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Call your distributor if you do the directions. 5/92ASt-161 coven March1993 Effective With 3000 Welding Generator Welding 25 Volts DC At 60% Duty Cycle Auxiliary Power With Overload Protection Air-Cooled, Four-Cycle, Gasoline Engine...
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MILLERS (Equipment This limited warranty supersedes LIMITED WARRANTY Subject conditions below, terms MIg. Co., Appleton. Wisconsin, wsrrsnts to originsl effective date of this limited MILLER equipment sold sfter the tects in material workmanship time it is shipped by LIEU OF OTHER WARRANTIES.
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1~oIsfi OWNERS MANUAL CC/DC For SMAW Amperes, kVAJkW DC Kohler CH5+ Optional Read and follow these instructions and all blocks safety carefully. Have only trained install, operate, service this unit. Callyourdistributorifyoudonotunderstand the directions. ST-161 8/92 cover March Effective (jJOJ1 PAW 100 Generator Welding Welding...
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ARC WELDING SAFETY PRECAUTIONS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN PACEMAKER WEARERS KEEP AWAY UNTIL AWAY. welding, in most jobs, exposure below is safety information given only Standards listed the next page. Read and follow all Safety INSTALLATION, OPERATION, MAINTENANCE, HAVE ALL...
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CYLINDERS explode contain gas under Shielding cylinders pressure. If cylinder damaged, IL~c cylinders normally process, be to treat them sure Protect compressed cylinders mechanical shocks, arcs. upright position by chaining Install and cylinders secure them stationary equipment cylinder support falling tipping.
SECTION Read all safety messages Obey safety messages of WARNING and CAUTION. Learn the meaning ELECTRIC SHOCK kill touch live electrical parts. betore~ Disconnect input power installing servicing. NOTE Off switch when Turn SECTION Specification Type Output Constant Rated Weld Output Amperage Range 40 To 100 A...
SECTION 3INSTALLATION 3-1. Selecting Location And WARNING ENGINE EXHAUST GASES not breathe exhaust Use in open, well-ventilated outside and away from ENGINE EXHAUST SPARKS fire. U.S. only Forestry Department approved spark with all arrestor comply laws. arrestor is spark mandatory and in grass, brush, California,...
not let fuel leak from Figure Prestart Checks 3-2. Engine WARNING ENGINE FUEL explosion. before Stop engine fueling. Do not fuel while smoking overfill clean up any tank; during tilting. 3-3. Maximum Welding Generator Tilt fire REMOVE FUEL CAP cause SPRAY may under pressure.
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The Generator 3-3. Grounding generator auxiliary power neutral is connected to the machine frame. Tools Needed: Figure 3-4. Connecting To Weld Output WARNING ELECTRIC SHOCK Always dry insulating gloves. wear touch live electrical Stop engine before making Read Safety Precautions OM-160 Page Auxiliary...
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SECTION OPERATING THE WELDING GENERATOR WARNING ELECTRIC SHOCK touch live electrical Always dry insulating gloves. wear from work and Insulate yourself Stop engine before installing panels Keep covers WELDING can cause weld flammable material. near Watch for fire; keep extinguisher nearby. Do not locate unit combustible surfaces.
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OM-160 518 Page Tools Needed: Figure 4-3. Work Clamp Control Figure 4-4. Amperage Controls Figure 4-5. Engine Work Clamp Connect work clamp clean, location paint-free workpiece, close to weld possible. area as brush wire sandpaper clean metal at weld joint area.
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Figure Figure EquIpment~) Select Install & Connect Electrode _____ ________________ ________________ _____ Insert Electrode Begin Into_Holder _________________ Figure 4-8. Hour Meter (Optional) 4-6. Engine LOW OIL 4-7. Automatic Low Oil Shutdown ControI~~) Put On Personal Safety ~~JJ Equipment _____ _____ Weldin~ Sequence Of Shielded Metal...
OPERATING AUXILIARY EQUIPMENT SECTION WARNING ELECTRIC SHOCK touch live electrical before Stop engine making reconnection. Ground generator according national, state, and local codes. equipment grounding Connect earth ground. connect to any electrical distribution normally supplied by utility ELECTRIC SPARKS using auxiliary power disconnect both welding...
SECTION MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK not touch live electrical Always dry insulating gloves. wear Insulate yourself from work and Stop engine before installing Keep panels covers ENGINE EXHAUST GASES not breathe exhaust fumes. in open, well-ventilated outside and away from 6-1.
6-3. Adjusting Engine Speed Cleaner Service 6-4. READ SAFETY BLOCKS at Section Moving Parts Hazard. Have belt guard place before running engine. Figure 6-4. Engine Speed Adjustment READ SAFETY Section Figure 6-5. Air Cleaner Maintenance start before proceeding. Start and load.
Clean Air Intake And Cooling 6-5. 6-6. Drive Belt Adjustment Tools Needed: 9/16,5/8 7/16 Stop engine. Belt Guard Remove five securing belt guard. screws Remove guard inspect belt. Drive Belt Readjust belt tension if necessary. Replace cracked belt. Tensioning Screw Figure OM-160 518 Page...
Overload Protection 6-7. WARNING CAUTION :DC POWER FOR TOOLS AND LIGHTS ONLY NOT USE AC ONLY RATED TOOLS. CONSULT OWNERS MANUAL! 120V 1OA READ SAFETY BLOCKS Section before 125 volts Replacement fuse rating: maximum. greater, amperes Figure 6-8. Location Of Fl Fuse at start proceeding.
6-8. Troubleshooting WARNING ELECTRIC SHOCK not touch live electrical Always dry insulating gloves. wear Insulate yourself from work and Stop engine before installing Keep panels covers ENGINE EXHAUST GASES breathe exhaust fumes. Use in open, well-ventilated outside and away from any HOT PARTS can cause severe Allow...
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Trouble auxiliary power. Erratic auxiliary power. auxiliary power. Trouble Engine will not start. stalls. Engine rough runs Table 6-2. Power Trouble Auxiliary Remedy Check and replace fuse Authorized Service Station check brushes and Have Factory rings. Have Factory Authorized Service Station check brushes and rings.
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P O S I T I V E N E G A T I V E W E L D O U T P U T IIRC2 4 1 t t P / P t t t P L G 2 1 3 3 1 2 1 2 3 4 5 6 7 8 9 1161...
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r ( ~ ~ A L T E R N A T O R H O U S I N G 8 6 0 - B S T - 1 5 3 G e n e r a t o r W e l d i n g D i a g r a m N E G A T I V E...
SECTION WELDING METHODS & TROUBLESHOOTING WARNING ELECTRIC SHOCK Always dry insulating gloves. wear Insulate yourself from work and touch live electrical Keep panels covers FUMES GASES your health. of the fumes. Keep your head Ventilate breathing area, Safety Read Material Data Sheets manufacturers instructions for material used.
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Figure Figure 1O0~3O0 <~ End View Of Work Side View Of Electrode Angle GROOVE WELDS OM-160 518 Page Striking An Arc Scratch Start 8-3. 8-4. Striking Tapping Technique End View Of Work Angle Electrode Holder Figure 8-5. Positioning Electrode Workpiece Drag electrode workpiece...
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Weld bead NOTE ~ thickness of base metal. ______________________ Too Small Angle Too Short Slow Figure POOR WELD BEAD GOOD WELD BEAD Figure 8-6. Weld Bead Characteristics shape is affected electrode Correct Angle Drag ELECTRODE ANGLE Normal ARC LENGTH Normal TRAVEL SPEED Conditions That Affect Weld Bead...
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Normally, NOTE however, multiple ~~/3 Figure 2To3in (51-76 mm) 1/4in (6.4 OM-160 Page bead is single stringer satisfactory for wide groove weld joints bridging stringer beads work better. 8-8. Ele ctrode Mov ement During Welding ~~I~f 4jI~t~- Figure 8-9. Butt Joints 8-10.
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~... Causes Possible for electrode. Amperage high Decrease amperage voltage high Reduce length long Possible Causes Insufficient heat Increase amperage. Select input. welding technique. Place Improper Adjust Momentarily Keep Remove all grease, Workpiece dirty. welding. Lack of Penetration Possible Causes Material Improper joint preparation.
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Excessive Penetration Possible Causes Excessive heat input. Select lower amperage. Use Increase and/or maintain Possible Causes Excessive heat Select lower amperage. Use smaller electrode. input. Increase Possible Causes Unsteady hand. Possible Causes Excessive heat input. Use restraint Make tack welds Select lower amperage for electrode.