Miller 3000 User manual

March1993 Form:
OM-160518
Effective
With
Serial No. KD398640
OWNERS
MANUAL

Read and follow these
instructions
and
all

Give this manual
to
the
operator.
safety
blocks
carefully.

Have
only
trained and
qualified
persons
install,
operate,
or
service
this
unit.

Call
your
distributor
if
you
do
not
understand
the directions.

For
help,
call
your
distributor

or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI
54912
414-734-9821
Millerfi
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r.~1~Ic4...1
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~.w
Gold SealTM
Model
3000

CC/DC
Welding
Generator

For
SMAW
Welding

90
Amperes,
25
Volts DC At
60%
Duty Cycle

1.2
kVA/kW
DC
Auxiliary
Power With Overload
Protection

Kohler
CH5+
Air-Cooled,
Four-Cycle,
Gasoline
Engine

Optional
Low
Oil
Pressure
Shutdown
Switch
coven
5/92ASt-161
477
PRINTED
IN
~SA

s
a
MILLERS
TRUE
BLUETM
LIMITED WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of KC
or
newer)
This limited
warranty
supersedes
all
previous
MILLER
warranties
end is exclusive with
no
other
guerantees
or
warranties
eapressed
or
Implied.
u
LIMITED
WARRANTY

Subject
to
the
terms
end
conditions
below,
MILLER
Electric
MIg.
Co.,
Appleton.
Wisconsin,
wsrrsnts to
its
originsl
retell
purchsser
that
new
MILLER
equipment
sold
sfter the
effective date of this limited
warranty
is tree
of de
tects
in
material
end
workmanship
at
the
time it is
shipped by
MILLER. THIS
WAR
RANT?
IS EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED,
INCLUDING
THE WARRANTIES OF
MERCHANTABILITY
AND
FIT
NESS.
Within the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
pans
or
components
that
tall due
to
such detects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thiny
(30)
days
of such defect
or
failure,
at
which lime
MILLER
will
provide
instructions
on
the
warranty
claim
procadurea
to
be
followed.
MILLER shall
honor
warranty
claims
on
warranted
equipment
listed below
in
the
event
of
such
a
failure
within the
warranty
time
periods.
All
warranty
lime
periods
start
on
the
date that the
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
follows:
1.
5
Yearn
Pans

3 Years Labor
*
Original
main
power
rectifiers
2.
3 Yearn

Pans
and Labor
*
Transformer/Rectifier
Power
Sources

Plasma
Arc
Cutting
Power
Sources

Semi-Automatic
and
Automatic Wire Feeders
*
Robots
3.
2
Years

Pans
and Labor

Engine
Driven
Welding
Generators
(NOTE: Engines
are
warranted
separately by
the
angina
manufacturer.)
4.
I Year

Pans and Labor
*
Motor
Driven
Guns
*
Process
Controllers
*
Water
Coolant
Systems

HF
Units
*
Grids

Spot
Welders
*
Load
Banks

SDX Transformers

Running
Gear/Trailers
*
Fietd
Options
(NOTE:
Field
options
are
covered
under True
BIuenM
for
the
remaining
warranty
period
ol the
product
they
are
installed
in,
or
for
a
minimum
of
one
yaar

whichever
is
greater.)
5. 6
Months

Batteries
6.
90
Days

Pans and Labor
*
MIS
Guns/TIG
Torches
*
Plasma
Cutting
Torches
*
Remote Controls
*
Accessory
Kits
*
Replacement
Pans
MILLERS
True
BiuanM
Limited
Warranty
shall
not
apply
to:
1.
Items furnished
by
MILLER,
but manufactured
by
others,
such
as
anginea
or
trade accessories.
These items
are
covered
by
the
manufacturers
warranty,
it
any.
2.
Consumabla
components;
such
as
contact
tips,
cutting
nozzles,
conlaclorn
and
relays.
3.
Equipment
that has bean
modilied
by
any
party
other
than
MILLER.
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
aquipmenl
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which han
bean used for
operation
outside
of
the
spacifications
br the
equipment.
MILLER
PRODUCTS
ARE INTENDED FOR
PURCHASE
AND
USE BY
COMMER
CIALJINDUSTRIAL
USERS
AND
PERSONS TRAINED AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE OF WELDING
EOUIPMENT
In
the
avant
01
a
warranty
claim covarad
by
this
warranty,
the
eacluniva remedies
shall
ba,
at
MILLERS
option: (1)
repair;
or
(2) replacement;
or,
where authorized
in
writing by
MILLER
in
appropriate
cases.
(3)
the reasonabia
cost
of
repair
or
replace
ment
alan
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(lass
reasonable
depracialion
based
upon
actual
usa)
upon
return of
the
goods
at
customers risk and
expense.
MILLERS
option
of
repair
or
replacement
will
ba
FOB.,
Factory
atAppleton,
Wisconsin,
or
P.0.6.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER. Therefore
no
compensation
or
raimburse
went
for
transportation
costs
of
any
kind will
be allowed.
TO THE EXTENT PERMITTED BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
ARE THE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
NO
EVENT
SHALL MILLER
BE
LIABLE
FOR
DIRECT, INDIRECT,
SPECIAL.
INCIDENTAL
OR CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT).
WHETHER
BASED
ON CON
TRACT,
TORT OR
ANY
OTHER LEGAL THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN
AND ANY
IMPLIED WAR
RANTY,
GUARANTY OR
REPRESENTATION AS TO
PERFORMANCE,
AND ANY
REMEDY FOR BREACH OF CONTRACT
TORT
DR
ANY
OTHER
LEGAL
THEORY
WHICH.
BUT
FOR THIS
PROVISION,
MIGHT
ARISE BY
IMPLICATION,
OPERATION OF
LAW.
CUSTOM OF
TRADE
OR COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND ALL
EOUIPMENT
FURNISHED
BY MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
slates
in
the U.S.A. do
not
allow
limitations of
how
long
an
implied
warranty
lasts,
or
the esciusion of
incidental, indirect,
special
or
consequential
damages,
ao
the
above liwitatlon
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spa
citic
legal rights,
and other
rights
may
be
available,
but
may vary
from
stale
to
stale.
In
Canada,
legislation
in
some
provinces provides
br
certain
additional
warranties
or
remedies other than
as
staled
herein,
and
to
the
astant
that
they
may
not
ba
waived.
Ihe limitations and exclusions
set out
above
may
not
apply.
This Limited
Warranty
provides
specific
legal rights,
and other
rights
may
be
available,
but
may
vary
Irom
province
to
province.
I
r
_____________________________
I
RECEIVING-HANDLING
Before
unpacking
equ(pment,
check
carton
for
any
damage
that
may
have occurred
during
Shipment.
File
any
claims for
loss
or
damage
with the
delivering
carrier. Assistance
for
filing
or
settling
claims
may
be
obtained from distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
infDrmation about this
equipment,
always
provide
Mode)
Designation
and
Serial
or
Sty(e
Number.
USe
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number of
your
unit.
The information
is
located
on
the
rating
label
or
namep(ate.
Model
__________
Serial
or
Style
No.
Date of Purchase
miller
5192

March
1
993
Form:
OM-160
518
Effective
With
Serial
No.
KD398640
OWNERS
MANUAL
U
Read and follow
these instructions
and all
U
Give
this
manual
to
the
operator.
U
U
safety
blocks
carefully.
Have
only
trained and
qualified
persons
install,
operate,
or
service
this unit.
Callyourdistributorifyoudonotunderstand
the directions.

rt~i
U
U
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
1079,
Appleton,
WI
54912
Co.,
P.O.
Box
414-734-9821
1~oIsfi
(jJOJ1
cI~j\r~J~
PAW
100

CC/DC
Welding
Generator

For SMAW
Welding
U
90
Amperes,
25
Volts
DC
At
60%
Duty Cycle
U
1.2
kVAJkW
DC
Auxiliary
Power With Overload Protection

Kohler CH5+
Air-Cooled,
Four-Cycle,
Gasoline
Engine

Optional
Low
Oil Pressure Shutdown Switch
cover
8/92

ST-161
477
PRINTED
IN
~SA

ARC
WELDING SAFETY
PRECAUTIONS
5.
Properly
install and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and local
codes.
6.
When
making
input
connections,
attach
proper
grounding
conductor
first.
7.
Turn
off all
equipment
when
not
in
use.
8.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
9.
Do
not
wrap
cables around
your
body.
10.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
11.
Do
not
touch
electrode
if
in
contact
with
the work
or
ground.
12. Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
13.
Wear
a
safety
harness
if
working
above
floor
level.
14.
Keep
all
panels
and
covers
securely
in
place.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and skin.
Noise
from
some
processes
can
damage
hearing.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade of filter
(see
ANSI Z49.
1
listed
in
Safety
Standards)
to
protect
your
face and
eyes
when
welding
or
watching.
3.
Wear
approved
safety
glasses.
Side
shields
recommended.
4.
Use
protective
screens or
barriers
to
protect
others from flash
and
glare;
warn
others
not to
watch the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breathe the fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use an
approved
air-supplied respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and the
manufacturers
instruction
for
metals,
consumables,
coatings,
and cleaners.
5.
Work in
a
confined
space
only
if
it is well
ventilated,
or
while
wearing
an
air-supplied respirator.
Shielding
gases
used
for
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat and
rays
of
the
arc can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless the
coating
is
removed
from the
weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and hot
equipment
can cause
fires and
burns.
Accidental
contact
of
electrode
orwelding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
Protect
yourself
and others
from
flying
sparks
and hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable material.
Remove all
flammables
within 35
ft
(10.7 m)
of the
welding
arc.
If
this
is
not
possible, tightly
cover
them with
approved
covers.
Be alert that
welding
sparks
and
hot
materials
from
welding
can
through
small
cracks
and
openings
to
adjacent
areas
FLYING SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As welds
cool,
they
can
throw
off
slag.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor, bulkhead,
or
partition
can cause
fire
on
the hidden side.
Do
not
weld
on
closed containers
such
as
tanks
or
drums.
Connect work cable
to
the
work
as
close
to
the
welding
area as
practical
to
prevent
welding
current
from
traveling
long, possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove stick electrode from holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11. Wear
oil-free
protective
garments
such
as
leather
gloves, heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2. Wear
proper
body protection
to
protect
skin.
a
WARNING
ARC WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS INJURY OR
DEATH. KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below is
only
a
summary
of the
more
complete
safety
information
that
will
be found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION, MAINTENANCE,
AND
REPAIR
WORK PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal shocks
or
severe
burns.
The
electrode and
work circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and machine internal circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from work and
ground using dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
1.
Use
approved
ear
plugs
or ear
muffs
if
noise level is
high.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
srI
9/92

MOVING
PARTS
can cause
injury.
Moving
parts,
such
as fans,
rotors,
and belts
can
cut
fingers
and hands and
catch loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed and
securely
in
place.
2.
Stop
en
me
before
installing
or
connecting
unit.
Safety in Welding
and
Cutting,
ANSI
Standard
Z49.1,
from American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami FL 33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe Practices for the
Preparation
for
Welding
and
Cutting
of Containers
That
Have Held Hazardous
Substances,
Ameri
can
Welding
Society
Standard AWS
F4.i
from American
Welding
So
ciety,
550
N.W. LeJeune
Rd,
Miami,
FL
33126
National Electrical
Code,
NFPA
Standard
70,
from
National
Fire Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
ENGINES
can
be
hazardous.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air intakes.
1.
Stop
engine
before
checking
or
adding
fuel.
2. Do
not
add fuel
while
smoking
or
if
unit is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool before
fueling.
If
possible,
check
and add
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tank

allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
3.
Have
only
qualified people
remove
guards
or covers
for
maintenance
and
troubleshooting
as
necessary.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and
close
doors when
servicing
is
finished and
before
starting engine.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1R3.
Safe
Practices
ForOccupationAnd
Educational
Eye
And
Face
Protec
tion,
ANSI Standard
Z87.1,
from
American National Standards
Institute,
1430
Broadway.
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from National
Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
IL~c
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of the
welding
process,
be
sure
to treat
them
carefully.
Protect
compressed
gas
cylinders
from excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install and
secure
cylinders
in
an
upright
position by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other electrical
circuits.
4.
Never allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for the
specific application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn face
away
from valve
outlet when
opening cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use or
connected
for
use.
8.
Read and
follow instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
a
WARNING
ENGINE
EXHAUST GASES
can
kill.
Engines
produce
harmful exhaust
gases.
ENGINE
FUEL
can
cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face shield
when
working
on a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop engine
before
disconnecting
or
connecting battery
burn
eyes
and
skin,
cables.
Batteries
contain
acid and
generate
explosive
gases.
3.
4.
5.
Do
not
allow
tools
to
cause
sparks
when
working
on a
battery.
Do
not
use
welder
to
charge
batteries
or
iump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
4
~
.
(.~
~
~
STEAM
AND
COOLANT
can
skin.
The coolant
in
the
under
pressure.
PRESSURIZED
burn
face,
eyes,
radiator
can
be
very
h
HOT
and
ot
and
1.
2.
3.
Do
not
remove
radiator
cap
when
engine
is hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
Allow
pressure
to
escape
before
completely removing
cap.
PRINCIPAL
SAFETY
STANDARDS
Sri
9/92

TABLE
OF
CONTENTS
SECTION
1
-
SAFETY SIGNAL WORDS
.
SECTION
2 SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
2-3. Fuel
Consumption
2-4.
DC
Auxiliary
Power
Curve
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Generator
3-2.
Engine
Prestart
Checks
3-3.
Grounding
The Generator
Auxiliary
Power
System
3-4.
Connecting
To
Weld
Output
Terminals
SECTION 4OPERATING
THE
WELDING GENERATOR
SECTION
5
OPERATING
AUXILIARY
EOUIPMENT
5-1.
Auxiliary
Power
DC
Receptacle
5-2.
Auxiliary
Equipment
Operation
1
11
12
13
13
14
14
15
16
22334566
7
10
10
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine Maintenance
6-2.
Changing
Engine
Oil
6-3.
Adjusting Engine
Speed
6-4.
Air
Cleaner Service
6-5.
Clean
Air
Intake
And
Cooling
Areas
6-6.
Drive Belt
Adjustment
And
Replacement
6-7.
Overload
Protection
6-8.
Troubleshooting
SECTION 7 ELECTRICAL
DIAGRAMS
SECTION
8-
WELDING
METHODS
&
TROUBLESHOOTING
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
8-2.
Welding Troubleshooting
SECTION
9
PARTS LIST
Figure
9-1.
Main
Assembly
Figure
9-2.
Panel,
Front
w/Components
Figure
9-3.
Panel,
Control
w/Components
18
20
25
28
31
32
OM.160
518
3)93

SECTION
1

SAFETY
SIGNAL
WORDS

Read
all
safety
messages
throughout
this
manual.

Obey
all
safety
messages
to
avoid
injury.

Learn the
meaning
of WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Generator
rnodl.1
2/93
1
2
2
\
a CAUTION
/
;
3
_______________
______________
ELECTRIC
SHOCK
can
kill

MOVING
PARTS
can
injure.
L~
I
Disconnect
input
power
betore~
~

Keep
all
panels
and
covers
closed
I
I
Do
not
touch live
electrical
parts.

Keep
away
from
moving
parts,
I
installing
or
servicing.
when
operating.
I
5
READ
SAFETY BLOCKS
at
start
of
6
Section
3-1
before
proceeding
7H
NOTE
~
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard And
Result
4
Safety
Instructions To
Avoid
Hazard
5
Hazard
Symbol
(If Available)
6
Safety
Banner
Read
safety
blocks for
each
sym
bol
shown.
7
NOTE
Special
instructions for
best
oper
ation

not
related
to
safety.
Turn
Off
switch when
using high frequency.
Specification
Type
Of
Output
Rated Weld
Output
Amperage Range
Maximum
Open-Circuit
Voltage
Welding
Process
Description
Auxiliary
Power
Rating
Engine
Engine
Speed (No Load)
Fuel Tank
Capacity
Engine
Oil
Capacity
Drive
Belt Size
Overall
Dimensions
Weight
Options
Constant
Current/Direct
Current
(CC/DC)
90
Amperes,
25 Volts
DC
At 60%
Duty Cycle (See
Section
2-2)
40 To
100
A
75
Volts
DC
(See
Section
2-1)
Shielded
Metal
Arc
Welding (SMAW);
Flux Cored
Arc
Welding
(FCAW)
And
Gas
Tungsten
Arc
Welding
(GTAW)
Possible
With
Appropriate
Process
Options
1.2
kW,
120 Volts
DC,
10
Amperes
Kohler
CH5+
Air-Cooled,
One-Cylinder, Four-Cycle
Gasoline
Engine
1800
rpm
Idle
Speed;
4150
rpm
Weld
And Power
Speed
2.3
U.S.
gal
(8.7L)
22.4
oz
(0.66L)
1/2
x
.343
x
32.3
Cogged
See
Figure
3-2
Net:
101
lb
(46
kg);
Ship:
113
lb
(51
kg)
See
Rear Cover
OM-160
518
Page
1

2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
a
CAUTION
300
-
250
-
200
U)
150
w
a
<
100
.
75
.
Figure
2-2.
Duty Cycle
Chart
Cl)
0
>
0
100
90
80
70
60
50
40
30
20
10
0
The
volt-ampere
curves
show
the
minimum
and maximum
voltage
and
amperage
output
capabilities
of
the
welding
generator.
Curves
of
other
settings
fall
between
the
curves
shown.
rsDl.1
10/91

SB-152
541
025 50
75
100
125
150
DC AMPERES
EXCEEDING
DUTY
CYCLE RATINGS
will
damage
unit.

Do
not
exceed
indicated
duty cycles.
warn7.1
2/92
This
unit is
rated
at
60%
duty
cycle
allowing
welding
6 minutes
out
of
every
10 minutes.
RATED
OUTPUT
~......,
50-
---
--
10
15 20 25 30 40 50 60
7080
100
Duty cycle
is
how
long
the
unit
can
operate
within
a
ten minute
period
without
causing overheating
or
damage.
% DUTY CYCLE
sbl.2
10/91
SB-152
540
OM-160
518
Page
2

2-3.
Fuel
Consumption
The fuel
consumption
curve
shows
typical
fuel
use
under
weld
or
pow
er
loads.
~
-J
_j
ci,
w
I-
Q~
ci
1.89 0.42
0.50
1 .66
0.37
0.44
~
1.42
0.31
0.38
1 .18
0.26 0.31
DC
AUX
POWER
0.95
0.21
0.25
0.71
0.16 0.19
0.47 0.10
0.12
-IDLE
0.23 0.05
0.06
0
0 15
30 45 60 75 90
DC WELD
AMPERES
(25
VOLTS)
0.2
0.4 0.6
0.8
1.0
1.2
DC
POWER KW
rsb2.I
10/91

SB-153
250
Figure
2-3.
Fuel
Consumption
Curve
2-4.
DC
Auxiliary
Power
Curve
The
dc
power
curve
shows the
aux
iliary
power
in
amperes
available
at
140
the
120 volt dc
receptacle.
~80
0
>
Q60
40
20
00
2.5
5.0 7.5 10 12.5 15
DC
AMPERES
SB.152
758
Figure
2-4.
DC
Power
Curve
For
120
Volt
Receptacle
OM-160
518
Page
3

SECTION 3INSTALLATION
3-1.
Selecting
A
Location
And
Moving Welding
Generator
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.

Do
not
breathe
exhaust
fumes.

Use
in
open,
well-ventilated
areas,
or
vent
exhaust
outside and
away
from
building
air
intakes.
ENGINE
EXHAUST
SPARKS
can
cause
fire.

Use
only
U.S.
Forestry Department
approved
spark
arrestor
and
comply
with
all
local,
state,
and federal
laws.

A
spark
arrestor
is
mandatory
in all
National
Forests
and
in
grass,
brush,
or
forest
covered
lands in
California,
Oregon,
and
Washington.
Check
with
state
and
local
authorities
in
other
areas.

Properly
maintain the
spark
arrestor.

Stop
engine
and allow exhaust
system
to
cool down
before
servicing
spark
arrestor.

Service
spark
arrestor
away
from flammables.
HOT ENGINE EXHAUST
AND
EXHAUST
PIPE
can
cause
fires.

Keep
exhaust and
pipe
away
from
flammables.
FALLING EQUIPMENT
can cause
serious
personal injury
and
equipment
damage.

Lift
Unit
at
handles
on
ends of
base.

Have
two
persons
of
adequate
strength
lift
unit.

Move unit with hand
cart
or
similar
device of
adequate capacity.

It
using
a
fork
lift
vehicle,
secure
unit
on
a
proper
skid
before
transporting.
rwarnl.1
12/91
Keep
unit
level

tilting
can
cause
fuel and oil
leaks and
possible
fire
or
engine
damage.
2
2
1
18
in
(457
mm)
Open
Space
On
All
Sides
2
Lifting
Handles
Lift
unit with
hands
positioned
in
centerof
handles.
Obtain
help
to
lift
and
transport
unit.
3
Exhaust
Outlet
Keep
flammables
away
from
ex
haust
outlet.
Figure
3-1.
Location And Movement
Of
The
Welding
Generator
5T-161
4771
ST-151
556/
Ref.
5T.161
478
~<
Inches
Millimeters
A
B
C
19
14-5/8
28-3/4
483
371
730
C
>.-.~<
Figure
3-2.
Overall
Dimensions
OM-160
518
Page
4