ter

the

engine.

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generator.

protective

protection

Failure

bodily

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in

switch

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CONTROL

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amperage

7-3.

STARTING

THE

ENGINE

IMPORTANT



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Check

the

Make

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the

before

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I

1.

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in

as

re

2.

3.

4.

5.

all

Make

generator.

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the

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position.

engine

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to

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the

the

START

engine

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no

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gasoline.

and

CONTROL

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up

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push

oil

level

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parts

connections

the

to

start

electrical

be

should

idle

at

rpm.

necessary.

switchtothe

button.

radiator

are

laying

to

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unit.

connections

switchinthe

in

order

done

RUN

position.

coolant

in

the

the

level.

the

unit.

generator

fuel

tank

the

to

welding

AUTOMATIC

to

permit

the

IMPORTANT

button.

in.

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engine

I

full

the

I

Always

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stopped

otherwise

motor,

is

7.4.

6.

When

As

ENGINE

1.

Remove

2.

Allow

length

load.

the

the

engine

the

This

temperature

ensure

SHUT

all

of

rotating

engine

warms

weld

engine

time

idling

has

that

DOWN

if

time

a

the

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up,

and

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to

the

chance

the

ring

is

starter

before

or

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slowly

power

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engine

to

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to

re-engaging

pinion

the

push

loads

few

a

has

equalize.

pinion

may

START

the

from

minutes,

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that

and

the

be

damaged.

push

CHOKE

the

allow

operating

the

intemal

flywheel

starter

generator.

IMPORTANT

~

I

Make

120

minal

The
low
This

sure

VOLTS

strip

engine,

voltage

could

all

AC

is

when

at

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electrical

receptacle

turned

starting,

the

output

in

damage

equipment

off

before

has

receptacle

to

and

low

electrical

connected

120/240

starting

rpm

of

volts

ac

the

engine.

which

the

generator.

equipment.

to

causes

the

ter

3.

Do
120

during

Place

not

VOLTS

the

operate

the

Ignition

accessory

AC

receptacle

shutdown-idling

engine

switchinthe

IMPORTANT

power

or

equipment

120/240

period.

OFF

volts

position.

from

terminals

OM-457

the

Page

13

8-1.

1

If

work

any

the

remove

vent

engine

catching

and

casting

connect

GENERAL

Economical

power

generator

reasonable

Ottasional

pressed

periodically,

amount

attention.

air

of

ckist

is

to

spark

compression

the

repairpersons

the

the

negative

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blowing

recommended.

is

depending

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dirtinthe

SECTION

-

8

GENERATOR

CAUTION__.!

be

doneonthe

from

plugs

stationary

I-)

battery

trouble-free

and

based

of

out

upon

from

hand

adapter

upon

the

This

the

atmosphere.

o~enerator,

rotor

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turning

cable

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locationofthe

engine.

between

casting.

from

service

regular

with

should

This

the

the

the

inspections

clean

be

will

rotor

rotor

Also

battery.

this

of

dry

performed

unit

and

pre

and

dis

fan

weld/

and

com

the

MAINTENANCE

COLLECTOR

8-2.

The

proper

conditions.

extremely

brushes

made

dark

a

rings,

Never

into

8-3.

WELDING

Check

should

flon

cables

brushes

function.

for

weekly.

brown.

use

a

use

the

rings

connections

be

should

replaced.

emery

inspected

BRUSHES

RING

should

be

inspected

The

the

Under

If

or

it

finer

cloth

in

should

brush

generator

of

movement

normal

sandpaper

as

turn

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dustyordirty

freedom

3/0

and

CABLES

periodically

be

frequently

repaired

with

life

location,

use

become

part

destroy

electrical

periodically

is

very

been

has

a

and

the

slip

necessary

followed

of

the

emery

the

carbon

for

tightness.

and

all

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to

under

good

operating

check

close

cleanliness

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rings

to

a

by

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in

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embed

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the

tape

normal

should

the

their

in

of

cloth.

itself

cables

insula

or

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the

be

to

slip

the

SECTION

9-1.

LUBRICATION

This
become

engine

checked

be

some

about50hours

oil

and
factured
used
mended

during

The

quarts,

make

to

engine

fully

should

engines

change

by

as

a

replacement

grades

break-in

capacity

without

sure

will

a

any

oil

require

broken

be

number

will

of

the

and

and

of

a

level

kept

use

running

oil

one

types

to

the

filter

at

in.

as

of

oil

filter.

of

oil.

use

engine

change.

is

up

least

During

as

light

times

during

time

Premium

the

major

Table

of

oil

after

withafilter

the

to

50

hours

this

period,

possible.

during

the

break-in

the

on

oil

9-1

to

use

break-in

the

4

quarts.

required

an

break-in

heavy

companies,

gives

~mixd4erenandso!ls.GeneraIly,motor

oils

fall

into

two

sulphonate

the

produce

chemical

cating

~cause

In

normal

hours

of

oil

should

normal
ticle

suspension

drained.
crankcase

removal

base.

sulphonates

good

reaction

properties

extensive

operation,

operation

be

drained

operating

in

Foreign

when

thus

and

categories:

The

phosphate

alkaline.

are

oils,

mixing

which

of

either

to

damage

should

oil

with

filter

a

after

oil

oil

and

tend

is

the

allowed

temperature,

the

particles

the

contaminating

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greatly

oil.

The

the

engine.

be

change

engine

thus

thereby

to

the

phosphate

base

Although

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changed

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promoting

removal

settle

to

cool,

new

bases

every

at

oil

of

running

the

The

oil

operating

period.

duty

list

a

to

keep

oil

change

Check

operating

base,

oils

are

both

produces

the

of

oils

after

150

been

warmed

when

the

bottom

thereby

added.

9

-

time

loadonthe

level

should

day,

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oil,

manu

oil,

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of

recom

oil

level

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is

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dip

level.

and

acidic;

bases

lubri

could

about

hours.

up

foreign

the

of

avoiding

ENGINE

to

as

After

the

be

up

4-1/2

stick

a

1

50

The

to

par

oil

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the

MAINTENANCE

9-2.

COOLANT

Caution

ing

almost

has
within
before

neck.

a

glove

from

N

If

the

make
added

often

lU.S.

During

est

dangersisover-heating.

of

over-heating,

engine

At

the

make

Temperature

static

head.

determined

170F

the

valve

the

system

SYSTEM

should

radiator

the

full

made

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completely

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or

possible

engine

sure

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the

to

as

necessary.

Measure).

the

break-in

lubrication

first

sign

a

thorough

of

valve

locatedinthe

This

unit

tem~erature

180

and

opens

begins.

be

exercised

pressure

position,

open

to

permit

radiator.

removing

removing

be

used

rag

exposure

is

to

be

operated

good

gradeofethylene

coolant

system.

The

period

but

the

and

coolant

of

over-heating,

check

to

the

engine

retards

F.

When

and

free

CAUTION

at

all

The

cap.

at

which

venting

Allow

the

the

cap

is

the

coolant

is

the

it

cap,

to

protect

to

extremely

in

a

temperature

Change

system

of

a

new

engine,

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basic

determine

the

circulationofthe

are

items

circulation.

shut

coolant

outlet

at

flowoLcoolant

reached,

desired

the

is

the

usually

temperature

times

will

cap

point

built

pressure

from

recommended

the

operators

hot

coolant.

glycol

the

coolant

capacity

several

for

consideration

the

engine

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regulated

frontofthe

when

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provision

up

to

the

anti-freeze

one

possible

by

varying

coolant

remov

to

pressure

escape

radiator

that

hand

below

solution

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9

of

the

down

thermo

a

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until

between

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0F,

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great

causes

a

U

I

is

as

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and

pre

Page

Above

Not

low

As

above

Aslowas

Lower

below

lower

slow

Table

90

degrees

than

10

as

zero

lOdegrees

zero

than

zero

9-1.

32

degrees

Fahrenheit

Fahrenheit

10

degrees

Fahrenheit

Selection

Oil

Fahrenheit

degrees

Guide

SAE3O

.

SAE

1OW-30or1OW-20

SAE

1OW-30

SAE

1OW-30or1OW-20

SAE

20

20W

lOW

SW

or

or

or

or

10W-30
20W

1OW-20

5W-20

1

th~

Ensure

rating.

the

thermostat

heat.

without

run

a

result,

become

The

engine

mal

wear

periodically.

50

hours

placed.



tliermostal

that

the

Do

not

run

If

the

thermostat

a

thermostat,

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contaiminated

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fan

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Check

of

operation,

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replacement

the

engine

remains

remains

will

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with

and

alternator

be

and

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fail,

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without

closed,

the

accumulate

sludge.

belts

checked

and

whenever

replace

an

the

open,

engine

are

for

tension

it

immediately.

equal

thermostat.

a

engine

or

will

and

subject

proper

after

belts

temperature

will

over

the

engine

cold.

run

oil

the

to

tension

the

are

will

nor

first

re

I

If

is

As

14

9-3.

GOVERNOR

The

governor

obtain

to

set

load

ing

factory

less

absolutely

speed

Correct

conditions.

locked

SERVICE

setting

weld

with

a

necessary.

The

lead

and

rpm

governor

seal.

NOTE

sensitivity

and

engine

speed

Do

not

setting

response

control

remove

are

this

factory

to

chang

setting

seal

9-5.

VACUUM

In

order

fitting

is

un

idle

This

gasoline
engine

to

type

control

brass

or

operation.

CIRCUIT

provide

air

valve.

fitting

suitable

a

cleaner

See

will

clean

solvent

AIR

air

is

provided

Figure

have

FILTER

for

the

vacuum

on

9-3

for

location

be

removed

to

periodicelly

(Figure

circuit,

the

underside

on

and

to

ensure

9-3)

the

cleaned

brass

a

of

the

engine.

in

proper

9-4.

A.

The

governor,

does

,d~cribed

The

engine

1800

and
tion

concerning

Manual,

CARBURETOR

Zenith

Carburetor

Do

not

bodies.

endofthe

right

freely

To

ensure

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tance

machined

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body

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the

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Page

The

angles

on

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1/32

of

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the

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bend,

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the

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used

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Engine

set

to

it

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float

9-1)

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body

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to

the

the

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with

1200

at

speed.

refer

between

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plus

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device

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vacuum

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9-4)

the

an

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9-6.

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Air

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Page

15

9-8.

A.

The

air

tube

which

rounding

around
prevent

Figure

operating

remain

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warm

slide

it

AIR

CLEANER

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door

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on

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B.

Weekly

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tions

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a

Page

9.6.

Air

Figure

16

Cleaner

Service



A

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Figure

9-4

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1

10

9-9.

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226

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17

6.

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the

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(23)

(23)

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(22)

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screw

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spring

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spring

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governor

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screw

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ed,

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speed

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sensitivity

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the

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its

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IDLE

IDLE

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when

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the

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fitting

Figure

the

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time-delay

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going

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rpm

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idle

idle

(12)

travel;

socket

fixed

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butts

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butts

CONTROL

Operation

IDLE

CONTROL

position.

remain

time

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the

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this

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idle

to

go

time-delay

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into

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to

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screw

rpm

rpm.

freedom

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the

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to

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stop

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in

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the

device

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switch

engine

arc

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immediately

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Figure

about

for

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carburetor

9-8

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until

the

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rotation

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point

burning.

MODIFICATION

with

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4000

operation

adjustment

proceed

nut

generator.

the

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fuel

the

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LUBRICATION

adjustable

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follows:

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particular

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carburetor

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the

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non-gumming

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oil

Page

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While

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1000

in

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adjustment

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instructions:

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screw

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nuts

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high

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speed

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idle

rpm

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nut

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LOCK

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speed

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1800

maintain

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by

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the

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if

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I

A.

Inspection

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2.

3.

The

engine

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the

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the

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Check

arrestor

exhaust

equipped

ordered

maintained

if

this

National

a

or

state

your

the

corrosion.

stopped,

a

flashlight

and

vanes

vanes

outlet

factor

mounting

mounted.

system

with

as

in

welding

forest

Public

Resources

and

local

outsideofthe

look

the

outlet

must

be

tube

must

in

clamp

this

on

a

spark

an

optional

effective

generator

Forest,

covered

laws.

inside

other

or

tube

attached

firmly

be

completely

maintaining

to

ensure

welding

arrestor

accessory.

working

or

on

land

Code).

device

the

source.

light

for

generator

unless

is

California

Section

(see

For

spark

metal

to

intact

spark

that

it

A

order,

be

to

other

for

holes,

arrestor

Visually

weld

or

inlet

the

(this

arresting

the

spark

I

B.

Servicing

I

Service

from

I

I

1.

2.

Stop

Remove

arrestor

hole,

3.

Start

particles

discharge,

stack.

4.

Stop

The

the

device

sparks

flying

the

engine

the

cleanout

withawrench.

break

it

the

engine

out

momentarily

the

engine.

Carbon

and

loose

and

the

Replace

Trap

in

an

hot

or

allow

plug

with

run

cleanout

where

area

carbon

the

from

If

a

screwdriver

a

it

at

hole.

cover

and

secure

particles.

exhaust

the

crust

idle

rpm

If

the

there

is

system

bottom

has

formed
similar

or

to

particles

end

of

the

cleanout

no

blow

of

to

the

are

danger

cool.

the

spark

over

tool.

collected

slow

exhaust

plug.

I

the

to

Hazardous

cuitry
running.

inspection

Troubleshooting

formed

The

following

remedies

welding

for

generator.

of

Shut

by

some

voltages

the

welding

down

work

or

qualified

chart

of

CAUTION

are

the

of

internal

personnel

is

the

present

generator

engine

the

on

designed

troubles

9-8.

Figure

SECTION

t~ternalcir

on

while

inside

diagnose

that

the

attempting

of

should

develop

may

before

circuitry

only.

to

High-Altitude

10-

TROUBLESHOOTING

is

engine

any

the

unit.

be

per

and

provide

in

this

Vacuum

Motor

Unit

Carburetor

It

according

generator

developed.

Use

performing

remedied

Factory

all
recommendations

Adjustment

is

assumed

Section

to

has

this

chart

troubleshooting

after

Authorized

of

cases

that

3

been

functioning

in

conjunction

performing

Service

equipment

should

proper

of

this

procedures.

malfunction,

be

strictly

installation

manual,

properly

with

these

Station

and

until

circuit

the

If

the

procedures,

should

the

followed.

TC-003

has

been

that

the

this

diagram

trouble

the

be contacted.

manufacturers

OM-457

226

made,

welding

trouble

while

is

not

nearest

Page

In

ig

No

weld

output

terminals.

receptacle

~

No

output

terminals.

well

as

VOLTS

.

No

output

receptacle

well

as

output

No

weld

Erratic

Engine

when

CONTROL

AUTOMATIC

-

Engine

when

CONTROL

AUTOMATIC

output

from

AC

120/240

is

normal.

.

or

weld

speed

arc

will

arc

TROUBLE

120/240

120

RC1

Output

from

Weld

Output

as

output

receptacle

from

Rd.

volts

ac

power

current.

-

remains

is

struck

switch

IDLE

return

not

broken

is

Switch

IDLE

or

120/240

volts

volts

VOLTS

normal,

~S

120/240.voltsac

is

normal

from

RC1.

120

VOLTS

Weld

output

plant

power

output,

-

-.

-



-

at

idle

rpm

and

IDLE

S2

is

position.

-

idle

to

rpm

and

IDLE

S2

is

position.

-

AC

120

AC

ac

as

in

in

~

~

-Defective

-

-

Shorted

PROBABLE

R

EM

0

CONTROL
REMOTE

remote

connected

Remote

n

AMPERAGE

receptacle

Loose

volts

Defective

Loose

AC

Defective

Defective

Damp

Loose

Check

RANGE

Magnetic

switch

Coilofidle

GS1

Filter

Idle

Idle

Leak

S2.

t

o

Fuse

Fl

ac

receptacle

burned

on

control

control

in

amperage

secure

connections

terminals.

connection

or-defective

or

dirty

.leads

Switch-S3.

CR1.

solenoid

vacuum

IDLE

T

E

position

a

mpe

to

RC2.

and/or

power

120

brushes.

rotor.

and

field

-

control

out.

valve

-

valve

CAUSE

AM

P

switch

rage

welding

control

i

A

n

CONTROL

F2

is

open.

at

winding.

120

at

Rd.

volts

ac

winding.

electrodes.

connections.

Contacts

not

closing

solenoid

plugged.

GS1

closed.

GS1

plugged.

line.

CONTROL

EAAG

is

S5

with

control

generator.

plug

EMOTE

120/240

VOLTS

of

the

reed

-

-

valve-

switch

-

E

in

no

is

Place

the

REMOTE

STANDARD

the

controltothe

RC2.

Insert

remote

and

RC2

Check

Secure

Have

Secure

Have

station.

Replace

Have

Use

Check

and

connections.

power

all

120

brushes.

rotor

dry

new,

Connections

rotate-as

replace

connections

generator.

Discoloring

loose

by

Replace

Apply

connection.

CR1.

-

12

vdc

operation.

filter.

Clean

valve

Open

Remove

Check

Check

-

and

line.

switchS2with

-

REMOTE

amperage

winding

volts

replaced

electrodes.

of

brass

to

-

See

GS1

clean

-

position

far

fuses

replaced

ac

winding

at

contacts

solenoid

Section

by

turning

GS1.

-

-

AEMEDY

AMPERAGE

AMPERAGE

control

as

possible

FlorF2

120

to

authorized

both

Replace

9-8

ohmmeter.

-

or

connect

plug

in

a

as

at

authorized

VOLTS

replaced

service

inside

and

could

contact

-

coil

GS1

for

cleaning

in

counterclockwise

a

-

-

CONTROL

a

CONTROL

fully

clockwise

required.

AC

receptacle

authorized

at

station.

outside

indicate

switch

or

and

-

procedure.

-

-

-

-

remote

into

service

heating

check

-

switch

amperage

receptacle

receptacle

direction.

station.

PCi.

-

-

of

welding

plate

for

-

direction.

-

S5

service

caused

53.

of

proper

in

-

Page

1f it

20

becomes

necessary

to

replace

any

fuseinthe

welding

generator,

ensure

that

proper

sizeisused.

the

fuse

of

a

-

NOTE

GROUND

INSTALLED

ERAME

NEUTRAL

POWER

AC

r~<CI

lh-<

EIT

GAS

CAUTION

OWNERS

TO

REFER

p

I

I

I

I

AlT

TIME

ATTEMPTING

AND

METER

UOLTDGE

1-

EQUIPMENT

GROUND

STRAP

RETWEEN

AND

WELDER

RE

MUST

ENGINE

FRAME

I

I

I

INCLUDING

I

C0)

OPTIONDL

RECEPTACLE

P4RU.

LP
TOTAL

2ADVOLT

GROUNDING

IF

DESIRED

I3~ft45

~

j3,

JR~~

PIC.R

~

~t50~

23

REAR

127

DIEW

ThERR4

30t~

2D

5333

~

LOW

Figure

1O~1.

Circuit

Diagram

Circuit

Diagram

No.

CB-901

775-itt

OM-457

Page

21

April

1978

FORM:

OM-457C

Effective

With

Serial

No.

HJ134589

PARTS

LIST

54
55

56

57

58

OM-457

Page



A

Figure

1

Main

Assembly

CD

11

w

~

~

a1_

a

0

0

-I

0

9

(11

0

CD

03

C~

0

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Page

A

Figure

1

2

3

4

017

010434

006698

018

602

5

6

7

8

9
10
11
12

13

14

15

.

16
17

010870

010

006 014

007

010

017

031

018

018

008698

010 433

*017

018

000

18

19

20

21

22

23

24

25

26
27

28
29

30
31
32

33

34

35
36

37

38
39

40

010

018
023

022 899

010515

005612

008766

035

027
010

*028262

015

010

073

027564

053724

017
028

605
008
006015
006
005

41
42
43

44

45
46

47

48

018

017

020
025
025

025
605
026

49

50

51

605

025181
005108
010

52

53

54

Batt

55

5~

3

57

Figure

017421

017

*015

023
017

Main

Assembly

430

858

938

STRAP,

mounting

STRIP,rubber

TANK,fuel

tank-fuel

CAP,

.

FITTING,

pipe

-

fuel

2x

1/2x

(consisting

-

of)

galvanized

FITTING,pipe-brassnipplehexl/8NPT

318

829
289
479

868

765

859

VALVE,

FITTING,

fuel

LINE,

FITTING,

SEAL,

BRACKET,

AIR

CLEANER,

CAP,

.

shut-off

weather

cleaner

air

-

-

brass

flared

(usedwith

-

brass

flared

-

lift

mounting

intake

-

w/strainer

Marvel

eye

-

intake

.BAFFLE,dust-cap

-

7/16-20

309

861

272

861
365
626

NUT,

.

ELEMENT,

.

BODY,

.

CLAMP,

.

CLAMP,

HOSE,

CABLE,

DOOR,

BOLT,J

wing

air

air

hose

intake

battery

access

5/16-18

steel

air

cleaner

cleaner

cleaner

1-1/16-2

-

air

-

-

battery

clamp

insulated

DOOR,side

COVER,top

968
529
875

WASHER,

cotter

PIN,
CLAMP,

neoprene

1/4x3-1/2

muffler2inch

5-7/8

MUFFLER,exhaust

700

955

355

BRACKET

WASHER,

.

SPR

.

ING,

compression

ASSEMBLY,

-

flat

steel

13/32

.SPACER,anti-noise

GUARD,fan

363

404

982

777

i~adiator

HOSE,

RADIATOR

radiator7lb

CAP,

.

ENCLOSURE,

-

upper

(consisting

pressure

radiator

FITTING,pipe-brassdraincockl/4NPT

037

112

757

594

365

453
884

182

429
837
430

radiator-lower

HOSE,

ENGINE,

BLADE,

.

CONTROL,

.

CLAMP,

.

STOVE,

.

SENDER,

.

SENDER,

.

BRACKET,

.

ALTERNATOR,

.

INSULATOR,

.

PULLEY,

.

-

electric

gas

fan

(included

weld/idle

-

stove

manifold

temperature

pressure

mounting

terminal

single

start

manifold

-

oil

35

amp

belt

vacuum

.TUBING,steel5/BODxl2gawallxl/2

.PIPE,blackl-1/2x

089

B

FITTING,

.

GENERATOR

CATCH,door

477

ROD,

709

BATTERY,

641

CABLE,

431

HOLDER,

pipe

holddown

12

battery

battery

-

brass

ASSEMBLY

-

battery

53

volts

-

uninsulated

15

tank

2

plug

inverted

-

Schebler

inverted

air

cleaner

-

carburetor

dia

3-5/8

x

dia

mounting

ID

of)

(consisting

with

engine

-

alternator

volts

12

-

nylon

coupling

(See

amp

elbow

connector

dry

x

1/16

-

muffler

2

OD

x

-

see

(See

Fig.

negative

(engine

NPT

1/8

Page

male

1/4

carburetor)

male

type

(consisting

(consisting

1/8

x

of)

engine

D

Page

ground

alternator)

6)

1/8

x

1/4

parts

10)

NPT

TBG

list)

of)

of)

2
2

1

1

1
1
1

2

1

NPT

1/8

x

1

1
1

1
1
1
1
1

1

1

5

1
1

1

4

2

1
1

6

1
1
1

2

1

2

2

1

1
1
1
1
1
1
1
1
1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Figure

58

59

60
61
62
63

64
65
66
67

68

69
70

71

72
73

74

75

76

77

78

78

79

80

81
82

83

A

R2,3

TEl

VR1

SR1,2

Zi

VS1

Z2

030

060

023892

007

894

010266
017420
004 444

000 553

144

010

107

603

621

038

967

053

038

620
372

052

035860

038493

035

704

031

926

008

780

004

291

036259
025138

025

139

025

140

004

556

031

318

Figure

932

025

218

028

031

220

603

125

004 426

Main

Assembly

RESISTOR,

(Contd.)

WW

adj

CABLE,ground
MOUNT,

engine

SPRING,extension

LATCH,door

-

base

stud

7/16

-

rectifier

.

terminal

-

mtg.

ASSEMBLY

center

UPRIGHT,

MOUNT,

CLAMP,

HOSE,

BLOCK,

dual

nylon

neoprene

terminal

INSULATION,

LINK,

jumper

BRACKET,

RECTIFIER

.VARISTOR,3joule390volts

.RECTIFIER,

HEAT

UPRIGHT,

BASE

REACTOR

integrated

rectifier

SINK,

base

(consisting

-

front

.COIL,lefthand

center

COIL,

.

COIL,

.

DOOR,

PANEL,

C

PANEL,

SUPPRESSOR,
FRAME,

STABILIZER

STRIP,

KIT,

label

hand

right

access

hinged

front

mounting

cotton

(includes

-

front

-

lower

-

upper

0.75uf10

1/8

375

-

generator

dia

slit

5/32

30

amp

terminal

of)

lower

with

-

reactor

4(4ft

x

all

labels)

20

watt

ID

x

4

pole

block

strip

(consisting

6amp

or

(used

right

components

ohm

w/leads

&

stabilizer

reqd

ohm

11/32

600

when

-

order

OD

of)

volts

unit

(See

by

(order

has

Page

ft)

by

TAC)

8)

foot)

2

1

1
2
2

1

2

1

1

ft.

1

1
2

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1
4

ft.

1

A2

RC2

S4

Shunt

TAC

025

103

103

604

234

025

031

317

027 847

311

038

011

281

010

082

010805

011

948

019

603

024694

769

038

103633
103634

318

604
039 046
039 044

039

045

032

053

601

976

880

601
601

879

027

851

030

084

032936

Parts

for

Optional

METER,

amp

RECEPTACLE,

CAP,

straight.grounded

TUBING,

HANDLE,

GUIDE,

KNOB,

BEARING

CONTACT

&

ball

SWITCH

BRACKET,

.

INSULATOR,

.

SWITCH,

.

. .

..

.

.

..

..

.

.

Equipment

dc

5OMV

straight

TERMINAL,

mounting

switch

polarity

steel

5/8

switch

contact-switch

BOARD

..BUSBAR

MOUNTING

..

NUT,

.

.

.TERMINAL

BUS

..

TERMINAL

. .

CLIP,

..

SCREW,

.

.

NUT,

..

NUT,

..

COVER,
SHUNT,

BAR

BOARD

-

steel

self.tocking

BOARD,

BOARD,

.

spring

steel-hex
steel-hex

meter

bus

-

steel

cap

switch&terminal

5OMV

TACHOMETER,electric

0-600

.

duplex

2P3W

polarity

.

switch

.

polarity

(consisting

OD

5/32

x

ASSEMBLY,

hex

power

black

bar

hex

hd

1/2-13

jam

full

1/2-13

board

600

amp

12

volts

scale

grounded

(used

&

&

of)

wall

1/4-20

output

1/2-13

4000

with

power

terminal

1/2

x

movable

-

black

1-1/2

x

rpm

2P3W

15

RC2)

output

(consisting

board

Ig

(consisting

amp

of)

250

volts

of)

1

1

1

..

1
1

1

1

2

1

2

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

OM-457

Page

4

Item

No.

Figure

Dia.

Mkgs.

A

Factory

Part

No.

Main

Assembly

(Contd.)

Description

-

~

Quantity

*Re~mmended

BE

SURE

TO

Spare

PROVIDE

TT

V

Parts.

STOCK.

97

017
020

032

025

027
010

010
031

MODEL,

98

390

374

936

638

561
429

875
466

99



BRACKET,
BRACKET,

METER,
METER,

MUFFLER,

JET,

CLAMP,

PIPE,

AND

100

mtg.

mtg.

hour

volts

exhaust

carburetor

muffler

black

1-1/2

SERIAL

-

-

4-40

dc

0-100

-

high

2

NUMBERS

x

tachometer

tachometer

volts

scale

-

low

noise

altitude

inch

dia

4-3/4

WHEN

to

engine

ORDERING

REPLACEMENT

2

PARTS.

Page

TO-006

562

BGenerator

Figure

5

Assembly

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Figure

91

92
93
94
95
96
97
98

99

100
101

102

103
104

105

106
107

108

109

110

111

112

113

114
115

116

117

B

SR3

F1,2

SR3

025271
025517
025305
037
025 306
026
039 269

*012625

039169
010493
059017
039207

032311

**003

024617

053390
035917
035776

025525

010021
018614

018665

600270

*020034

025321
025516

025305

037956

957

203

632

Generator

ENDBELL
DIODE

ASSEMBLY,

.INSULATOR

DIODE,

INSULATOR

CHANNE.L,

fuse-holder

BOX,
FUSE,

cartridge

HOLDER,

BUSHING,

STATOR

BAFFLE,

GUARD,

ROTOR,

RING,

generator

retaining-external

BEARING,

rotor

FAN,

steel

KEY,

threaded

ROD,

CLAMP,

BRUSH

CAP,

steel

SET

brush

.BRUSHHOLDER

BRUSH,

BRACKET,

DIODE

ASSEMBLY,

.INSULATOR

DIODE,

Assembly

275

amp

neoprene

45

fuse

cartridge

5/8ID7/8

snap

air

generator

ball

3/8x3/8

end

cushion

(consisting

holder

contact

mounting

275

amp

Fig.

volts

inch

250

60

A

polarity

reverse

volts

amp

(See

reverse

250

1/4

amp

mounting

(consisting

2

x

dia

9/16

of)

-

brush

holder

volts

polarity

straight

straight

250

Page

x

of)

x

11-1/2

250

11/32

3

Item

52)

(consisting

polarity

long

volts

hole

hole

(consisting

polarity

of)

of)

1

1

2
3

5

1
1

2

1

1

1

1

1

1
1

1
1
1

6

2

1
1

1

1

1

1

2

3

*Recommended
**Rotor

BE

is

SURE TO

available

Spare

PROVIDE

on

Parts.

an

exchange

STOCK,

basis.

MODEL,

Contact

AND

Factory

SERIAL

Service

NUMBERS

Department

WHEN

for

details.

ORDERING

REPLACEMENT

PARTS.

OM-457

Page

6

Figure

Cl

146

Page

164

071-A

TC-006



C

Figure

7

Panel,

Front

-

Upper

With

Components

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Figure

131
132

133

134

135

136

137
138

139

140
141
142
143

144

145

146
147

148

149
150

151

152

153

154

155
156

157

158

159
160

161

162
163
164

C

S3

Ri

S2,5

RC3

RC1
Si
P81

CR1

Oil

A

Temp

019
010

039
601

039044

601
039

039

601

010
059

059262
011

*605

053
032

604
005
011

034876

039
601
039043
039049

601

039044

601
031
019
602
019
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039

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836

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879

Front

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HANDLE,

PIN,

spring

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TERMINAL,

NUT,

.

Upper

switch

-

compression

power

steel-hex

(order

.BUSBAR

880

045

043

976

528

343

413

960

359

897

176
372
767

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S~NITCH,

SWITCH,

steel.hex

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.

TERMINAL

.

CLIP,

.

SCREW,

.

TUBING,
BRACKET,
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SWITCH,

RHEOSTAT,

spring

cap

steel

mounting
mounting

range

BOARD,

-

-

WW

toggle

RECEPTACLE,

RECEPTACLE,straight-duplex

ignition

push

RELAY,reed

047
976

TERMINAL,

SCREW,

.

cap

power

-

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880

879
858

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237
239

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.

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.

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HANDLE,

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steel

BAR

steel-hex

front

rheostat

set-steel

push

pressure

amp

temperature

hex

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dc

With

-

range

output

full

jam

bar

bus

hex

steel

OD

1/2

(See

300

SPST

twistlock

-

key

button

output

steel

hex

jam

full

upper

1/4.20

-

pull

-

oil

60-0-60

by

1/2-13

1/2-13

black

x

.

meter

-

meter

Fig.

watt

20

type

-

starter

1/2-13

1/2-13

stock,

hd

11

Cl

amp

-

hd

x

Components

model,

-

black

(consisting

1/2-13

x

wall

x

ga

9)

Page

34

ohm

volts

125

grounded

grounded

start

w/o

-

red

(consisting

1/2-13x1-1/2

3/8

(used

(See

and

1-1/2

1-1/4

2P3W

with

Fig.

serial

of)

2P3W

of)

handle)

A

Page

numbers)

15

amp

4

Item

79)

1
1
1
1

1

1

1

1
1

1

1
1

1

1

2

125

volts

1

1

1

1

1
1

1
1

1

1

1

*Recommended

BE

SURE

TO

Spare

PROVIDE

Parts

STOCK,

MODEL,

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-457

Page

8

Item

No.

171

172
173
174
175
176

177

178
179
180
181

182

183

184

185

186
187

188
189

190
191
192

Figure

Cl

Factory

Part

No.

011

413

011

322

010

671

017

428

011

412

011

490

011

025

011

010

011

009

200

010

010

202

010

201

011

007

011

018

011

489

011

018

010

200

010

202

010

201

011

095

011

019

011

012

011

013

Switch,

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LOCATOR,

CONTACT

CONTACT

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SHIM,
GUIDE,

Range

BOARD

guide

contact

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mounting

quadrant

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pressure

switch
switch

contact
contact
contact

pressure

stationary

ASSEMBLY,

stationary

contact

contact
contact

BOARD,

BOARD,

.

contact

board

C

Page

Fig.

-

swit~h

ASSEMBLY

movable

-

copper

-

bronze

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thick

thick

1/8
1/16

thick

stationary

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thick

1/8

thick

thick

1/16

stationary

movable

board

-

stationary

Description

8

Item

144)

(consisting

(consisting

(consisting

(consisting

of)

of)

of)

of)

Quantity

1

1

3

1

2

2

1

9
6
2

1

2

2
3
3

Page

TB-Oil

BE

9

SURE

273

TO

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MODEL,

AND

Figure

SERIAL

Cl

NUMBERS



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PARTS.

TB-Oil

412

Item

No.

Figure

Dia.

Mkgs.

D

Factory

No.

Part

757

018

Control,

Weld/Idle

Vacuum

Description

(See

Fig.

A

Page

Quantity

3

42)

Item

201

202

203

204
205

206

207

208

209

210
211

212

213
214

215

216

217

218
219
220
221

SR4

GS1

417

017

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604

392

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603

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023

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799

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206

LINKAGE

NUT,

speed

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steel-round

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CHAMBER,
HOSE,

neoprene

brass

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12

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steel

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hook

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clevis-rod

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inch

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screw

-

brass

3/16

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vacuum

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1/8

1/8

x

selenium

copper

voltsdc2

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round

mounting

rubber

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1/4-28

1/4-28

pipe

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end

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pipe

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vacuum

head

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1/4

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reducer

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x

4

ID

x

OD

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vent

head

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vacuum

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actuator

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port

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orifice

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1

1

1

202.

201.

.207

205

208

209

211

757-C

TA-018

WHEN

Vacuum

ORDERING

REPLACEMENT

PARTS.

OM-457

Page

10



D

Figure

BE

SURE

TO

PROVIDE

STOCK,

MODEL,

AND

Control,

SERIAL

Weld/Idle

NUMBERS