blue star 180k service t436
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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
TM-436 Page 3Blue Star 180K
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
TM-436 Page 4 Blue Star 180K
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
TM-436 Page 5Blue Star 180K
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
TM-436 Page 6 Blue Star 180K
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
TM-436 Page 7Blue Star 180K
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
TM-436 Page 8 Blue Star 180K
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
TM-436 Page 9Blue Star 180K
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
TM-436 Page 10 Blue Star 180K
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
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
6 Engine On-Off Switch
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
TM-436 Page 11Blue Star 180K
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.
2 Engine On-Off Switch
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
TM-436 Page 12 Blue Star 180K
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,
and rotors.• Keep all doors, panels, covers, and guards closed
and securely in place.
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
TM-436 Page 13Blue Star 180K
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
Use GFCI-protected extension cords.
Figure 5-2. Optional 240 Volt Duplex Receptacle And Circuit Breakers
TM-436 Page 14 Blue Star 180K
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
Use GFCI-protected extension cords.
Figure 5-3. Optional Twistlock Receptacle And Circuit Breakers
TM-436 Page 15Blue Star 180K
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
TM-436 Page 16 Blue Star 180K
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
TM-436 Page 17Blue Star 180K
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
TM-436 Page 18 Blue Star 180K
SECTION 7 – TROUBLESHOOTING
7-1. Troubleshooting Tables
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before inspecting, maintaining, orservicing.
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.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
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
TM-436 Page 19Blue Star 180K
Trouble Remedy Section
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
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 resistance and connections of amperage control R1. R1 is10 kilohms ±10%. Replace R1 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 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
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
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
Check engine speed, and adjust if necessary. 9-5
Check slip rings, and install new brushes if necessary. 7-6
Tune engine and check governor according to engine manual. – –
Check main rectifier SR4, and replace if necessary. 7-2
Check integrated rectifiers SR2 and SR3, and replace if neces-sary.
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 stabilizer DC-Z for signs of failure. Check all connectionsand continuity of winding. Replace DC-Z if necessary.
7-2
TM-436 Page 20 Blue Star 180K
Table 7-2. Auxiliary Power Trouble
Trouble Remedy Section
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
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
Low power output. Check engine speed, and adjust if necessary. 9-5
Check receptacles RC1 and RC2 wiring and connections. 7-2
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
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
High power output. Check engine speed, and adjust if necessary. 9-5
Erratic power output. Check fuel level. 3-3
Check engine speed, and adjust if necessary. 9-5
Check receptacles RC1 and RC2 wiring and connections. 7-2
Check slip rings, and install new brushes if necessary. 7-6
TM-436 Page 21Blue Star 180K
Table 7-3. Engine Trouble
Trouble Remedy Section
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.
Check engine speed, and adjust if necessary. 9-5
Check current transformer CT1 for signs of winding failure. Checkcontinuity across windings and check for proper connections. Re-place CT1 if necessary.
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 engine speed, and adjust if necessary. 9-5
Check idle solenoid TS1 paddle, and readjust if necessary. 9-5
TM-436 Page 22 Blue Star 180K
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
TM-436 Page 23Blue Star 180K
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
a) Tolerance – ±10% unless specified
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
a) Tolerance – ±5% unless specified
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
TM-436 Page 24 Blue Star 180K
7-3. Waveforms For Section 7-2
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• 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)
Test Equipment Needed:
gnd gnd
Figure 7-2. Waveforms For Section 7-2
TM-436 Page 25Blue Star 180K
7-4. Troubleshooting Field Current Regulator Board PC1
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before making or changing meter leadconnections and before disconnecting orconnecting any leads.
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.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
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. smwarn2.3 3/93
Test Equipment Needed:
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)
TM-436 Page 26 Blue Star 180K
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
TM-436 Page 27Blue Star 180K
7-5. Troubleshooting Idle Module PC2
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before making or changing meter leadconnections and before disconnecting orconnecting any leads.
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.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
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. smwarn2.3 3/93
Test Equipment Needed:
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)
TM-436 Page 28 Blue Star 180K
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
TM-436 Page 29Blue Star 180K
7-6. Replacing Brushes And Cleaning Slip Rings
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before inspecting, maintaining, orservicing.
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.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
and rotors.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
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
TM-436 Page 30 Blue Star 180K
7-7. Checking Unit Output After Servicing
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before inspecting, maintaining, orservicing.
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.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
and rotors.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
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
Test Equipment Needed:
1
2
3
45
Figure 7-7. Checking Unit Output
Blue Star 180K TM-436 Page 31
SECTION 8 – DISASSEMBLY AND REASSEMBLY
WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.
• Stop engine before repairing unit.
• Allow cooling period before servicing.
MOVING PARTS can cause injury.• Keep away from moving parts such as fans, belts,
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
TM-436 Page 32 Blue Star 180K
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
TM-436 Page 33Blue Star 180K
SECTION 9 – MAINTENANCE
WARNINGELECTRIC 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.
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.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
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.
HOT PARTS can cause severe burns.• Allow cooling period before servicing.
• Wear protective gloves and clothing when workingon a hot engine.
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
TM-436 Page 34 Blue Star 180K
°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
TM-436 Page 35Blue Star 180K
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
TM-436 Page 36 Blue Star 180K
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
READ SAFETY BLOCKS at start ofSection 9 before proceeding.WARNING
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
TM-436 Page 37Blue Star 180K
9-5. Adjusting Engine Speed
READ SAFETY BLOCKS at start ofSection 9 before proceeding.WARNING
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
TM-436 Page 38 Blue Star 180K
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:
1 Engine On-Off Switch
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
TM-436 Page 39Blue Star 180K
9-7. Servicing Optional Spark Arrestor
READ SAFETY BLOCKS at start ofSection 9 before proceeding.WARNING
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
TM-436 Page 40 Blue Star 180K
NOTES
TM-436 Page 41Blue Star 180K
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
TM-436 Page 42 Blue Star 180K
SC-141 329-B
Figure 10-1. Circuit Diagram For Blue Star 180K Effective With Serial No. KB012373 Thru KB110694
TM-436 Page 43Blue Star 180K
SC-169 843
Figure 10-2. Circuit Diagram For Blue Star 180K Effective With Serial No. KE696137 And Following
TM-436 Page 44 Blue Star 180K
Figure 10-3. Wiring Diagram For Blue Star 180K Effective With Serial No. KE696137 And Following
TM-436 Page 45Blue Star 180K
Coat terminals with dielectric grade, nonconductive,electric grease (MILLER Part No. 146 557) or equivalent. SD-169 844-A
TM-436 Page 46 Blue Star 180K
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
TM-436 Page 47Blue Star 180K
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
TM-436 Page 49Blue Star 180K
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-434 Page 50 Blue Star 180K
Figure 11-1. Main Assembly (Continued)
Description QuantityPartNo.
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
TM-436 Page 51Blue Star 180K
Description QuantityPartNo.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-434 Page 52 Blue Star 180K
Description QuantityPartNo.
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.
TM-436 Page 53Blue Star 180K
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.
TM-434 Page 54 Blue Star 180K
Description QuantityPartNo.
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
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