Blue Star 180K service T436

Use MILLER Testing Booklet (Part No.150 853) when servicing this unit.

Use only genuine MILLER replacementparts.

May 1996 Form: TM-436

Effective With Serial No. KB012373

TECHNICAL MANUALService And Parts

WARNING

For help, call FactoryService Department:414-735-4505

SERVICING can be hazardous.• Have all service procedures performed only by

qualified persons following standard safetypractices.

Or FAX inside the USA:800-637-2348Outside the USA:414-735-4136

Or write to:MILLER Electric Mfg. Co.P.O. Box 1079Appleton, WI 54912 USA

cover_tm1 – ST-144 336-A PRINTED IN USA 1996 MILLER Electric Mfg. Co.

Blue Star 180KCC/DC Welding Generator For SMAW Welding

OM-436D – 3/96 / SPM-436B – 5/94

EMF INFORMATION

The following is a quotation from the General Conclusions Sectionof the U.S. Congress, Office of Technology Assessment, BiologicalEffects of Power Frequency Electric & Magnetic Fields –Background Paper, OTA-BP-E-53 (Washington, DC: U.S.Government Printing Office, May 1989): “. . . there is now a verylarge volume of scientific findings based on experiments at thecellular level and from studies with animals and people which clearlyestablish that low frequency magnetic fields can interact with, andproduce changes in, biological systems. While most of this work isof very high quality, the results are complex. Current scientificunderstanding does not yet allow us to interpret the evidence in asingle coherent framework. Even more frustrating, it does not yetallow us to draw definite conclusions about questions of possiblerisk or to offer clear science-based advice on strategies to minimizeor avoid potential risks.”

To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away aspractical.

5. Connect work clamp to workpiece as close to the weld aspossible.

About Pacemakers:The above procedures are among those also normallyrecommended for pacemaker wearers. Consult your doctor forcomplete information.

Considerations About Welding And The Effects Of Low Frequency Electric AndMagnetic FieldsNOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 – SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Volt-Ampere Curves 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Fuel Consumption 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. AC Auxiliary Power 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Connecting The Battery 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Engine Prestart Checks 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Generator Auxiliary Power System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Selecting And Preparing Weld Output Cables 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Connecting To Weld Output Terminals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATING THE WELDING GENERATOR 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING AUXILIARY EQUIPMENT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. 120 Volt Duplex Receptacles And Circuit Breakers 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Optional 240 Volt Duplex Receptacle 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Optional 240 Volt Twistlock Receptacle (Full KVA) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Wiring Instructions For 120/240 Volt AC Twistlock Plug 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – THEORY OF OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Troubleshooting Tables 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Troubleshooting Circuit Diagram For Welding Generator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Waveforms For Section 7-2 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Troubleshooting Field Current Regulator Board PC1 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Troubleshooting Idle Module PC2 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Replacing Brushes And Cleaning Slip Rings 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Checking Unit Output After Servicing 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – DISASSEMBLY AND REASSEMBLY 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – MAINTENANCE 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Changing Engine Oil And Filter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Replacing Fuel Filter 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Overload Protection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Adjusting Engine Speed 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6. Replacing Battery And Checking Battery Voltage 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7. Servicing Optional Spark Arrestor 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – ELECTRICAL DIAGRAMS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

sr1.1.1 2/94

ARC WELDING SAFETY PRECAUTIONS

WARNINGPROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS KEEP A WAY UNTIL CONSULTING YOUR DOCTOR.In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. Thesafety information given below is only a summary of the more complete safety information that will be found in theSafety Standards listed on the next page. Read and follow all Safety Standards.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BYQUALIFIED PEOPLE.

ARC WELDING can be hazardous.

ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded 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 big enough to prevent any physical contact withthe work or ground.

4. Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power accordingto OSHA 29 CFR 1910.147 (see Safety Standards).

5. Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.

6. Always verify the supply ground – check and be sure that inputpower cord ground wire is properly connected to ground

terminal in disconnect box or that cord plug is connected to aproperly grounded receptacle outlet.

7. When making input connections, attach proper groundingconductor first – double-check connections.

8. Frequently inspect input power cord for damage or bare wiring –replace cord immediately if damaged – bare wiring can kill.

9. Turn off all equipment when not in use.10. Do not use worn, damaged, undersized, or poorly spliced

cables.11. Do not drape cables over your body.12. If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.13. Do not touch electrode if you are in contact with the work,

ground, or another electrode from a different machine.14. Use only well-maintained equipment. Repair or replace

damaged parts at once. Maintain unit according to manual.15. Wear a safety harness if working above floor level.16. Keep all panels and covers securely in place.17. Clamp work cable with good metal-to-metal contact to

workpiece or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin;NOISE can damage hearing; FLYINGSLAG OR SPARKS can injure eyes.Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) rays thatcan burn eyes and skin. Noise from some processescan damage hearing. Chipping, grinding, and weldscooling throw off pieces of metal or slag.

NOISE1. Use approved ear plugs or ear muffs if noise level is high.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter toprotect your face and eyes when welding or watching (see ANSIZ49.1 and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.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 hazardousto your health.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

1. Keep your head out of the fumes. Do not breathe the fumes.2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.3. If ventilation is poor, use an approved air-supplied respirator.4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,cleaners, and degreasers.

5. Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trainedwatchperson nearby. Welding fumes and gases can displaceair and lower the oxygen level causing injury or death. Be surethe breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or sprayingoperations. The heat and rays of the arc can react with vapors toform highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from theweld area, the area is well ventilated, and if necessary, whilewearing an air-supplied respirator. The coatings and any metalscontaining these elements can give off toxic fumes if welded.

CYLINDERS can explode if damaged.Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat,mechanical shocks, slag, open flames, sparks, and arcs.

2. Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electricalcircuits.

4. Never drape a welding torch over a gas cylinder.5. Never allow a welding electrode to touch any cylinder.6. Never weld on a pressurized cylinder – explosion will result.7. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them andassociated parts in good condition.

8. Turn face away from valve outlet when opening cylinder valve.9. Keep protective cap in place over valve except when cylinder is

in use or connected for use.10. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in SafetyStandards.

sr1.1.1 2/94

WELDING can cause fire or explosion.Welding on closed containers, such as tanks, drums,or pipes, can cause them to blow up. Sparks can flyoff from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires andburns. Accidental contact of electrode to metalobjects can cause sparks, explosion, overheating, orfire. Check and be sure the area is safe before doingany welding.

1. Protect yourself and others from flying sparks and hot metal.2. Do not weld where flying sparks can strike flammable material.3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partitioncan cause fire on the hidden side.

7. Do not weld on closed containers such as tanks, drums, orpipes, unless they are properly prepared according to AWSF4.1 (see Safety Standards).

8. Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long,possibly unknown paths and causing electric shock and firehazards.

9. Do not use welder to thaw frozen pipes.10. 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.12. Remove any combustibles, such as a butane lighter or

matches, from your person before doing any welding.

WARNING ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill.Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside andaway from any building air intakes.

ENGINE FUEL can cause fire orexplosion.Engine fuel is highly flammable.

1. Stop engine and let it cool off before checking or adding fuel.2. Do not add fuel while smoking or if unit is near any sparks or

open flames.

3. Do not overfill tank – allow room for fuel to expand.4. Do not spill fuel. If fuel is spilled, clean up before starting

engine.

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts cancut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed andsecurely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers formaintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnectnegative (–) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from movingparts.

6. Reinstall panels or guards and close doors when servicing isfinished and before starting engine.

SPARKS can cause BA TTERY GASESTO EXPLODE; BATTERY ACID canburn eyes and skin.

Batteries contain acid and generate explosivegases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting batterycables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

STEAM AND PRESSURIZED HOTCOOLANT can burn face, eyes, andskin.It is best to check coolant level when engine is coldto avoid scalding.

1. If the engine is warm and checking is needed, follow steps 2and 3.

2. Wear safety glasses and gloves and put a rag over cap.3. Turn cap slightly and let pressure escape slowly before

completely removing cap.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding 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 andCutting of Containers That Have Held Hazardous Substances, Ameri-can Welding Society Standard AWS F4.1, from American Welding So-ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA PamphletP-1, from Compressed Gas Association, 1235 Jefferson Davis High-way, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale Bou-levard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Insti-tute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from NationalFire Protection Association, Batterymarch Park, Quincy, MA 02269.

TM-436 Page 1Blue Star 180K

SECTION 1 – SAFETY INFORMATIONmod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible deathor serious injury can happen.

CAUTION means possible minorinjury or equipment damage canhappen.

3 Statement Of Hazard AndResult

4 Safety Instructions To AvoidHazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-bol shown.

7 NOTE

Special instructions for best op-eration – not related to safety.

2

NOTE

ELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Disconnect input power beforeinstalling or servicing.

WARNING

READ SAFETY BLOCKS at start ofSection 3-1 before proceeding.WARNING

5

4

6

7

1 2

CAUTIONMOVING PARTS can injure.• Keep away from moving parts.

• Keep all panels and covers closedwhen operating.

3

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 – SPECIFICATIONS

Table 2-1. Welding Generator

Specification Description

Type Of Output Constant Current (CC), Direct Current (DC)

Rated Weld Output 180 Amperes, 25 Volts DC At 60% Duty Cycle (see Section 2-2)

140 Amperes, 25 Volts DC At 100% Duty Cycle (see Section 2-2)

Amperage Range 50-180 A

Maximum Open-Circuit Voltage 75 Volts DC

Welding Process Shielded Metal Arc Welding (SMAW)

Auxiliary Power Rating Single-Phase, 5 kVA/kW, 120 Volts AC, 42 Amperes, 60 Hz

Engine Kohler CH 12.5 Air-Cooled, One-Cylinder, Gasoline Engine

Engine Speed (No Load) 3750 rpm Weld/Power Speed; 2400 rpm Idle Speed

Fuel Tank Capacity 3.8 gal (14.4 L)

Overall Dimensions Length: 31-1/2 in (800 mm); Width: 25 in (635 mm); Height: 24 in (610 mm)

Weight Net: 346 lb (157 kg); Ship: 360 lb (164 kg)

TM-436 Page 2 Blue Star 180K

2-1. Volt-Ampere Curves

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilitiesof the welding generator. Curves ofother settings fall between thecurves shown.

rsb1.1 10/91 – SB-145 168

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTIONWELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.• Do not weld at rated load longer than shown below. warn7.1 8/93

Duty Cycle is percentage of 10minutes that unit can weld atrated load without overheating.

sb1.4* 8/93 - SB-129 658

0

10

Minutes

60% Duty Cycle At 180 Amperes

DefinitionChart

6 Minutes Welding 4 Minutes Resting

100% Duty Cycle At 140 Amperes

Continuous Welding

Figure 2-2. Duty Cycle


2-3. Fuel Consumption

The fuel consumption curve showstypical fuel use under weld or pow-er loads.

rsb2.1 10/91 – SB-145 107

Figure 2-3. Fuel Consumption Curve

2-4. AC Auxiliary Power

The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacles.

rsb3.1 2/92 – SB-145 169

Figure 2-4. AC Power Curve For 120 And 240 Volt Receptacles


SECTION 3 – INSTALLATION

3-1. Selecting A Location And Moving Welding Generator

WARNINGENGINE EXHAUST GASES can kill.• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaustoutside and away from building air intakes.

ENGINE EXHAUST SPARKS can causefire.• Use only U.S. Forestry Department approved

spark arrestor and comply with all local, state, andfederal laws.

• A spark arrestor is mandatory in all NationalForests and in grass, brush, or forest covered landsin California, Oregon, and Washington. Check withstate and local authorities in other areas.

• Properly maintain the spark arrestor.

• Stop engine and allow exhaust system to cooldown before servicing spark arrestor.

• Service spark arrestor away from flammables.

HOT ENGINE EXHAUST AND EXHAUSTPIPE can cause fires.

• Keep exhaust and pipe away from flammables.

FALLING EQUIPMENT can causeserious personal injury and equipmentdamage.• Use lifting eye to lift unit only, NOT running gear,

gas cylinders, trailer, or any other heavy options,accessories, or devices.

• Use equipment of adequate capacity to lift the unit.

TILTING OF TRAILER can result inpersonal injury or equipment damage.• Install unit properly on trailer (if applicable)

according to trailer manual.

rwarn1.1 3/93

rsb20.1 12/94 – Ref. ST-800 652 / ST-800 402 / ST-144 336-A

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Trailer

Install unit on trailer according totrailer manual.

OR

1

Movement

Location And Airflow

2

OR

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

3

Figure 3-1. Movement And Location Of Welding Generator


S-0024-C

25°25°

25°25°

Do not exceed operating angles whilerunning or engine damage will occur .

Figure 3-2. Maximum Welding Generator Operating Angles

3-2. Connecting The Battery

WARNINGSPARKS can cause BA TTERY GASES TO EXPLODE; BA TTERY ACID can burn eyes and skin.• Stop engine before disconnecting or connecting battery cables.

• Always wear a face shield and proper protective clothing when working on a battery.

• Do not allow tools to cause sparks when working on a battery.rwarn2.1 9/91

ST-153 469-A / S-132 278-B / Ref. S-0756-B

1 Engine On-Off Switch

Place switch in the Off position.

2 Positive (+) Battery Terminal

3 Positive (+) Battery Cable

Connect positive cable first.

4 Negative (–) Battery Terminal

5 Negative (–) Battery Cable

Connect negative cable last.

If engine does not crank, checkbattery voltage according to Sec-tion 9-6.

Tools Needed:

3/8, 7/16 in

1

2

–

+

4

3

5

Figure 3-3. Connecting The Battery


3-3. Engine Prestart Checks

WARNINGENGINE FUEL can cause f i re orexplosion.• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

REMOVE FUEL CAP SLOWLY; FUELSPRAY may cause injury; FUEL may beunder pressure.• Rotate fuel cap slowly and wait until hissing stops

before removing cap.rwarn3.1 3/93

FUEL

OIL

2

3

Full

1 in(25 mm)

Check all fluids daily. Engine mustbe cold and on a level surface.

Add fresh fuel before starting en-gine the first time (see Figure 9-2).

1 Fuel Cap

2 Oil Dipstick

3 Oil Fill Tube

If oil is not up to full mark, add oil(see Figure 9-2). Engine stops if oilpressure gets too low.

Full

rsb4.1* 11/92 – ST-144 336-A

1

Figure 3-4. Checking Fluid Levels

3-4. Generator Auxiliary Power System

A. Selecting Equipment

WARNINGELECTRIC SHOCK can kill.• Use only grounded or double insulated equipment.

Ref. ST-153 470 / ST-800 577

1 Auxiliary Power Receptacles– Neutral Bonded To Frame

2 3-Prong Plug From CaseGrounded Equipment

3 2-Prong Plug From DoubleInsulated Equipment

1OR

2

Be sure equipment has thissymbol and/or wording.

3

Figure 3-5. Proper Equipment To Use


B. Grounding The Generator To A Truck Or T railer Frame

S-0854

1 Generator Base

2 Metal Vehicle Frame

3 Equipment GroundingTerminal

4 Grounding Cable

OR

1

2 Electrically bond generatorframe to vehicle frame bymetal-to-metal contact.

GND/PE Use #10 AWG orlarger insulatedcopper wire.

2

3 4

Use GFCI-protectedextension cords.

Figure 3-6. Grounding Methods

C. Grounding The Generator When Connecting To Home, Shop, Or Farm Wiring

rsb5.1 10/95 – ST-800 576-B

1 Equipment GroundingTerminal

2 Grounding Cable

Use #10 AWG or larger insulatedcopper wire.

3 Driven Ground RodGround generator to system earthground if supplying power to apremises (home, shop, farm) wiringsystem (see Auxiliary Power Guide -lines Booklet).

GND/PE

Use or driven ground rod or othermeans as stated in electrical codes.

3

2

3

1 2

Figure 3-7. Grounding When Supplying Building Systems


3-5. Selecting And Preparing Weld Output Cables

1 Weld Output Cable

Determine total cable length inweld circuit and maximum weldingamperes. Use Table 3-1 to selectproper cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage ca-pacity and hole size for connectingto work clamp or electrode holder.

3 Insulated Electrode Holder

Install according to manufacturer’sinstructions.

4 Work Clamp

Install onto work cable.

5 Dinse-Type Connector

Install onto weld cable as shown inFigure 3-9.

Tools Needed:

10 ft (3 m)

Total CableLength In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)For Example,

sb6.2* 5/94 – S-0656

2

3

4

1

5

Figure 3-8. Selecting And Preparing Weld Output Cables

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less 150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

WeldingAmperes

10 To 60%Duty Cycle

60 Thru 100%Duty Cycle 10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D


1 Weld Output Cable

2 Handle

3 Sleeve

Slide handle onto cable; strip cableand install sleeve.

4 Connector Body

5 Setscrew

Insert cable with sleeve fully intoconnector body, tighten setscrew,and slide handle over connector.

If job requires cable larger than 3/0AWG, use 2 ft (610 mm) or shorterpiece of 3/0 AWG cable for Dinse-Type connector installation. Con-nect other end of short cable to the4/0 or larger weld cable.

ST-156 496

Tools Needed:

1

2

3

1 in(26 mm)

3

4

5

Figure 3-9. Dinse-Type Connector Assembly

3-6. Connecting To Weld Output Terminals

WARNINGELECTRIC SHOCK can kill.• Always wear dry insulating gloves.

• Do not touch live electrical parts.

• Stop engine before making any weld output connections.

• Read Safety Precautions at beginning of this manual. rwarn13.1 2/92

Ref. ST-141 050-A / ST-151 653

1 Positive (+) Weld Output Re-ceptacle

2 Negative (–) Weld Output Re-ceptacle

For Direct Current Electrode Posi-tive (DCEP), connect work cable to– receptacle and electrode holdercable to + receptacle.

For Direct Current Electrode Neg-ative (DCEN), reverse cable con-nections.

3 Weld Output Receptacle

4 Connector

Align keyways on connector andreceptacle. Insert connector andturn clockwise until tight.

3

4

1

2

Figure 3-10. Weld Output Connections


SECTION 4 – OPERATING THE WELDING GENERATOR

ELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Stop engine before installing or servicing.

• Keep all panels and covers securely in place.

WELDING can cause fire or explosion.• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;NOISE can damage hearing.• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

FUMES AND GASES can be hazardous.• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) andmanufacturer’s instructions for material used.

ENGINE EXHAUST GASES can kill.• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaustoutside and away from any building air intakes.

ENGINE FUEL can cause fire or explo-sion.• Stop engine before fueling.



MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,

and rotors.• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-RENTS can affect pacemaker operation.• Pacemaker wearers keep away.

• Wearers should consult their doctor before goingnear any welding operations.

See Safety Precautions at beginning of manual for ba-sic welding safety information.

WARNING

rwarn5.1 10/91

ST-153 470 / ST-153 646

1 Amperage Control

2 Engine Hour Meter

3 Run/Idle Switch

4 Choke Lever

5 Engine Start Button


1 2 3

6

5

4

Right Side

Figure 4-1. Controls

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With SideShields

3 Welding Helmet With CorrectShade Of Filter (See ANSIZ49.1)

sb3.1 1/94

1 2 3

Figure 4-2. Safety Equipment


1 Work Clamp

Connect work clamp to a clean,paint-free location on workpiece,as close to weld area as possible.

Use wire brush or sandpaper toclean metal at weld joint area. Usechipping hammer to remove slagafter welding.

sb4.1 2/93

Tools Needed:1

Figure 4-3. Work Clamp

Ref. ST-141 050-A

1 Amperage Control

Use control to adjust weld amper-age. The scale surrounding thecontrol is marked in amperes.

Amperage control may be adjustedwhile welding.

1

Figure 4-4. Amperage Control

ST-153 470 / ST-153 646 / S-132 278-B

1 Choke Lever

Use control to change air-fuel mix-ture to engine. Move lever to right(full-choke) before starting engine.Move lever to left if starting warmengine.


Switch must be On to start engineusing Start button.

3 Engine Start Button

Push button to energize starter.

To Start: Turn On-Off switch to Onposition and push Start button. Re-lease Start switch when enginestarts. Do not crank engine whileflywheel is turning.

As engine warms up, move chokelever slowly to left.

To Stop: Move On-Off switch toOff position. Keep switch in Offposition when unit is not in use.

4 Optional Recoil Starter (NotShown)

Pull starter handle with quick,smooth motion to start engine.

5 Run/Idle Switch

In Run/Idle position, engine runs atidle speed with no load applied,and weld or power speed with loadapplied.

In Run position, engine runs atweld or power speed all the time.

5

2

1

3

Figure 4-5. Engine Controls


1 Engine Hour Meter

Use meter to check total operatinghours (see Section 9-1). This me-ter operates only when engine isrunning.

1

rsb6.1 2/92

Figure 4-6. Engine Hour Meter

InsertElectrode

Into Holderrsb8.1 9/92

Install &Connect

Equipment

SelectElectrode

Put OnPersonal Safety

EquipmentSet Controls Start Engine

Turn OnAuxiliary

Equipment

Begin Welding

Figure 4-7. Sequence Of Shielded Metal Arc Welding (SMAW)

SECTION 5 – OPERATING AUXILIARY EQUIPMENT

WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Stop engine before making internal inspection orreconnection.

• Ground generator according to all applicablenational, state, and local codes.

• Connect equipment grounding terminal to a properearth ground.

• Do not connect to any electrical distribution systemnormally supplied by utility power unless a propertransfer switch and grounding procedure areemployed (see Auxiliary Power GuidelinesBooklet).

MOVING PARTS can cause seriousinjury.• Keep away from moving parts such as fans, belts,



ELECTRIC SPARKS can cause fire.• If using auxiliary power only and not welding,

disconnect both welding cables to prevent liveelectrode from causing electric shock and firehazards.

• Watch for fire.

• Keep a fire extinguisher nearby, and know how touse it.

The weld output receptacles are electrically energizedwhen the engine is running and the contactor, ifapplicable, is energized.

LOW VOLTAGE AND FREQUENCY candamage electrical equipment.• Turn off or unplug all electrical equipment

connected to auxiliary power receptacles beforestarting or stopping the engine.

When starting or stopping, the engine has low speedwhich causes low voltage and frequency.

rwarn8.1 10/92

Limited auxiliary power is available while welding to run lights and heaters. Ifequipment does not run properly, disconnect auxiliary power load or wait untilwelding is stopped.

NOTE


5-1. 120 Volt Duplex Receptacles And Circuit Breakers

Ref. ST-141 050-A

1 120 V 15 A AC Duplex Re-ceptacles RC1 And RC2

RC1 and RC2 supply 60 Hz single-phase power at weld/power speed.Maximum output from each duplexreceptacle half is 1.8 kVA/kW.

2 Circuit Breakers CB1Through CB4

CB1 thru CB4 protect each recep-tacle half from overload. If a circuitbreaker opens, the receptacle halfdoes not work. Press button to re-set breaker.

3 Total Auxiliary Power Output

Combined output of receptacleslimited to 5 kVA/kW output of thegenerator.

EXAMPLE: If 21 A is drawn fromRC1, only 20 A is available at RC2:

(120 V x 21 A) + (120 V x 20 A) =5.0 kVA/kW

1

2

3

1

Use GFCI-protected extension cords.

Figure 5-1. Auxiliary Power Receptacles And Circuit Breakers

5-2. Optional 240 Volt Duplex Receptacle

Ref. ST-148 693-A

1 120 V 15 A AC Duplex Re-ceptacle RC1

See Figure 5-1 for description.2 240 V 15 A AC Duplex Re-

ceptacle RC2RC2 supplies 60 Hz single-phasepower at weld/power speed. Maxi-mum output from RC2 is 3.6 kVA/kW.3 Circuit Breakers CB1 And

CB3CB1 and CB3 protect each half ofRC1 from overload. If CB1 or CB3opens, the receptacle half does notwork. Press button to reset.4 Circuit Breakers CB2 And

CB4CB2 and CB4 protect each half ofRC2 from overload. If CB2 or CB4opens, output to both halves ofRC2 stops. 120 volts may still bepresent at RC2.5 Total Auxiliary Power OutputCombined output of receptacleslimited to 5 kVA/kW output of thegenerator.EXAMPLE: If 21 A is drawn fromRC1, only 10 A is available at RC2:(120 V x 21 A) + (240 V x 10 A) =5.0 kVA/kW

2

5

3 4

3 4

1


Figure 5-2. Optional 240 Volt Duplex Receptacle And Circuit Breakers


5-3. Optional 240 Volt Twistlock Receptacle (Full KVA)

1 120 V 15 A AC Duplex Re-ceptacle RC1 (SeeFigure 5-1 For Description)

2 240 V 21 A AC Twistlock Re-ceptacle RC2

RC2 supplies 60 Hz single-phasepower at weld/power speed. Maxi-mum output from RC2 is 5.0 kVA/kW. See Section 5-4 for matchingplug wiring instructions.

3 Circuit Breakers CB1 AndCB3

CB1 and CB3 protect each half ofRC1 from overload. If CB1 or CB3opens, the receptacle half does notwork. Press button to reset break-er.

4 Circuit Breakers CB2 AndCB4

CB2 and CB4 protect RC2 andRC1 from overload. If CB2 or CB4opens, output to RC2 and half ofRC1 stops. 120 volts may still bepresent at RC2.

5 Total Auxiliary Power Output

Combined output of receptacleslimited to 5 kVA/kW output of thegenerator.

EXAMPLE: If 15 A is drawn fromRC2, only 11 A is available at RC1:

(240 V x 15 A) + (120 V x 11 A) = 5.0kVA/kW

Ref. ST-151 013

5

23 4

3 4

1


Figure 5-3. Optional Twistlock Receptacle And Circuit Breakers


5-4. Wiring Instructions For 120/240 Volt AC Twistlock Plug

WARNINGELECTRIC SHOCK can kill; INCORRECT CONNECTIONS can cause fatal electric shock.• Do not touch live electrical parts.

• Wire the 120/240 volts twistlock plug according to Figure 5-4.

• Have only qualified persons make wiring connections.

The NEMA L14-30P plug for the120/240 volt twistlock receptaclecan be wired to supply a 240 volt,2-wire load or a 120/240 volt,3-wire load. See circuit diagramwhen wiring plug.

1 Plug Wired For 120/240 Volt,3-Wire Load

2 Plug Wired For 240 Volt,2-Wire Load

3 Neutral (Silver) Terminal

4 Load 1 (Brass)Terminal

5 Load 2 (Brass) Terminal

6 Ground (Green) Terminal

7 Outer Shell with Cord Grip

Strip cord jacket back enough toseparate conductors. Strip con-ductors enough to make good con-tact with plug terminals. Make plugconnections and reinstall outershell. Tighten cord grip screws.

rsb12.1* 2/92 – SB-085 361-D

120V

120V

240V

240V

13

4

5

2

4

5

6

Tools Needed:

7

6

Figure 5-4. 120/240 Volt AC Twistlock Plug Connections

rsb11.1 2/93

See AuxiliaryPower Guidelines

Booklet

Install &Connect

EquipmentStart Engine

Place Run/IdleSwitch In Run/Idle

Position

Turn OnAuxiliary

EquipmentBegin Operation

Figure 5-5. Sequence Of Auxiliary Equipment Operation


1 Engine

Supplies force to turn revolvingfield.

2 Low Oil Pressure Switch S4/Control Relay CR3

S4 deenergizes CR3 to stop en-gine if oil pressure is too low.

3 Control Relay CR6

Disables S4 during start-up.

4 Revolving Field (Rotor)

Turns at 3750 rpm maximum forweld or power, and 2400 rpm atidle.The speed and excitation cur-rent of the field coils determinesvoltages in stator windings.

5 Stator Windings

Supplies power to exciter, auxiliarypower, and weld circuits.

6 Fuse F1

Protects the excitation winding.

7 Integrated Rectifier SR1

Changes ac output from stator ex-citer winding to dc to supply excita-tion current to revolving field.

8 Field Current RegulatorBoard PC1

Controls output of weld winding byadjusting field current level in re-volving field.

9 Isolation Transformer T1

Supplies control power to PC1.

10 Amperage Control R1

Controls level of excitation currentsupplied to revolving field fromPC1.

11 Current Transformer CT1

Senses output from either auxiliarypower or weld windings and sig-nals idle module PC2 to maintainor increase to weld speed (3750rpm).

12 Idle Module PC2

Controls operation of idle solenoidTS1 through CR4. If no signal fromCT1, PC2 lowers engine speed to2400 rpm.

13 Run/Idle Switch S3

Run position locks engine speed atweld/power. Run/Idle position letsPC2 control engine speed.

14 Control Relay CR4/Idle Sole-noid TS1

CR4 energizes TS1 when acti-vated. TS1 decreases enginespeed when energized.

Figure 6-1. Functional Diagram

SECTION 6 – THEORY OF OPERATION

10

AmperageControl R1

Control Relay CR3

Low Oil PressureSwitch S4/

Engine

Control Relay CR4/Idle Solenoid TS1

Field CurrentRegulator

Board PC1

RevolvingField

(Rotor)

Idle Module

IntegratedRectifier

Fuse F1

1

14

8

4

7

6

Excitation

Stator Windings(Stator)

Power

Weld

Run/IdlePC2Switch S3

2

1213

5

IsolationTransformer T1

9

SR1

Control RelayCR6

3


15 Current Transformer CT2

Supplies excitation current to PC1.

16 Integrated Rectifiers SR2And SR3

Change ac output from weld wind-ing to dc.

17 Circuit Breakers CB1-CB4

Protect ac receptacles RC1 andRC2 from overload.

18 AC Receptacles RC1 AndRC2

Provide connection point and pow-er for auxiliary equipment.

19 Main Rectifier SR4

Changes ac weld current to dc.

20 Stabilizer DC-Z

Smooths out current to dc weldoutput receptacles.

21 Weld Output Receptacles

Provide dc weld output.

AC Or DC Control Circuits

3φ Power

Mechanical Coupling

Weld Current Circuit

Magnetic Coupling

CircuitBreakersCB1-CB4

Auxiliary PowerReceptaclesRC1, RC2

Integrated

16

MainRectifier

SR4

StabilizerDC-Z

Positive (+)Weld OutputReceptacle

ElectrodeWork

Negative (–)Weld OutputReceptacle

φ3

φ3

φ3

15 19

17

18

21 21

20

RectifiersSR2, SR3

Current TransformerCT2

Current TransformerCT1

11


SECTION 7 – TROUBLESHOOTING

7-1. Troubleshooting Tables


• Stop engine before inspecting, maintaining, orservicing.



HOT PARTS can cause severe burns.• Allow cooling period before servicing.

• Wear protective gloves and clothing when workingon a hot engine.

ENGINE FUEL can cause f i re orexplosion.• Stop engine before fueling.




and rotors.

STATIC ELECTRICITY can damage partson circuit boards.• Put on grounded wrist strap BEFORE handling

boards or parts.• Use proper static-proof bags.

Have only qualified persons familiar with and followingstandard safety practices perform troubleshootingprocedures. smwarn1.4 3/93

Use MILLER Testing Booklet (Part No. 150 853) when checking solid-state parts.NOTE

Table 7-1. Welding Trouble

Trouble Remedy Section

No weld output. Check fuse F1, and replace if open. 9-4

Check slip rings, and install new brushes if necessary. 7-6

Check integrated rectifiers SR1, SR2, and SR3, and replace if nec-essary.

7-2

Disconnect leads 28 and 33 from brushes, and check continuityacross slip rings. Replace rotor if necessary.

7-2

Check main rectifier SR4, and replace if necessary. 7-2

Check field current regulator board PC1 and connections, and re-place if necessary. If PC1 is bad, check voltage from isolationtransformer T1 before replacing PC1.

7-4

Check current transformer CT2 for signs of winding failure. Checkcontinuity across windings and check for proper connections. Re-place CT2 if necessary.

7-2

Check stabilizer DC-Z for signs of winding failure. Check continuityacross windings, and check for proper connections. Replace DC-Zif necessary.

7-2

Check isolation transformer T1 for signs of winding failure. Checkcontinuity across windings and check for proper connections. Re-place T1 if necessary.

7-2

Check resistance of weld windings. Replace stator if necessary. 7-2

Check engine charging system according to engine manual. – –

Low weld output. Increase Amperage control R1 setting. Figure 4-4

Check engine speed, and adjust if necessary. 9-5



Low weld output. (Continued) Check integrated rectifiers SR1, SR2, and SR3, and replace if nec-essary.

7-2

Disconnect leads 20 and 26 from integrated rectifier SR1, andcheck continuity between leads 20 and 26. Replace stator if neces-sary.

7-2

Check capacitor C2 for a short or open, and check for proper con-nections. Replace C2 if necessary.

7-2


7-2

Check resistance and connections of amperage control R1. R1 is10 kilohms ±10%. Replace R1 if necessary.

7-2


Check field current regulator board PC1 and connections, and re-place PC1 if necessary. If PC1 is bad, check voltage from isolationtransformer T1 before replacing PC1.

7-4

Check resistance of weld windings, and replace stator if neces-sary.

7-2

High weld output. Check engine speed, and adjust if necessary. 9-5

Check resistance and connections of amperage control R1. R1 is10 kilohms ±10%. Replace R1 if necessary.

7-2

Check suppressor R3/VR1 resistance and connections. R3 resist-ance is 1 kilohm ±10%. Replace R3/VR1 if necessary.

7-2

Check resistance and connections of resistor R2; R2 is 250 ohms±10%. Replace R2 if necessary.

7-2


7-4

Erratic weld output. Be sure connection to work piece is clean and tight. Figure 4-3

Change to proper electrode polarity. 3-6

Be sure electrode is dry and proper type for SMAW. – –

Check internal and external weld output connections. 3-6, 7-2



Tune engine and check governor according to engine manual. – –


Check integrated rectifiers SR2 and SR3, and replace if neces-sary.

7-2


7-4

Check stabilizer DC-Z for signs of failure. Check all connectionsand continuity of winding. Replace DC-Z if necessary.

7-2


Table 7-2. Auxiliary Power Trouble


No power output. Reset circuit breakers CB1 through CB4. 5-1, 5-2, 5-3

Check receptacles RC1 and RC2 wiring and connections. 7-2

Check fuse F1, and replace if open. 9-4

Check integrated rectifier SR1, and replace if necessary. 7-2

Check resistance of auxiliary power windings between leads 4 and5, and leads 6 and 7. Replace stator if necessary.

7-2


7-4

Low power output. Check engine speed, and adjust if necessary. 9-5


Check resistance of auxiliary power windings between leads 4 and5, and leads 6 and 7. Replace stator if necessary.

7-2

Check integrated rectifier SR1, and replace if necessary. 7-2

Check capacitor C1 for a short or open, and check for proper con-nections. Replace C1 if necessary.

7-2

Check isolation transformer T1 for signs of winding failure. Checkall connections and continuity of windings. Replace T1 if neces-sary.

7-2


7-4

High power output. Check engine speed, and adjust if necessary. 9-5

Erratic power output. Check fuel level. 3-3





Table 7-3. Engine Trouble


Engine will not start; starter turns overslowly or not at all.

Check battery and engine charging system according to enginemanual.

– –

Check continuity of engine start button PB1, and replace if neces-sary.

7-2

Engine will not start; starter turns over. Check fuel level. 3-3

Check continuity of engine on-off switch S2, and replace if neces-sary.

7-2

Check oil level. Check low oil pressure shutdown switch S4. 3-3, 7-2

Effective with Serial No. KC313049, check control relay CR6 coilvoltage and connections. Check continuity of coil and condition ofcontacts. Replace CR6 if necessary.

7-2

Engine stops during normal operation. Check fuel level. 3-3

Check oil level. Check low oil pressure shutdown switch S4. 3-3, 7-2

Battery discharges between uses. Clean battery terminals and posts with baking soda/water solution;Rinse with clear water.

– –

Periodically recharge battery (approximately every three months). 9-6

Check battery and replace if necessary. 9-6

Check low oil pressure shutdown switch S4. 7-2

Check voltage regulator and alternator according to engine manu-al.

– –

Engine idles but does not reach weldspeed.



7-2

Check idle module PC2 and connections, and replace if neces-sary.

7-5

Check control relay CR4 coil voltage and connections. Check con-tinuity of coil and condition of contacts. Replace CR4 if necessary.

7-2

Engine does not return to idle speed. Move Run/Idle switch S3 to Run/Idle position. Figure 4-5

Remove load from weld output and auxiliary power receptacles. – –

Check plug PLG3 and receptacle RC3 connection. 7-2

Check operation of idle solenoid TS1. Replace TS1 if necessary. 9-5

Check control relay CR4 coil voltage and connections. Check con-tinuity of coil and condition of contacts. Replace CR4 if necessary.

7-2

Check idle module PC2 and connections, and replace if neces-sary.

7-5

Unstable or sluggish engine speed. Tune engine according to engine manual. – –


Check idle solenoid TS1 paddle, and readjust if necessary. 9-5


Figure 7-1. Troubleshooting Circuit Diagram For Welding Generator

7-2. Troubleshooting Circuit Diagram For Welding Generator

Test Equipment Needed:

V1, R3

V12,

V6, R4 I1

V13

V11, R1

R2

V2

WARNING READ SAFETY BLOCKS at startof Section 7 before proceeding.

See also Section 7-4for PC1 data

V7, R5

Throttle ControlRelay CR4

See also Section 7-5for PC2 data

IdleSolenoid TS1

Engine CrankRelay CR5

V16,R11

V15,R10

Low Oil PressureShutdown Relay CR6


V1 60 volts ac

V2 178 volts dc

V3 27 volts ac

V4 27 volts ac

V5 27 volts ac

V6 44 volts ac

V7 18 volts ac

V8 34 volts dc

V9 201 volts dc

V10 25 volts dc

V11 33.5 volts dc

V12 0 volts dc(13.9 volts dcat idle speed)

V13 7.6 volts ac

V14 77 volts ac

V15 77 volts ac

V16 77 volts ac

V1 110 volts ac

V2 152 volts dc

V3 57 volts ac

V4 57 volts ac

V5 57 volts ac

V6 46.3 volts ac

V7 18.5 volts ac

V8 0 volts dc

V9 0 volts dc

V10 74.5 volts dc

V11 33 volts dc

V12 0 volts dc(13.9 volts dcat idle speed)

V13 0 volts ac

V14 131 volts ac

V15 131 volts ac

V16 131 volts ac

Resistance Values

a) Tolerance – ±10% unless specified

b) Condition – 70 °F (21°C); coldmachine (no warm-up); no load

c) Wiring Diagram – See Section 10

d) Stop engine before checkingresistance

R1 4.4 ohms

R2 12.2 ohms

R3 Less than 1 ohm

R4 7.4 ohms

R5 1.7 ohms

R6 thru R12 Less than 1 ohm

R13 All values for CT2 are less than 1 ohm

SC-169 843 / ST-157 559

Voltage Readings


b) Reference – to circuit common(lead 33) unless noted

c) All readings at weld/power rpm

b) Condition – 70 °F (21°C); coldmachine (no warm-up)

d) Wiring Diagram – see Section 10

OutputOpen-Circuited

(No Load)

Output AtRated Weld Load

(25 V, 180 A)

V5, R8

V8

V14

I2

V10, A, B

V9

See Section 7-3for waveforms A, B

R12

R9

Amperage Readings


b) Condition – 70 °F (21°C); coldmachine (no warm-up); no load

I1 5.95 amps dc

I2 0 amps dc

OutputOpen-Circuited

(No Load)

Output AtRated Weld Load

(25 V, 180 A)

I1 5.95 amps dc

I2 180 amps dc

V4, R7

V3,R6

R13


7-3. Waveforms For Section 7-2


• Stop engine before making or changing any test equipment leads or cable connections.

Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.smwarn3.2 12/93

5 ms 50 V

A. DC Open-Circuit Voltage, AmperageControl R1 At Maximum

5 ms 10 V

B. 25 Volts DC, 112 Amperes(Resistive Load)


gnd gnd

Figure 7-2. Waveforms For Section 7-2


7-4. Troubleshooting Field Current Regulator Board PC1


• Stop engine before making or changing meter leadconnections and before disconnecting orconnecting any leads.









and rotors.





Be sure plugs are secure beforetesting. See Table 7-4 for specificvalues during testing.

1 Field Current RegulatorBoard PC1

2 Receptacle RC1

ST-157 559 / SA-167 344

1

2

Figure 7-3. Field Current Regulator Board PC1 Testing Information (Use With Table 7-4)


Table 7-4. Field Current Regulator Board PC1 Test Point Values (Use With Figure 7-1 And Figure 7-3)

Voltage Readings:

a) Tolerance – ±10% unless specified b) Reference – to circuit common(lead 33) unless noted

c) Values taken under the following conditions unless noted: Engine On-Off switch S2 in On position, and Run/Idleswitch S3 in Run position.

Receptacle Pin Value

RC1 1 Circuit common

2 +10 to +32 volts dc output from min to max of Amperage control R1 with weld output receptaclesshort-circuited; 32 volts dc with no load

3 +18 volts ac input with respect to pin 4

4 +18 volts ac input with respect to pin 3

5 Circuit common

6 0 volts dc input with no weld load; +201 volts dc input with full weld load

7 +5 volts dc input with Amperage control R1 at max

8 Not used

9 0 volts dc input with no weld load; +34 volts dc input with full weld load

10 0 to +5 volts dc input from min to max of Amperage control R1

11 +148 volts dc input

12 +12 volts dc input


7-5. Troubleshooting Idle Module PC2


• Stop engine before making or changing meter leadconnections and before disconnecting orconnecting any leads.









and rotors.





See Figure 7-5 for specific test val-ues. Voltage reading tolerance±10%.

1 Idle Module PC2

ST-157 559 / SB-142 724-B

1

Figure 7-4. Idle Module PC2 Testing Information (Use With Figure 7-5)


Replaceidle module.

NO

NO

NO

NO

Stop engine before connecting or changingmeter leads and before replacing any parts.

Connect meter (DC) betweenterminal B (+) and terminal E (–).

YES

YES

Connect meter (AC) betweenterminal G and terminal E.

Start engine, and place Run/Idle

+12 vdc present?

Approximately +10 vdc presentafter 12 to 18 seconds?

Check control relay CR4, throttlesolenoid TS1, and connections.

Connect meter (DC) betweenterminal C (+) and terminal E (–).

0 (zero) vac present?

YES

Reinstall cover.

switch in Run/Idle position.

Check connectionsto Run/Idle switchS3, and ground

connection

Replaceidle module.

Check for internalload such as

shorted diode in

Connect a 100 watt light bulb to120 vac duplex receptacle.

Connect meter (AC) betweenterminal G and terminal E.

Minimum of 1 vac present?

YES

Disconnect 100 watt light bulband meter leads.

Connect meter (DC) betweenterminal C (+) and terminal E (–).

0 (zero) vdc present?

YES

Reinstall cover.

Check control relay CR4.

Start engine, and place Run/Idleswitch in Run/Idle position.

Check connectionsto current

transformer CT1.

Engine does not go to idle speed(2400 rpm) with no load applied.

Engine does not go to weld/powerspeed (3750 rpm) with load applied.

NO

main rectifier SR4.

(lead 33).

Figure 7-5. Troubleshooting Flow Chart For Idle Module PC2


7-6. Replacing Brushes And Cleaning Slip Rings






and rotors.






Have only qualified persons familiar with and followingstandard safety practices perform troubleshootingprocedures.

smwarn1.4 3/93

Stop engine and allow to cool.

1 Lower Front Panel

2 Fan Shroud

3 Stator Barrel

Remove panel. Remove shroudfrom barrel.

4 Bolt

5 Lock Washer

6 Flat Washer

7 Rotor Shaft

Remove bolt and washers fromshaft.

8 Fan

Gently work fan off shaft.

9 Brush Holder Bracket

Remove bracket.

10 Brush Holder

11 Brush With Spring

12 Brush Holder Cap

Mark and disconnect brush leadsat caps.

Replace brushes if damaged, or ifbrush is at or near minimum length.

13 Slip Rings

Inspect slip rings. Under normaluse, rings turn dark brown.

If slip rings are corroded or surfaceis uneven, insulate brush leads,start engine, and clean rings with acommutator stone. Remove aslittle material as possible. Stop en-gine.

Install brushes in holder and rein-stall bracket. Reconnect leads.

Reinstall fan and secure with boltand washers. (see Figure 8-1 fortorque values).

Reinstall shroud and lower frontpanel.

ST-157 560-B / S-0233-A

1

1/4, 5/16, 3/8, 1/2, 9/16 in

5/32 in

1/2 in

Tools Needed:

5/16 in (8 mm)Minimum Length

9/16 in(14.3 mm)

New Length

Replace DamagedBrushes

11

10

9

24

56

3

8

13

7

12

Figure 7-6. Replacing Brushes And Cleaning Slip Rings


7-7. Checking Unit Output After Servicing






and rotors.






Have only qualified persons familiar with and followingstandard safety practices perform troubleshootingprocedures.

smwarn1.4 3/93

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged(see Parts List).

Check fuel and oil (see Section 3-3).

Check and correct any fluid leaks.

Clean weld output and battery terminals. Tighten connections.

Clean outside of unit.

ST-ST-157 559 / SA-167 344

Check and adjust engine speeds, if neces-sary (see Section 9-5).

1 120 V 15 A AC Duplex ReceptaclesRC1 And RC2

Check voltage at each receptacle. With noload applied, there should be 128 - 132 voltsac present.

Check voltage at optional 240 volt duplexand twistlock receptacles. With no load ap-plied, there should be 256 - 264 volts acpresent.

Adjust engine speed if voltage is incorrect.

2 Weld Output Receptacles

Check open-circuit voltage between weldoutput receptacles. Open-circuit voltageshould be 72 - 75 volts dc (see Section 7-2).Adjust engine speed if voltage is incorrect.

Stop engine.

3 Field Current Regulator Board PC1

4 Potentiometer R1 Adjustment

5 Potentiometer R2 Adjustment

Connect load bank to weld output terminals.

Start engine and check short circuit current.

With Amperage control at min., short circuitcurrent should be 51 - 53 amperes dc.

With Amperage control at max., short circuitcurrent should be 194 - 196 amperes dc.

Stop engine.

If short circuit current is incorrect, first adjustR1 to correct Amperage control minimumsetting, then adjust R2 to correct Amperagecontrol maximum setting.

Apply a 140 ampere, 25 volt dc load to weldoutput receptacles. Engine should run at3500 rpm. Adjust engine speed if incorrect.

Stop engine. Reinstall top cover.

Allow engine to cool, then complete pre-op-erational checks in table.

Pre-Operational Check

Tools Needed:

3/8 in


1

2

3

45

Figure 7-7. Checking Unit Output

Blue Star 180K TM-436 Page 31

SECTION 8 – DISASSEMBLY AND REASSEMBLY


• Stop engine before repairing unit.

• Allow cooling period before servicing.


and rotors.• Before working on generator, remove spark plugs

or injectors to keep engine from kicking back orstarting.

• Keep hands, hair, loose clothing, and tools away.

• Block flywheel so that it will not turn while workingon generator components.

FALLING EQUIPMENT can causeserious personal injury and equipmentdamage.• Use equipment of adequate capacity to lift

components.• Securely attach components to lifting equipment.

UNCONTROLLED TILTING OR TIPPINGOF UNIT can result in personal injuryand equipment damage.• Do not put any body part under unit while lifting.

• Use adequate blocks to support components asneeded during job.

PINCH POINTS can injure.• Be careful when working on stator and rotor

assemblies.

ENGINE FUEL can cause fire orexplosion.• Do not smoke, and keep flames and sparks away

from work area.

BATTERY EXPLOSION can BLIND andINJURE.• Wear a face shield, rubber gloves, and protective

clothes while working on battery.• Keep welding, sparks, flames, or smoking away.

• Disconnect negative (–) cable first and connect itlast.

BATTERY ACID can BURN SKIN.• Do not tip. • Replace damaged battery.

• Flush eyes and skin immediately with water.

FLYING METAL AND DIRT can injureeyes.• Wear safety glasses with side shields during job.

• Use Parts List to order parts.

• Use only genuine MILLER replacement parts.

• Reinstall injectors and bleed air from fuel systemaccording to engine manual.

Have only qualified persons familiar with and followingstandard safety practices perform any repairprocedures. smwarn5.1 5/94

SD-144 337-B

1 Brush Holder Bracket2 Brush Holder3 Brush With Spring4 Brush Holder Cap5 Brush Retaining Bar6 O-Ring7 Retaining Ring

8 Bearing

9 Key

10 Rotor

11 Engine Adapter

12 Engine Shaft

13 Stud

14 Stator

15 Endbell

16 Rotor Fan

17 Flat Washer

18 Lock Washer

19 Fan Shroud

A 12 ft lb (16 N.m)

B 60 in lb (7 N.m)

C 30 ft lb (41 N.m)

D 10 ft lb (14 N.m)

Torques:1 2

3

4

5

6

10

78

9

11

13

14

15

1617

19

18

C

A

D

12

B

Figure 8-1. Generator Assembly, Component Locations, And Torques


WARNING

READ SAFETY BLOCKS at start of Section 8 before proceeding.

ST-800 995

Disassembly

Disconnect battery cables. Dis-connect fuel line at filter. Plug fuelline, and remove fuel line mountingclamps. Remove spark plug.

At connectors in control box, markand disconnect stator leads, brushlead, and leads run through CT1.Disconnect other brush lead fromresistor R2, and starter wiring fromCR5 relay. Disconnect exciterwinding leads from fuse F1 and in-tegrated rectifier SR1. Unplug en-gine wiring harness at bottom ofcontrol box.

Disassemble in sequence shown.

Use hoist and lifting strap to re-move engine/generator.

1 Rotor Removal Tool (MillerPart No. 147 551)

Install tool on engine fan. Use strapwrench to remove rotor.

Reassembly

Reassemble in reverse order ofdisassembly. Apply anti-seizecompound (Loctite 767) to engineshaft threads, and 20W oil to statorstud threads before installing.

See Figure 8-1 for generator as-sembly and torque values.

Reconnect leads (see circuit dia-gram). Use cable ties to keep leadsfrom hot or moving parts. Keepleads away from air duct in bottomof control box.

Reconnect fuel line and securewith clamps. Wipe up spilled fuel.Reinstall spark plug, battery, pan-el, and cover. Reconnect battery.

Tools Needed:

5/16, 3/8, 7/16, 1/2, 5/8, 1-1/4 in

5/32 in

Torque screw to 49 ft lb (66 N.m)when reassembling.

8 mm screw

Do not damagerotor or stator.

Reassemble so stator seamaligns with marks on engineadapter and endbell.

1

Figure 8-2. Disassembly Of Unit


SECTION 9 – MAINTENANCE


• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Stop engine before installing or servicing.

• Keep all panels and covers securely in place.



ENGINE FUEL can cause fire or explo-sion.• Stop engine before fueling.








ENGINE EXHAUST SPARKS can causefire.• Use only U.S. Forestry Department approved

spark arrestor and comply with all local, state, andfederal laws.

• A spark arrestor is mandatory in all National For-ests and in grass, brush, or forest covered lands inCalifornia, Oregon, and Washington. Check withstate and local authorities in other areas.

• Properly maintain the spark arrestor.

• Stop engine and allow exhaust system to cooldown before servicing spark arrestor.

• Service spark arrestor away from flammables.

Maintenance to be performed only by qualified per-sons.

rwarn9.1 10/93

9-1. Routine Maintenance

Stop engine before maintaining.

FUEL

OILfull

CheckFluid

Levels

ChangeOil

ChangeOil

Filter

Clean AndTightenBattery

Connections

ReplaceUnreadable

Labels

Tape OrReplaceCrackedCables

SeeSection

3-3

9-2

9-2

9-6

11

– –

8 Hours

50 Hours

100 Hours

200 Hours

500 Hours

1000 Hours

F U

LO

IL E Wipe

UpSpills

– –

CleanCoolingSystemengine

manual

CleanAnd

TightenWeld

Connections3-6

CleanAnd

CheckAir

Cleanerenginemanual

FUEL

ReplaceFuelFilter

9-3

Do not throw away enginefluids – take to area recyclingcenter.

CheckAnd

CleanSpark

Arrestor 9-7

20 HoursOR

Blow OutOr

VacuumInside

– –During Heavy Service,

Clean Monthly

Figure 9-1. Maintenance Schedule


°C

+30

+20

+10

0

-10

-20

-30

°F

KOHLER CH12.5 GAS ENGINE

Check

5W-2

0, 5

W-3

0

+

S-141 972-D

Spark Arrestor Inspection And Service 20 operating hours -. see Owner’s Manual

Fuel Capacity 3.8 gal (14.4 L). . . . . . . Fuel Grade Unleaded, 87 Octane min.. . . . . . . . . Fuel Filter MILLER 066 699, Kohler 2505002. . . . . . . . . .

12 Volt Battery BCI Group U1. . . . . . . . . . . . . . . . . . . . . . . . Cranking Performance at 0°F (-18°C) 260 Amps min.. . . .

Engine RPM – No LoadWeld/Power 3750Idle 2400. . . . . .

Air Filter Service 100 hours or less – see Owner’s Manual. . . . Air Filter Element MILLER 066 700, Kohler 4708301. . . .

Spark Plug Gap 0.040 in. (1.02 mm). . . . . Spark Plug Champion RC-12YC. . . . . . . . .

Use only resistor spark plugs and wires.

0

+32

10W

-30,

10W

-40

+100

Recommended Oil API Service Classifi-. . . cation SF-SG/CC-CD

Oil Change 100 hours. . . . . . . . . Oil Filter Change 200 hours. . . . Oil Filter MILLER 066 698,. . . . . . . . . . . .

Kohler 1205001Oil Capacity 56 oz qt (1.6 L) or. . . . . . . .

62 oz (1.8 L) with filter change

daily.

See Engine Manual for complete engine care. Give engineSpecification and Serial Number when ordering parts.

Gasoline

Figure 9-2. Maintenance Label


9-2. Changing Engine Oil And Filter

WARNINGSPARKS can cause BATTERY GASESTO EXPLODE; BA TTERY ACID can burneyes and skin.• Stop engine before disconnecting or connecting

battery cables.• Do not allow tools to cause sparks when working on

a battery.

• Always wear a face shield and proper protectiveclothing when working on a battery.

• Do not spill acid.

• Observe correct polarity (+ and –) on batteries.

• Do not use welder to charge batteries or jump startvehicles.

rwarn10.1* 9/91

Ref. ST-153 471 / Ref. ST-158 800

Stop engine.

Change oil while engine is stillwarm.

1 Battery

2 Hold Down

To replace oil filter, remove batteryas follows:

Remove terminal cover from bat-tery. Disconnect battery cables,negative (–) cable first. Removehold down and battery.

3 Oil Filter

See engine manual for filter re-placement procedure.

4 Oil Fill Cap/Dipstick

5 Oil Drain Plug

Remove oil fill cap/dipstick anddrain plug.

Wait for oil to drain completely. Re-install plug. Fill crankcase with newoil to full mark on dipstick. SeeFigure 9-2 for specifications.

Reinstall oil fill cap/dipstick.

Reinstall battery. Reconnect bat-tery, negative cable last. Reinstallterminal cover.

5

4

Tools Needed:

3/8, 7/16 in

3

1

2

Figure 9-3. Changing Engine Oil


9-3. Replacing Fuel Filter

READ SAFETY BLOCKS at start ofSection 9 before proceeding.WARNING

ST-153 472

Stop engine, and allow to cool.1 Fuel Line

Clamp fuel line between filter andfuel tank to prevent fuel from leak-ing while changing filter.2 Fuel Filter

3 Hose Clamp

Remove clamps and filter.Inspect fuel line; replace if crackedor damaged.Install new filter with hose clamps.Remove clamp from fuel line. Wipeup any spilled fuel.Start engine, and check for fuelleaks.Stop engine, tighten connectionsas necessary, and wipe up fuel.

Tools Needed:

1

2

3

Left Side

Figure 9-4. Replacing Fuel Filter

9-4. Overload Protection


ST-153 473

Stop engine.

1 Fuse F1 (See Parts List)

2 Rectifier SR1

F1 protects the exciter excitationwinding from overload. If there isno weld and auxiliary power out-put, F1 may be open.

Remove top panel, check and re-place F1, and reinstall panel beforeoperating unit.

If fuse continues to open, checkSR1.

Tools Needed:

3/8 in

1

2

Figure 9-5. Fuse F1 Replacement


9-5. Adjusting Engine Speed


Stop engine.

Engine speeds have been factoryset and should not require adjust-ment. After tuning engine, checkengine speeds with a tachometer.See table for proper no loadspeeds. If necessary, adjustspeeds as follows:

1 Speed Adjustment Bracket

2 Securing Screws

Loosen screws 1-1/4 turns.

Start engine and move Run/Idleswitch to Run position.

Slide bracket forward or backwarduntil engine runs at weld/powerspeed. Tighten screws.

Move Run/Idle switch to Run/Idleposition. After engine idles down,return switch to Run and recheckweld/power speed. Readjustbracket if necessary.

Stop engine.

3 Governor Arm

4 Carburetor

5 Idle Paddle

6 Idle Solenoid Post

7 Idle Solenoid Bracket

Push governor arm towards carbu-retor as far as possible.

Check gap between paddle and so-lenoid post. Gap should be about1/16 in (2 mm) and paddle shouldalign squarely with solenoid brack-et. Release governor arm. If neces-sary, adjust gap as follows:

8 Securing Screw

Loosen screws.

Adjust paddle so gap betweenpaddle and solenoid bracket is 1/4in (6 mm) at top and 5/16 in (8 mm)at bottom. Tighten screws.

Push governor arm towards carbu-retor and recheck gap betweenpaddle and solenoid post. Readjustif necessary.

9 Air Cleaner Cover

Remove air cleaner cover. Do notremove air cleaner base.

Start engine and move Run/Idleswitch to Run/Idle position.

10 Idle Speed Adjusting Screw

Turn screw until engine runs at idlespeed.

If engine does not run at idle speed,stop engine and recheck idlepaddle/idle solenoid bracket gapand alignment. Repeat idle speedscrew adjustment if necessary.

Reinstall air cleaner cover.

SC-144 335-B

Tools Needed:

10 mm, 1/4 in

Rear Of Unit

1/4 in(6mm)

5/16 in(8 mm)

1

2

6

7

5

8

3

4

9

10

Engine Speed

Weld/Power

Idle

RPM

3750

2400

Figure 9-6. Engine Speed Adjustment


9-6. Replacing Battery And Checking Battery Voltage

WARNINGSPARKS can cause BATTERY GASESTO EXPLODE; BA TTERY ACID can burneyes and skin.• Stop engine before disconnecting or connecting

battery cables.• Do not allow tools to cause sparks when working on

a battery.

• Always wear a face shield and proper protectiveclothing when working on a battery.

• Do not spill acid.

• Observe correct polarity (+ and –) on batteries.

• Do not use welder to charge batteries or jump startvehicles.

rwarn10.1* 9/91

ST-158 800 / S-132 278-B / Ref. S-0679-A

If engine does not crank, checkbattery voltage as follows:


Place switch in the Off position.

2 Battery

3 Negative (–) Battery Cable

4 Positive (+) Battery Cable

5 Voltmeter

Remove terminal cover from bat-tery.

If battery voltage is less than 12.4volts, charge battery following bat-tery charger’s instructions.

To replace battery, proceed as fol-lows:

Disconnect battery cables, nega-tive cable first.

6 Hold Down

Remove hold down and battery.When reconnecting battery, con-nect negative (–) cable last. Rein-stall terminal cover.

Tools Needed:

3/8, 7/16, 9/16 in

1

3

2

6

4

5

Figure 9-7. Replacing Battery And Checking Battery Voltage


9-7. Servicing Optional Spark Arrestor


ST-157 559 / ST-144 340-A

Stop engine and allow to cool.

1 Muffler

2 Spark Arrestor

3 Screw

Clean and inspect spark arrestorscreen. Replace spark arrestor ifscreen wires are broken or missingor if openings exceed 0.023 in.(0.58 mm).

Tools Needed:

1

2

3

Left Side View

Figure 9-8. Servicing Spark Arrestor


NOTES


SECTION 10 – ELECTRICAL DIAGRAMS

� The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit insidemachine case or contact factory for actual circuit, if needed.

The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:

1 Know unit Model and Serial or Style Number.

2 Use this list to find diagram number.

3 Include your FAX number or mailing address with your request.

4 FAX Technical Publications Department at 414-735-4011 or call 414-735-4356.

Model Serial Or Style Number CircuitDiagram

WiringDiagram

Main ReasonFor Change

Blue Star 180K KB012373 thru KB110694 SC-141 329-B C-142 117-A♦♦

KB110695 thru KC313048 C-147 173♦♦ C-146 982-B♦♦ Added CR5

KC313049 thru KE696136 C-154 945♦♦ D-154 942-C♦♦ Added CR6, CR3 diode, re-ceptacle options

KE696137 and following SC-169 843 SD-169 844-A Hourmeter standard

Circuit Board PC1 KB012373 thru KE613733 SB-142 013-C

KE613734 and following SB-167 346

♦♦ Not included in this manual


SC-141 329-B

Figure 10-1. Circuit Diagram For Blue Star 180K Effective With Serial No. KB012373 Thru KB110694


SC-169 843

Figure 10-2. Circuit Diagram For Blue Star 180K Effective With Serial No. KE696137 And Following


Figure 10-3. Wiring Diagram For Blue Star 180K Effective With Serial No. KE696137 And Following


Coat terminals with dielectric grade, nonconductive,electric grease (MILLER Part No. 146 557) or equivalent. SD-169 844-A


SB-142 013-C

Figure 10-4. Circuit Diagram For Field Current Regulator Board PC1 Effective WithSerial No. KB012373 Thru KE613733

SB-167 346

Figure 10-5. Circuit Diagram For Field Current Regulator Board PC1 Effective WithSerial No. KE613734 And Following

May 1996 Form: TM-436

Effective With Serial No. KB0123373

SECTION 11 – PARTS LIST


Blue Star 180KCC/DC Welding Generator For SMAW Welding

TM

-436 Page 48

Blue S

tar 180K

Figure 11-2

Figure 11-1. Main Assembly

1

3 4

5

6

7

89

1011

1213

14

15

17 18

1920

21

22

2324

2520

16

26

272829

3031

3233

3435

36

37

38

39

40

42

434445

46

4748

49

28

30

51

50

52

53545556

57

58

2S

T-144 339-D

41

Figure 11-4

Figure 11-3


Figure 11-1. Main Assembly

Description QuantityPartNo.

Dia.Mkgs.

ItemNo.

1 +141 036 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 108 487 LABEL, warning falling equipment 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 141 209 UPRIGHT, base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fig 11-4 CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 148 418 KIT, fuel tank replacement (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 147 896 TANK, fuel 3.8gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 126 239 SCREEN, fuel line pick-up 5/16tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 127 405 TUBING, urethane ester .250 ID x .312 OD x 5.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 124 253 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 124 252 FITTING, hose stl elb 1/4tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 084 173 CLAMP, hose .460-.545clp dia slfttng 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 107 816 HOSE, SAE .250 ID x .500 OD (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 332 STRIP, rbr adh back .125 x 1.000 x 1.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 +141 027 BASE, (Prior to KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 +146 981 BASE, (Eff w/KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fig 11-3 GENERATOR/SHROUD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 010 909 NUT, stl slflkg hex reg .375-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 142 155 DUCT, air engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 141 453 ENGINE, Kohler gas elec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152 741 TUNE-UP & FILTER KIT, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 066 698 OIL FILTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 066 699 FUEL FILTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 066 700 AIR FILTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 067 025 PRECLEANER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 067 007 SPARK PLUG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 S4 142 095 SWITCH, pressure oil 4PSI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 125 802 MOUNT, eng nprn .312-18 dual stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 141 033 BRACKET, mtg engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 141 029 TUBING, stl .625 OD x 12ga wall x 1.625 lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 HOUSING w/SOCKETS, (see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 PLG2 136 810 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 141 559 PADDLE, solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TS1 142 291 SOLENOID, idle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 601 965 SCREW, cap stl hexhd .375-16 x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 602 213 WASHER, lock stl split .375 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 010 910 WASHER, flat stl SAE .375 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PB1 141 670 SWITCH, starter push button (Prior to KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PB1 046 433 SWITCH, PB MC NO 36VDC (Eff w/KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 021 385 BOOT, tgl switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 S2 011 611 SWITCH, tgl DPDT 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 146 985 CABLE, bat pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 052 553 COVER, cable bat post red No. 4-10 wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 141 205 BRACKET, hold down battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 142 102 CABLE, bat neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142 103 CABLE, grd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 BATT 003 426 BATTERY, stor 12V 230crk 32RSV 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 604 311 GROMMET, rbr .250 ID x .375mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 604 538 WASHER, flat stl SAE .312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 604 433 NUT, stl slflkg hex hvy .312-18 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 168 385 LABEL, warning battery explosion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CR5 119 722 CONTACTOR, solenoid 12VDC 400A SPNO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 114 923 BOOT, insulator term post red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 604 435 BOLT, crg stl .312-18 x 7.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 009 043 SCREW, cap stl hexhd .375-16 x 3.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 010 955 WASHER, flat stl .406 ID x 2.000 OD x .125thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 010 047 TUBING, stl .625 OD x 12ga wall x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 010 954 WASHER, flat stl .406 ID x 1.250 OD x .125thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 127 595 SCREW, cap stl hexhd .375-16 x 2.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 127 593 MOUNT, gen nprn adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 013 367 LABEL, warning moving parts etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 125 738 STRAP, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Figure 11-1. Main Assembly (Continued)


Dia.Mkgs.

ItemNo.

53 +141 037 PANEL, front lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 132 709 LABEL, engine fuel can cause fire or explosion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 126 723 WASHER, neck tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 126 994 CAP, fuel tank screw on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 128 333 BAFFLE, air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fig 11-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 713 KIT, label 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +When ordering a component originally displaying a precautionary label, the label should also be ordered.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

1

23

4

56 7

8*

9

10

1113

1415

5

19 18 17 16

SB-144 338-B / SA-167 344

11

12

*Includes Item 9

Figure 11-2. Panel, Front w/Components



Dia.Mkgs.

ItemNo.

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 58)

1 602 221 WASHER, lock stl intl tooth .375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CB1-4 +125 524 CIRCUIT BREAKER, man reset 1P 15A 250V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2,4 ♦ 144 474 CIRCUIT BREAKER, man reset 1P 25A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RC1,2 ++039 684 RECEPTACLE, str dx grd 2P3W 15A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . . RC2 ♦ 129 067 RECEPTACLE, twlk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 898 PLUG, twlk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . . RC2 ♦♦ 604 103 RECEPTACLE, str dx grd 2P3W 15A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

025 234 PLUG, str grd 2P3W 15A 250V. . . . . . . . . . . . . . . . . . . . . . . 4 C3,4 131 646 CAPACITOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Neg, Pos 129 525 RECEPTACLE, jack 400A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

042 418 CONNECTOR KIT, Dinse male 50 series (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 746 WRENCH, hex 5mm short 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 147 898 STAND-OFF SUPPORT, PC card No. 6scr 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PC1 167 343 CIRCUIT CARD, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A1 165 411 IC, linear 2904 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1 000 859 CAPACITOR, elctlt 220uf 35VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C2,3,6,8-10 122 723 CAPACITOR, cer mono .1uf 50VDC 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4 031 699 CAPACITOR, polye film .0022uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7 166 197 CAPACITOR, cer disc .1uf 500VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR1 093 192 RELAY, encl 24VDC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1 037 399 DIODE, sig .0085A 60V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2 026 202 DIODE, rect 1A 400V SP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3 037 243 DIODE, zener 18V 1W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 070 250 DIODE, rect 3A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D5,7 129 310 DIODE, fast recovery 8A 400V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 117 566 DIODE, rect 6A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8 004 176 DIODE, zener 24V 5W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HS1 126 906 HEAT SINK, case 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HS2,3 105 489 HEAT SINK, solderable tap .960mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5 092 648 RESISTOR, WW fxd zero ohm (Prior to KE613734) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1 126 069 TRANSISTOR, mosfet 16A 400V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q2 037 200 TRANSISTOR, NPN 200mA 40V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1 035 848 POTENTIOMETER, cermet trmr 25/T .5W 10K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R2 009 391 POTENTIOMETER, cermet trmr 25/T .5W 50K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R3 093 030 RESISTOR, MF .25W 15K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R4 108 437 RESISTOR, MF .25W 4.75K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R5 093 037 RESISTOR, MF .25W 47.5K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R6 052 145 RESISTOR, MF .25W 475K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R7 000 885 RESISTOR, MF .25W 10K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R8,10 044 789 RESISTOR, MF .25W 100K ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R11 072 559 RESISTOR, MF .25W 22.1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R12 074 056 RESISTOR, C .5W 390 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R13 108 432 RESISTOR, MF .25W 2.21K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R14 030 055 RESISTOR, C 2W 10 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R15 072 560 RESISTOR, MF .25W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R16 089 318 RESISTOR, WW fxd 5W .1 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R17 133 711 RESISTOR, WW fxd .5W .05 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R19 030 839 RESISTOR, WW fxd 5W 220 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R20 074 060 RESISTOR, C .5W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R21 030 114 RESISTOR, C .5W 150 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC1 116 512 TERMINAL, hdr 12 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SR1 021 939 RECTIFIER, integ 1.5A 400V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U1 167 367 IC, linear 2524BJ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 130 203 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 R1 072 462 POTENTIOMETER, w/shaft lock (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 072 590 LOCK, shaft pot .375-32 x .250dia shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 S3 089 085 SWITCH, tgl SPST 20A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CR3,4 090 104 RELAY, encl 12VDC SPST (Prior to KC313049) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CR4,6 173 069 RELAY, encl 12VDC SPDT (Eff w/KC313049) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Dia.Mkgs.

ItemNo.

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 58) (Continued)

12 CR3 149 823 RELAY, encl 12VDC SPST (Eff w/KC313049) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 141 038 PANEL, front (Prior to KE696137) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 169 842 PANEL, front (Eff w/KE696137) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦♦ 042 367 HOUR METER, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HM ♦ 145 247 METER, hour 4-40VDC (Eff w/KE696137 became standard) 1. . . . . . . . . . . . . . . . . . . . . . .

604 784 SCREW, mach brs rdh 6-32 x .500 (Eff w/KE696137. . . . . . . . . . . . . . . . . . . . . . . . . became standard) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 829 NUT, brs hex 6-32reg (Eff w/KE696137 became standard) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 083 030 STUD, brs grd .250-20 x 1.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 010 915 WASHER, flat brs .250 ID x .625 OD x .031thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 601 836 NUT, brs hex .250-20 jam hvy 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+Circuit Breaker (CB1,3) (CB1-4) remains the same for Option 042 625 and 042 627 Receptacle Kits respectively.++Receptacle (RC1) remains the same for Option 042 625 and 042 627 Receptacle Kits.♦ Part of Option 042 625 240V Twistlock Receptacle Kit.♦♦ Part of Option 042 627 240V Duplex Receptacle Kit.♦♦♦ OPTIONALBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.


DescriptionPartNo.

ItemNo. Quantity

Figure 11-3. Generator/Shroud (Fig 11-1 Item 15)

1 125 548 HOLDER, brush elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 005 614 HOLDER, brush 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 *126 984 BRUSH w/SPRING 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 047 885 CAP, brushholder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 047 879 BAR, retaining brushholder 2 brushes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 +142 216 STATOR, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 110 463 TUBING, corrugated plastic slit .250dia (order by ft) (Eff w/KE575508) 1ft. . . . . . . . . . . . . . . . . . . . . 8 038 502 CABLE TIE, 0-3.000 bundle (Eff w/KE575508) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

004 214 BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole (Prior to KE575508) 1. . . . . . . . . . . . . . . . . . . . . . . . 9 013 367 LABEL, warning moving parts etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 142 153 ROTOR, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 024 617 RING, retaining ext 1.272 shaft x .050thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 053 390 BEARING, ball rdl sgl row 1.370 x 2.830 x .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 551 TOOL, puller rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 127 786 KEY, stl .250 x .250 x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 142 156 SCREW, cap stl hexhd .375-16 x 1.750 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 602 213 WASHER, lock stl split .375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 010 910 WASHER, flat stl SAE .375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 141 129 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 141 042 STUD, stl .312-18 x 10.625 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 020 279 CLAMP, stl cush .750dia x .281mtg hole 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 153 301 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 163 881 FAN, rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 127 596 WASHER, flat stl .344 ID x 1.500 OD x .125thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128 341 CLAMP, hose 1.880-2.060clp dia (Prior to KD493174) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 126 582 SHROUD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1234

5

10

1112

13

1415

16

9

17

18

19

21

2223

24 SD-144 337-B

20

86

7

Figure 11-3. Generator/Shroud

*Recommended Spare Parts.+When ordering a component originally displaying a precautionary label, the label should also be ordered.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.



Dia.Mkgs.

ItemNo.

Figure 11-4. Control Box (Fig 11-1 Item 5)

1 DCZ 128 183 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CT1 105 370 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SR1-3 035 704 RECTIFIER, integ 40A 800V 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 R3,VR1 046 819 SUPPRESSOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 127 783 BRACKET, mtg rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SR4 142 502 RECTIFIER, si 3ph 200A 400PIV 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 012 571 HOLDER, fuse mintr .250 x 1.250 clip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F1 *027 419 FUSE, mintr cer 15A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 087 111 CLAMP, capacitor 1.375dia clip 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C1,2 156 289 CAPACITOR, elctlt 240uf 200VDC 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 141 035 ENCLOSURE, mtg components (Prior to KC313049) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 154 946 ENCLOSURE, mtg components (Eff w/KC313049) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 R2 142 277 RESISTOR, WW fxd 100W 250 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 129 524 TERMINAL, frict male .250 x .032 3 pair 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 T1 141 210 TRANSFORMER, control isolation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PC2 142 724 MODULE, pull to idle 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PLG3 135 556 HOUSING PLUG & SOCKETS, (Prior to KC313049) (consisting of) 1. . . . . . . . . . . . . . . .

114 066 TERMINAL, female 1skt 20-14 wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PLG3 168 071 HOUSING PLUG & PINS, (Eff w/KC313049) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . .

114 066 TERMINAL, female 1skt 20-14 wire 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 004 214 BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 RC3 116 045 HOUSING PLUG & PINS, (Prior to KC313049) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . .

113 633 TERMINAL, male 1 pin .084dia 20-14 wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 RC3 168 071 HOUSING PLUG & PINS, (Eff w/KC313049) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . .

113 633 TERMINAL, male 1 pin .084dia 20-14 wire 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CT2 126 296 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2

3

4

5

6

7

8

9

1011

1213

141516

17

1819

SC-135 073

Figure 11-4. Control Box

*Recommended Spare Parts.

PRINTED IN USA 1997 Miller Electric Mfg. Co.

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International Headquarters–USAPhone: 920-734-9821USA & Canada FAX: 920-735-4134International FAX: 920-735-4125

European Headquarter s –United KingdomPhone: 44 (0) 1625-525556FAX: 44 (0) 1625-537553