cover 5/94 − ST-133 781-A PRINTED IN USA
© 1994 MILLER Electric Mfg. Co.
CC/CV DC Welding Generator
For SMAW And GMAW Welding
350 Amperes, 40 Volts DC/CC At 100% Duty Cycle;
400 Amperes, 36 Volts DC/CV At 100% Duty Cycle
3 kVA/kW AC Auxiliary Power With Overload Protection
Teledyne-Continental TMD-27, Liquid-Cooled, Diesel Engine
Automatic Low Oil Pressure/High Coolant Temperature Shutdown
Glow Plugs For Cold Weather Starting
For Options And Accessories, See Rear Cover
Trailblazer® 55D
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
October 1994 Form: OM-456N
Effective With Serial No. KE709897
OM-456N − 10/94
EMF INFORMATION
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects 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 very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
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 as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
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 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Fuel Consumption 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. AC Auxiliary Power 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Muffler 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting The Battery 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Engine Prestart Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Generator Auxiliary Power System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Selecting And Preparing Weld Output Cables 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting To Weld Output Terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote A/V Receptacle Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Remote 14 Receptacle Or Terminal Strip Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATING THE WELDING GENERATOR 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATING AUXILIARY EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. 120 Volt Duplex Receptacles 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Optional 240 Volt Duplex Receptacle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Servicing Air Cleaner 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Fuel Filter And Sludge Drain Plug 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Adjusting Engine Speed 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Checking Battery Voltage Or Replacing Battery 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Jump-Starting Welding Generator 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Optional Remote Oil Filter 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Optional Spark Arrestor Inspection And Cleaning 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − RUN-IN PROCEDURE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Run-In Procedure Using Load Bank 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Run-In Procedure Using Resistance Grid 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − AUXILIARY POWER GUIDELINES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. How Much Power Does Equipment Require? 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. How Much Power Can Generator Supply? 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Typical Connections To Supply Standby Power 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Selecting Extension Cord 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-1. Main Assembly 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2. Generator 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-3. Panel, Front w/Components 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-4. Switch, Selector 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-5. Contact Board, Switch Selector 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-6. Switch Assembly & Rheostat 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-7. Contact Board, Switch Slope/Current 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-456 Page 1
SECTION 1 − SAFETY INFORMATION
mod1.1 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 death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation - not related to safety.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when 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/Constant Voltage (CC/CV), Direct Current (DC)
Welding Processes Shielded Metal Arc (SMAW), And Gas Metal Arc Welding (GMAW)
Auxiliary Power Rating Single-Phase, 3 kVA/kW, 120 Volts AC, 60 HZ
Engine Teledyne-Continental TMD-27 Liquid-Cooled, Diesel Engine (See Engine Manual)
Engine Speed (No Load) Weld/Power Speed: 1850 rpm; Idle Speed: 1200 rpm
Coolant System Capacity 9 qt (8.5 L)
Fuel Tank Capacity 17.5 gal (66.2 L)
Overall Dimensions See Figure 3-2
Weight Net: 1940 lb (880 kg); Ship: 1980 lb (898 kg)
CC/DC Mode CV/DC Mode
Rated Weld Output 350 Amperes, 40 Volts At 100% Duty Cycle (See
Section 2-2)
400 Amperes, 36 Volts At 100% Duty Cycle (See
Section 2-2)
Amperage Ranges MIN-70 A, 60-110 A, 90-200 A, 125-275 A,
200 A-MAX
50 to 450 A
Open-Circuit Voltage Ranges 55-90 V 18-29 V, 21-35 V, 26-42 V, 34-55 V
Max. Open-Circuit Voltage 95 V 60 V
OM-456 Page 2
2-1. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
rsb1.1 10/91 − SB-085 475-C / SB-085 455-C / SB-085 445-C / SB-086 131-C
A. For Min. Slope CV Mode
C. For Max. Slope CV Mode
B. For Med. Slope CV Mode
D. For CC Mode
Figure 2-1. Volt-Ampere Curves
OM-456 Page 3
2-2. Duty Cycle
CAUTION
WELDING 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 10
minutes that unit can weld at
rated load without overheating.
Continuous Welding
sb1.1 8/93 − ST-053 214-B / ST-053 312-B
0
10
Minutes
100% Duty Cycle At 400 AmperesDefinition
Charts
A. For CC Mode B. For CV Mode
Figure 2-2. Duty Cycle
2-3. Fuel Consumption
The fuel consumption curve shows
typical fuel use under weld or power
loads.
rsb2.1 10/91 − SB-086 206-A
Figure 2-3. Fuel Consumption Curve
OM-456 Page 4
2-4. AC Auxiliary Power
The ac power curve shows the aux-
iliary power in amperes available at
the 120 and 240 volt receptacles.
rsb3.1 2/92 − SB-005 192-B
Figure 2-4. AC Power Curve For 120 And Optional 240 Volt Receptacles
SECTION 3 − INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
WARNING
ENGINE EXHAUST GASES can kill.
• Do not breathe exhaust fumes.
• Use in open, well-ventilated areas, or vent exhaust
outside and away from building air intakes.
ENGINE EXHAUST SPARKS can cause
fire.
• Use only U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
laws.
• A spark arrestor is mandatory in all National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in other areas.
• Properly maintain the spark arrestor.
• Stop engine and allow exhaust system to cool down
before servicing spark arrestor.
• Service spark arrestor away from flammables.
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
• Keep exhaust and pipe away from flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
• 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 in
personal injury or equipment damage.
• Install unit properly on trailer (if applicable)
according to trailer manual.
rwarn1.1 3/93
OM-456 Page 5
rsb20.2 5/94 − Ref. ST-800 652 / ST-800 477 / ST-133 781-A
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
3 Cross Member Support
If using lifting forks, lift only from end
with cross member support.
4 Trailer
Install unit on trailer according to
trailer manual.
Location And Airflow
OR
OR
1
Movement
2
3
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
4
Figure 3-1. Movement And Location Of Welding Generator
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
NOTE
ST-158 403
B
A
C
Inches Millimeters
A 55-1/4 1403
B 25 635
C 74-3/4 1899
D 72 1829
E 69 1753
F 64-1/8 1629
G 57 1448
H 55 1397
J 40-1/16 1018
K 32-1/4 819
L 20-1/4 514
M 18-1/4 464
N 7-7/8 200
P2 51
Q 11/16 17
R 23 584
S 24-7/8 632
T 21/32 Dia. 17 Dia.
20 Holes 20 Holes
D
E
F
G
H
J
K
L
M
N
P
QR
S
T
Figure 3-2. Overall Dimensions And Base Mounting Hole Layout
OM-456 Page 6
Do not exceed operating angles while
running or engine damage will occur.
30°
30°
30°
30°
S-0024-C
Figure 3-3. Maximum Welding Generator Operating Angles
3-2. Installing Muffler
rsb19.1* 5/92 − ST-158 449
Stop engine and allow to cool.
Open and secure right side door.
1 Muffler
2 Exhaust Pipe
Install muffler on pipe so outlet
faces rear of unit.
3 Clamp
Secure muffler to pipe with clamp.
Close door.
Do not blow exhaust toward
air cleaner or air intake.
1/2 in
Tools Needed:
1
2
3
Figure 3-4. Installing Muffler
OM-456 Page 7
3-3. Connecting The Battery
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY 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
Ref. ST-145 221-A / Ref. ST-138 751-C / Ref. S-0756-D
1 Engine Control Switch
Place switch in the Off position.
2 Screw
3 Battery Box Door
Remove screw to open door.
4 Positive (+) Battery Terminal
5 Positive (+) Battery Cable
Connect positive cable first.
6 Negative (−) Battery Terminal
7 Negative (−) Battery Cable
Connect negative cable last.
Close battery door.
If engine will not crank, check bat-
tery voltage according to Section
6-5.
Tools Needed:
1/2 in
1
3
2
−
+
5
7
4
6
Figure 3-5. Connecting The Battery
OM-456 Page 8
3-4. Engine Prestart Checks
ENGINE FUEL can cause fire or
explosion.
• Stop engine before fueling.
• Do not fuel while smoking or near sparks or flames.
• Do not overfill tank; clean up any spilled fuel.
USE OF GASOLINE will damage engine.
• Do not use gasoline.
Lack of lubrication in gasoline damages injector pump
and injectors.
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
• Turn fuel cap slowly and wait until hissing stops
before removing cap.
HOT PRESSURIZED COOLANT AND
STEAM can cause serious personal
injury.
• Let engine cool before removing radiator cap.
• Wear proper gloves, and cover cap area with rag
when removing radiator cap.
• Turn radiator cap slowly and wait until pressure is
gone before removing cap.
INCORRECT ENGINE TEMPERATURE
can damage engine.
• Do not run engine without a properly working 180° F
(80° C) thermostat and 7 psi (48 kPa) radiator cap.
Sludge and carbon can build up in engine if run cold.
Engine can be damaged if overheated.
WARNING
rwarn15.1 8/94
rsb4.4 8/94 − Ref. ST-158 437-A
FUEL
OIL
Full
3
4
Full
1/2 in
(13 mm)
Check all fluids daily. Engine must
be cold and on a level surface.
Add fresh fuel before starting
engine the first time (see
Figure 6-2).
1 Fuel Cap
Do not run out of fuel or air enters
fuel system and causes starting
problems.
2 Fuel Valve
Open valve (On position).
3 Oil Dipstick
4 Oil Fill Tube
If oil is not up to full mark, add oil
(see Figure 6-2).
5 Radiator Cap Door
Supplied coolant is mixture of water
and ethylene glycol base anti-
freeze. Add antifreeze if using unit
in temperatures below 0° F (−18°
C).
6 Exhaust Pipe
Follow break-in procedure in
engine manual.
If unburned fuel and oil collect in
exhaust pipe during break-in, see
Section 8.
Full
1
COOLANT
5
6
S-013 466-C
OFF
FUEL ON
2
Figure 3-6. Checking Fluid Levels
OM-456 Page 9
3-5. Generator Auxiliary Power System
A. Selecting Equipment
WARNING
ELECTRIC SHOCK can kill.
• Use only grounded or double insulated equipment.
1 Auxiliary Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
OR
2
Be sure equipment has this
symbol and/or wording.
3
1
Ref. ST-133 782-A / ST-800 577
1/2 in
Tools Needed:
Figure 3-7. Proper Equipment To Use
B. Grounding The Generator To A Truck Or Trailer Frame
rsb5.1 9/93 − S-0854
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding
Terminal
4 Grounding Cable
OR
1
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
GND/PE
Use #10 AWG or
larger insulated
copper wire.
2
3 4
Figure 3-8. Grounding Methods
OM-456 Page 10
C. Grounding The Generator When Connecting To Home, Shop, Or Farm Wiring
rsb5.1 8/93 − ST-800 576
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Water Meter
4 Metal Water Pipe
5 Driven Ground Rod
Ground generator to system earth
ground if supplying power to a
premises (home, shop, farm) wiring
system − see Section 9.
2
4 or 5
OR
GND/PE
1 2
4
Use metal water pipe or driven ground rod or
other means as stated in electrical codes.
5
3
Figure 3-9. Grounding When Supplying Building Systems
3-6. Selecting And Preparing Weld Output Cables
sb6.5* 5/94 − S-0752
1 Weld Output Cable
Determine total cable length in weld
circuit and maximum welding am-
peres. Use Table 3-1 to select prop-
er cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, wire feeder or
electrode holder, and weld output
terminals.
3 Wire Feeder
4 Insulated Electrode Holder
Install according to manufacturer’s
instructions.
5 Work Clamp
Install onto work cable.
10 ft (3 m)
1
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)
For Example,
2
5
2
Tools Needed:
3 4
OR
Figure 3-10. Selecting And Preparing Weld Output Cables
OM-456 Page 11
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)
Welding
Amperes
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
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
*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
3-7. Connecting To Weld Output Terminals
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Do not touch live electrical parts.
• Stop engine before making any weld output connections.
• Do not use both Positive (+) output terminals at the same time.
• Both Positive (+) output terminals are electrically hot (energized) whenever the engine is running.
• Read Safety Precautions at beginning of this manual.
rwarn13.1* 2/92
Ref. ST-133 782-A
Open lower access door.
1 Weld Output Label
2 Negative (−) Weld Output Ter-
minal
3 Positive (+) GMAW Weld Out-
put Terminal
Provides CV (constant voltage)
output for GMAW welding.
4 Positive (+) SMAW Weld Out-
put Terminal
Provides CC (constant current)
output for SMAW welding.
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
− terminal and electrode holder or
wire feeder cable to proper +
terminal.
For Direct Current Electrode Nega-
tive (DCEN), reverse cable
connections.
Close access door.
Tools Needed:
3/4, 3/8 in
−
+
GMAW SMAW
POSITIVENEGATIVE
S-000 595-C
1
2
4
3
Use ONLY two weld output
terminals at a time.
Figure 3-11. Weld Output Connections
OM-456 Page 12
3-8. Remote A/V Receptacle Connections
Ref. ST-145 221-A
1 Remote A/V Receptacle RC3
2 Keyway
To connect remote amperage or
voltage control to this receptacle,
align keyway, insert plug, and turn
plug clockwise.
1
2
Figure 3-12. Remote A/V Receptacle Connections
3-9. Remote 14 Receptacle Or Terminal Strip Connections
A. Remote 14 Receptacle Connections
sb7.1 5/94 − ST-800 954 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B
1 Remote 14 Receptacle RC4
(See Table 3-2)
2 Keyway
3 Plug
4 Threaded Collar
To connect to receptacle, align
keyway, insert plug, and tighten
threaded collar.
3
4
OR
AJ
B
K
I
C
L
NH
D
M
G
E
F
1
2
3/8 in
Tools Needed:
Figure 3-13. Remote 14 Connections
Table 3-2. Remote 14 Socket Information
A 24 volts ac. Protected by circuit breaker CB3.
B Contact closure to A completes 24 volts ac contactor control circuit.
I 115 volts ac. Protected by circuit breaker CB4.
J Contact closure to I completes 115 volts ac contactor control circuit.
G Circuit common for 24 and 115 volts ac circuits.
K Chassis common.
Socket Information
*The remaining sockets are not used.
Socket*
OM-456 Page 13
B. Terminal Strip 1T Connections
WARNING
ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.
• Do not touch live electrical parts.
• Stop engine before making any internal inspection or connections.
• Do not connect to Remote 14 receptacle and terminal strip at the same time.
Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.
Ref. ST-133 781-A / ST-136 872-A
Stop engine.
Remove plug from remote control
cord.
1 Right Front Panel
2 Terminal Strip Label
Remove panel.
3 Strain Relief
4 Terminal Strip 1T
Route cord through strain relief.
Connect leads to 1T using informa-
tion on label.
Install side panel, and close access
door.
Tools Needed:
3/8 in
A
B
G
I
J
K
24VAC 10A MAX
Circuit Common
115VAC 10A MAX
Equipment Ground
115VAC Contactor Control
Power SupplyExternal Device
1T
S-136 798
24VAC Contactor Control
24VAC
115VAC
W
CR
CR
1
2
34
Rear Of
Front Panel
Figure 3-14. Terminal Strip 1T Connections
OM-456 Page 14
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) and
manufacturer’s instructions for material used.
ENGINE EXHAUST GASES can kill.
• Do not breathe exhaust fumes.
• Use in open, well-ventilated areas, or vent exhaust
outside 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 going
near any welding operations.
See Safety Precautions at beginning of manual for ba-
sic welding safety information.
WARNING
rwarn5.1 10/91
Ref. ST-133 782-A
1 Open-Circuit Voltage Switch
2 Amperage Range Switch
3 Amperage/Voltage Adjustment
Control
4 Slope Switch
5 Magnetic Shutdown Switch
6 Engine Control Switch
7 Amperage/Voltage Control
Switch
8 Output (Contactor) Control
Switch
9 Engine Hour Meter
10 Ammeter
11 Voltmeter
12 Tachometer (Optional)
13 Engine Oil Pressure Gauge
(Optional)
14 Engine Temperature Gauge
(Optional)
15 Battery Light
16 Engine Temperature And Oil
Pressure Light
12 3
4
5
6
7
89101112
13
14
15
16
Figure 4-1. Controls
OM-456 Page 15
Wear the following while welding:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
123
Figure 4-2. Safety Equipment
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93
Tools Needed:
1
Figure 4-3. Work Clamp
CAUTION
ARCING can damage switch.
• Do not change Slope switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail.
rwarn6.1* 2/93
1 Slope Switch
For GMAW, use switch to select
short-circuit current. The Min.
Slope position provides higher
short-circuit current than the Max.
Slope position (see Section 2-1).
For SMAW, place switch in SMAW
position.
1
Ref. ST-145 221-A
Figure 4-4. Slope Switch
OM-456 Page 16
CAUTION
ARCING can damage switch.
• Do not change Amperage Range switch or Open-Circuit Voltage switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail.
rwarn6.1* 2/93
1 Open-Circuit Voltage Switch
For GMAW, use switch to select
open-circuit voltage range. For
SMAW, place switch in SMAW po-
sition.
2 Amperage Range Switch
Use switch to select SMAW weld
amperage range.
3 Amperage/Voltage Adjustment
Control
Use control to adjust amperage/
voltage within range selected by
Open-Circuit Voltage switch or Am-
perage Range switch. Numbers
around control are for reference
only.
1
2
3
Set Amperage Range And Open-Circuit Voltage Set Percentage
In Example:
Range = 90 to 200 A DC
Percentage Of Range = 50%
Weld Output = 145 A DC (50% of 90 to 200 A)
Weld Output = 145 A DCSet Slope
Example: Front Panel Amperage Control For SMAW
Figure 4-5. Amperage/Voltage Controls
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