Miller BIG 30A DIESEL Owner's manual

cover 5/94 − Ref. ST-110 850-E PRINTED IN USA

 1995 MILLER Electric Mfg. Co.

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

March 1995 Form: OM-479F

Effective With Serial No. KF824571

CC/DC Welding Generator

For SMAW Welding

250 Amperes, 30 Volts DC At 60% Duty Cycle

200 Amperes, 28 Volts DC At 100% Duty Cycle

3 kVA/kW AC Auxiliary Power With Overload Protection

Optional 7.5/10 kVA/kW AC Auxiliary Power Plant

Deutz F3L1011 Air/Oil-Cooled, Diesel Engine

For Options And Accessories, See Rear Cover

Big 30A Diesel

OM-479F − 3/95

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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Fuel Consumption 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. AC Auxiliary Power 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Optional AC Power Plant Curves 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location And Moving Welding Generator 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Muffler Pipe Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connecting The Battery 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Engine Prestart Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Grounding Auxiliary Power System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting And Preparing Weld Output Cables 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting To Weld Output Terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Ether Cylinder (Optional Ether Starting Aid) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Optional Remote 14 Receptacle Or Terminal Strip 3T Information And Connections 12. . . . .

SECTION 4 − OPERATING THE WELDING GENERATOR 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING AUXILIARY EQUIPMENT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. 120 Volt Duplex Receptacles 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Optional 240 Volt Duplex Receptacle 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting Optional Auxiliary Power Plant 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Servicing Air Cleaner 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Oil And Fuel System Components 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Adjusting Engine Speed 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Replacing Battery Or Checking Battery Voltage 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Checking And Replacing Engine Belt 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Optional Ether Starting Aid Maintenance 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Optional Overspeed Shutdown Valve Adjustment 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Overload Protection 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Optional Spark Arrestor Inspection And Cleaning 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-11. Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − RUN-IN PROCEDURE 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Run-In Procedure Using Load Bank 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Run-In Procedure Using Resistance Grid 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − AUXILIARY POWER GUIDELINES 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. How Much Power Does Equipment Require? 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. How Much Power Can Generator Supply? 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Connections To Supply Standby Power 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Selecting Extension Cord 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-1. Main Assembly 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-2. Generator 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-3. Panel, Front w/Components 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Terminal Assembly, Pwr Output 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-5. Switch, Range 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-6. Control Box w/Components 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-479 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/9

3

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

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation − not related to safety.

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/Direct Current (CC/DC)

Rated Weld Output NEMA Class 1 (60/100) − 250 Amperes, 30 Volts At 60% Duty Cycle

200 Amperes, 28 Volts At 100% Duty Cycle

Amperage Range 40 − 325 A

Max. Open-Circuit Voltage 95 Volts DC

Welding Process Shielded Metal Arc Welding (SMAW)

Auxiliary Power Rating Single-Phase, 3 kVA/kW, 120 Volts AC, 26 Amperes, 60 Hz

Optional Auxiliary Power Plant Single-Phase, 7.5 kVA/kW, 120/240 Volts AC, 31 Amperes, 60 Hz

Three-Phase, 10 kVA/kW, 240 Volts AC, 24 Amperes, 60 Hz

Engine Deutz F3L1011, Air/Oil-Cooled, Three-Cylinder, Diesel Engine

Engine Speed (No Load) Weld/Power Speed: 1850 rpm; Idle Speed: 1200 rpm

Fuel Tank Capacity 11.3 gal (42.8 L)

Overall Dimensions See Figure 3-2

Weight Net: 1410 lb (640 kg); Ship: 1435 lb (650 kg)

OM-479 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-109 295-B

Figure 2-1. Volt-Ampere Curves

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.

sb1.4* 8/93 − SB-109 235-A

0

10

Minutes

60% Duty Cycle At 250 Amperes

Definition

Chart

6 Minutes Welding 4 Minutes Resting

100% Duty Cycle At 200 Amperes

Continuous Welding

Figure 2-2. Duty Cycle

OM-479 Page 3

2-3. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or pow-

er loads.

rsb2.1 10/91 − SB-126 012

Figure 2-3. Fuel Consumption Curve

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-109 365-B

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

OM-479 Page 4

2-5. Optional AC Power Plant Curves

rsb13.1 12/94 − SB-111 118-B / SA-112 449

The ac power curves show the

auxiliary power in amperes avail-

able at the single-phase 120/240

volt or three-phase 240 volt

terminals.

A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load)

B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load)

Figure 2-5. Optional AC Power Plant Curves

OM-479 Page 5

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

rsb20.2 5/94 − Ref. ST-800 477-A / Ref. ST-110 850-E

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

3 Trailer

Install unit on trailer according to

trailer manual.

Location And Airflow

OR

1

Movement

2

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Do not lift unit from end.

3

Figure 3-1. Movement And Location Of Welding Generator

OM-479 Page 6

Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.

NOTE

Inches Millimeters

A 41 1041

B 24-1/2 622

C 55-3/4 1416

D 23-1/4 591

E 24-5/8 625

F 11/16 17

G 2-7/8 73

H 4-1/2 114

J 27 686

K 41-1/4 1048

L 51-1/8 1299

M 54 1372

N 21/32 Dia. 17 Dia.

4 Holes 4 Holes

P 1/2 Dia. 13 Dia.

6 Holes 6 Holes

Ref. ST-110 850-E

B

A

C

D

E

F

G

H

J

L

M

N

P

K

Figure 3-2. Overall Dimensions And Base Mounting Hole Layout

S-0024-C

30°

Do not exceed operating angles while

running or engine damage will occur.

30°

Figure 3-3. Maximum Welding Generator Operating Angles

OM-479 Page 7

3-2. Muffler Pipe Installation

rsb19.5 5/92 − ST-154 089-A / ST-154 611

Stop engine and allow to cool.

Open and secure left side door.

1 Muffler Pipe

2 Exhaust Manifold

Install pipe over manifold so pipe

faces exactly as shown.

3 Clamp

Secure pipe with clamp.

Close door.

1/2 in

Tools Needed:

1

2

3

Top View

Do not blow exhaust toward

air cleaner or air intake.

1

Figure 3-4. Installing Muffler Pipe

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

ST-156 011-A / Ref. ST-143 195-B / S-0756

1 Engine Control Switch

Place switch in the Off position.

Open left side door.

2 Positive (+) Battery Terminal

3 Positive (+) Battery Cable

Connect positive cable first.

4 Negative (−) Battery Terminal

5 Negative (−) Battery Cable

Connect negative cable last.

Close side door.

If engine does not crank, check

battery voltage according to Sec-

tion 6-5.

Tools Needed:

1/2 in

1

4

2

+

−

5

3

Figure 3-5. Connecting The Battery

OM-479 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.

WARNING

rwarn3.1* 3/93

rsb4.2 11/92 − ST-800 159

FUEL

OIL

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.

3 Oil Dipstick

4 Oil Fill Tube

If oil is not up to full mark, add oil

(see Figure 6-2).

5 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

Valve Open

5

1

2

Figure 3-6. Checking Fluid Levels

OM-479 Page 9

3-5. Grounding Auxiliary Power System

A. Selecting Equipment

WARNING

ELECTRIC SHOCK can kill.

• Use only grounded or double insulated equipment.

ST-800 577

1 Auxiliary Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

1

OR

2

Be sure equipment

has this symbol and/

or wording.

3

Figure 3-7. Equipment Grounding Connection

B. Grounding The Generator To A Truck Or Trailer Frame

S-0854

1 Generator Base

2 Metal Vehicle Frame

3 Equipment Grounding

Terminal

4 Grounding Cable

OR

1

2

Electrically bond genera-

tor 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-479 Page 10

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

rsb5.1 9/93 − 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

sb6.1 5/94 − S-0653

1 Weld Output Cable

Determine total cable length in

weld circuit and maximum welding

amperes. Use Table 3-1 to select

proper 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, electrode hold-

er, and weld output terminals.

3 Insulated Electrode Holder

Install according to manufacturer’s

instructions.

4 Work Clamp

Install onto work cable.

Tools Needed:

10 ft (3 m)

1

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

2

4

3

2

Figure 3-10. Selecting And Preparing Weld Output Cables

OM-479 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

*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.

• Read Safety Precautions at beginning of this manual.

rwarn13.1 2/92

ST-800 162

Open left side door.

1 Bracket

Route weld cables through

bracket.

2 Positive (+) Weld Output

Terminal

3 Negative (−) Weld Output

Terminal

For Direct Current Electrode Posi-

tive (DCEP), connect work cable to

− terminal and electrode holder

cable to + terminal.

For Direct Current Electrode

Negative (DCEN), reverse cable

connections.

If equipped with optional polarity

reversing switch, connect elec-

trode holder cable to Electrode ter-

minal and work cable to Work

terminal.

Close door.

1

Tools Needed:

3/4 in

2

3

Figure 3-11. Weld Output Connections

OM-479 Page 12

3-8. Installing Ether Cylinder (Optional Ether Starting Aid)

WARNING

IMPROPER HANDLING OR EXPOSURE TO ETHER

can seriously harm your health.

• Follow manufacturer’s safety instructions on cylinder.

INJECTING ETHER WHILE ENGINE IS RUNNING

can damage engine.

• Do not use Ether Starting Aid while engine is running.

After installing cylinder, wait at least 10 minutes before use to let

ether particles settle to prevent atomizer plugging.

rsb15.1 6/92A − ST-153 382

Stop engine. Open side door(s) to

locate ether starting aid.

1 Ether Cylinder

Obtain cylinder.

2 Nozzle

Remove protective cover, and

clean nozzle and fitting area on

cylinder.

3 Clamp

4 Fitting

5 Cap

6 Valve

Remove valve cap, and clean fit-

ting area.

Insert cylinder through clamp and

onto fitting.

Tighten clamp when cylinder is

tight in fitting.

Put cap on fitting when cylinder is

removed.

1

2

3

4

6

5

Figure 3-12. Installing Ether Cylinder

3-9. Optional Remote 14 Receptacle Or Terminal Strip 3T Information And Connections

A. Remote 14 Receptacle Connections

sb7.1 5/94 − Ref. ST-110 850-E / Ref. S-0004-A / S-0750

1 Remote 14 Receptacle RC3

(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

AJ

B

K

I

C

L

NH

D

M

G

E

F

12

Figure 3-13. Remote 14 Connections

OM-479 Page 13

Table 3-2. Remote 14 Socket Information

A 24 volts ac. Protected by circuit breaker CB4.

B Contact closure to A completes 24 volts ac contactor control circuit.

I 115 volts ac. Protected by circuit breaker CB3.

J Contact closure to I completes 115 volts ac contactor control circuit.

G Circuit common for 24 and 115 volts ac circuits.

C +10 volts dc output to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

K Chassis common.

Socket Information

*The remaining sockets are not used.

Socket*

B. Terminal Strip 3T 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.

rwarn13.1* 2/92

Ref. ST-139 670-B / ST-155 758-A

Stop engine.

Remove plug from remote control

cord.

Open right side door.

1 Cover

2 Terminal Strip 3T

Remove cover.

Connect leads to 3T using terminal

information shown in Table 3-2.

Route cord out of unit along base.

Reinstall cover. Close door.

1

2

A

Tools Needed:

Right Side

Figure 3-14. Terminal Strip 3T Connections

OM-479 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

ST-800 160-A

1 Ampere Ranges Switch

2 Engine Oil Temperature

Gauge/Switch (Optional)

3 Engine Oil Pressure Gauge/

Switch (Optional)

4 Output (Contactor) Switch

(Optional)

5 Amperage/Voltage Control

Switch (Optional)

6 CC/CV Switch (Optional)

7 Amperage/Voltage Adjust-

ment Control

8 DC Voltmeter (Optional)

9 DC Ammeter (Optional)

10 Magnetic Shutdown Switch

(Optional)

11 Ether Starting Aid Switch

(Optional)

12 Polarity Reversing Or Polarity

And AC Selector Switch (Op-

tional)

13 Engine Control Switch

14 Engine Hour Meter

15 Fuel Gauge (Optional)

16 Low Oil Pressure Warning

Light

17 Battery Charging Light

1

23 45 6 7

8

9

10

17

16

15

14

13

12

11

Figure 4-1. Controls

OM-479 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

1 Low Oil Pressure Warning

Light

Light goes on if engine oil pressure

drops to 7 psi (48 kPa).

Stop engine if light comes on. Do

not run engine until trouble is fixed.

If unit is equipped with optional au-

tomatic shutdown, light goes on

and engine stops when oil temper-

ature rises to 250

°F (121°C) or oil

pressure drops to between 15 and

20 psi (103 to 138 kPa).

2 Battery Charging Light

Light is off when engine is running

and battery is being charged. Light

turns on when battery is not being

charged.

Stop engine if light comes on. Do

not run engine until trouble is fixed.

Lights are always on when engine

control switch is in Run and engine

is not running.

1

Stop engine if a light goes on.

2

Ref. ST-143 195-B

Figure 4-4. Engine Lights

OM-479 Page 16

CAUTION

ARCING can damage switch.

• Do not change Ampere Ranges switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

rwarn6.1 2/93

1 Ampere Ranges Switch

Use switch to select weld amper-

age range.

2 Amperage/Voltage Adjust-

ment Control

Use control to adjust amperage

within range selected by Ampere

Ranges switch.

The numbers are a percentage of

the range selected and not an

actual value.

Control may be adjusted while

welding.

1

2

Set Range Set Percentage

Example: Front Panel Amperage Control

In Example:

Range = 60 to 150 A DC

Percentage Of Range = 50%

Weld Output = 105 A DC (50% of 60 to 150)

Weld Output = 105 A DC

For best arc starts, use lowest

amperage range possible.

Figure 4-5. Amperage Controls

OM-479 Page 17

WARNING

INJECTING ETHER WHILE ENGINE IS RUNNING can damage engine.

• Do not use Ether Starting Aid while engine is running.

After installing cylinder, wait at least 10 minutes before use to let ether particles settle to prevent atomizer plugging.

rsb16.1* 4/92

1 Ether Starting Aid Switch

Push switch up and release while

cranking engine. Ether is sprayed

into engine manifold when switch

is released.

1

S-035 325-D

ETHER STARTING AID

CAUTION: Use only for starting engine. Inject

only while cranking the engine.

INSTRUCTIONS:

1. Start cranking engine.

2. Push switch for 1 second.

3. Release switch.

Repeat if unit does not start.

Figure 4-6. Ether Starting Aid Switch (Optional)

1 CC/CV Switch

Use switch to select type of weld

output.

Use constant current (CC) position

for SMAW.

Use constant voltage (CV) position

for wire feeding processes, GMAW

and FCAW. When using CV posi-

tion, place Ampere Ranges switch

in maximum position.

See Owner’s Manual for constant

voltage module option (OM-2801).

1

Figure 4-7. CC/CV Switch (Optional)

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