Miller Big Blue 600D Owner's manual

cover 7/93* − ST-134 686-C PRINTED IN USA

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

January 1994 Form: OM-481B

Effective With Serial No. KD536837

CC/CV, DC Welding Generator

For SMAW, GMAW, FCAW, SAW Welding And CAC-A

600 Amps, 44 VDC At 100% Duty Cycle

Deutz F4L912 Air-Cooled, Diesel Engine

3kVA/kW AC Auxiliary Power With Overload Protection

Automatic Shutdown For Low Oil Pressure, High Oil Temperature, Or

Cooling System Failure

Big Blue® 600D

OM-481B − 1/94

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

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

3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing Exhaust Pipe And Rain Cap 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connecting The Battery 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Lower Front Panel 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Grounding The Generator Auxiliary Power System 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Engine Prestart Checks 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Selecting And Preparing Weld Output Cables 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting To Weld Output Terminals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-10. Installing Optional Ether Cylinder 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATING THE WELDING GENERATOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING AUXILIARY EQUIPMENT

5-1. 120 Volt Duplex Receptacles 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Optional 240 Volt Duplex Receptacle 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Maintenance Lights 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Oil And Fuel System Components 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Servicing Air Cleaner 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Adjusting Engine Speed 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Checking Battery Voltage Or Replacing Battery 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Overload Protection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Checking And Replacing Alternator Belt 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Optional Ether Starting Aid Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Optional Spark Arrestor Inspection And Cleaning 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-11. Optional Overspeed Shutdown Valve Adjustment 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-12. Troubleshooting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − RUN-IN PROCEDURE

8-1. Run-In Procedure Using Load Bank 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Run-In Procedure Using Resistance Grid 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − AUXILIARY POWER GUIDELINES

9-1. How Much Power Does Equipment Require? 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. How Much Power Can Generator Supply? 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Connections To Supply Standby Power 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Selecting Extension Cord 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST

Figure 10-1. Main Assembly 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-2. Panel, Front w/Components 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-3. Panel, Front Lower w/Components 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Control Box 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-5. Generator 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-481 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)

Rated Weld Output 600 Amperes, 44 Volts DC At 100% Duty Cycle (See Section 2-2)

Amperage Range 45-800 A

Max. Open-Circuit Voltage 95 Volts DC

Welding Process Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), And Submerged Arc

Welding (SAW); Air Carbon Arc Cutting and Gouging (CAC-A)

Auxiliary Power Rating Single-Phase, 3 kVA/kW, 120/240 Volts AC, 26 Amperes, 60 Hz

Engine Deutz F4L912 Air-Cooled, Diesel Engine

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

Fuel Tank Capacity 19 gal (72 L)

Overall Dimensions See Figure 3-2

Weight Net: 2250 lb (1021 kg); Ship: 2380 lb (1080 kg)

Options See Rear Cover

OM-481 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-133 004 / SB-133 003

A. For Constant Current (CC) Mode B. For Constant Voltage (CV) Mode

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.

Continuous Welding

sb1.1 8/93 − SB-134 397-A

0

10

Minutes

100% Duty Cycle At 600 Amperes

Definition

Chart

Figure 2-2. Duty Cycle

OM-481 Page 3

2-3. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or power

loads.

rsb2.1 10/91 − SB-133 838

Figure 2-3. Fuel Consumption Curve

2-4. AC Auxiliary Power

The ac power curve shows the auxil-

iary power in amperes available at

the 120 and optional 240 volt

receptacles.

rsb3.1* 2/92 − SB-109 365-B

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

OM-481 Page 4

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* 11/93 − ST-800 477 / ST-134 686-C

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 (engine

end).

Location

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)

Figure 3-1. Movement And Location Of Welding Generator

OM-481 Page 5

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

NOTE

ST-156 466

B

A

C

Inches Millimeters

A 58 1473

B 32 813

C 68 1727

D 68 1727

E 62-3/8 1584

F 50-1/2 1283

G 46-1/2 1181

H 36 914

J 28-3/16 716

K 13-3/4 349

L 9-3/4 248

M 6-1/8 156

N 29-7/8 759

P 32 813

Q 1-1/16 27

R 21/32 Dia. 16.7 Dia.

16 Holes 16 Holes

D

E

F

G

H

J

K

L

M

N

P

Q

R

Engine End

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

1 Trailer Hitch

Install unit onto trailer according to

trailer manual.

S-0024-B

1

20°

15°

Engine

End

17.5°

Figure 3-3. Maximum Welding Generator Tilt Angles

3-2. Installing Exhaust Pipe And Rain Cap

rsb19.4* 5/92 − ST-154 087

Stop engine and allow to cool.

1 Exhaust Pipe

2 Muffler Pipe

Install exhaust pipe over muffler

pipe. Secure exhaust pipe to top

cover using supplied hardware.

3 Rain Cap

Install so cap opens toward front of

unit.

1/2 in

Tools Needed:

1

2

3

Do not blow exhaust toward

air cleaner or air intake.

Figure 3-4. Installing Exhaust Pipe And Rain Cap

OM-481 Page 6

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-153 654-A / Ref. ST-131 784-A / Ref. S-0756

1 Engine Control Switch

Place switch in the Off position.

Remove rear left side panel.

2 Positive (+) Battery Terminal

3 Positive (+) Battery Cable

Connect positive cable first.

4 Negative (−) Battery Terminal

5 Negative (−) Battery Cable

Connect negative cable last.

Reinstall side panel.

If engine does not crank, check bat-

tery voltage according to Section

6-6.

Tools Needed:

1/2 in

1

4

2

+

−

3

5

Figure 3-5. Connecting The Battery

3-4. Lower Front Panel

Ref. ST-134 687-A

Open lower front door.

1 Equipment Grounding

Terminal (Section 3-5)

2 Remote 14 Receptacle

(Section 3-9)

3 Positive (+) Weld Output

Terminals (Section 3-8)

4 Negative (−) Weld Output Ter-

minals

Close door.

Tools Needed:

3/8, 1/2 in

1

2

34

Route all cables under bar.

Figure 3-6. Lower Front Panel

OM-481 Page 7

3-5. Grounding The Generator Auxiliary Power System

GND/PE

rsb5.1 8/93 − Ref. ST-134 687-A / S-027 657-D

1 Equipment Grounding

Terminal

1

Tools Needed:

1/2 in

Connect To Earth Ground

If Required By National

Or Local Codes

The generator auxiliary power neutral

is connected to the machine frame.

Figure 3-7. Equipment Grounding Connection

3-6. Engine Prestart Checks

WARNING

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.

• Rotate fuel cap slowly and wait until hissing stops

before removing cap.

rwarn3.1* 3/93

rsb4.2 11/92 − ST-156 467-B

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 Oil Dipstick

3 Oil Fill Tube

If oil is not up to full mark, add oil

(see Figure 6-2).

Engine stops if oil pressure is too

low or oil temperature is too high

(see Figure 4-9).

4 Exhaust Pipe

Follow break-in procedure in

engine manual.

If unburned fuel and oil collect in

exhaust pipe during break-in, see

Section 8.

Close door

1

FUEL

OIL

2

3

Full

1/2 in

(13 mm) Full

4

Figure 3-8. Checking Oil And Fuel

OM-481 Page 8

3-7. Selecting And Preparing Weld Output Cables

sb6.5* 11/92 − 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

5 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

5

3

2

4

OR

Figure 3-9. 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)

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

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0

1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

*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. Ref. S-0007-C

OM-481 Page 9

3-8. 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

Ref. ST-134 687-A / ST-145 043

1 Positive (+) Weld Output

Terminals

2 Negative (−) Weld Output Ter-

minals

For Direct Current Electrode Posi-

tive (DCEP), connect work cable to

− terminal and electrode holder

cable to + terminal.

For Direct Current Electrode Nega-

tive (DCEN), reverse cable con-

nections.

To prevent overheating and dam-

age, two terminals are provided for

each polarity in case more than one

cable is needed to carry current to

a single arc (see Table 3-1). This

unit is not designed to supply multi-

ple arcs.

Tools Needed:

3/8, 7/8 in

12

Figure 3-10. Weld Output Connections

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

A. Remote 14 Receptacle

sb7.1 3/93 − Ref. ST-145 043 / Ref. S-0004-A / S-0750

1 Remote 14 Receptacle RC3

2 Keyway

3 Plug

4 Threaded Collar

To connect to this receptacle, align

keyway, insert plug, and tighten

threaded collar.

AJ

B

K

I

C

L

NH

D

M

G

E

F

1 2

34

Socket Information:

Remote Contactor

A 24 volts ac. Protected by circuit breaker CB4.

B Contact closure to pin A completes 24 volts ac contactor control

circuit.

I 115 volts ac. Protected by circuit breaker CB3.

J Contact closure to pin I completes 115 volts ac contactor control

circuit.

G Circuit common for 24 and 115 volts ac circuits.

Remote Amperage/Voltage Control

C Command reference; +10 volts dc.

D Control circuit common.

E Input command signal (potentiometer wiper or 0 to +10 volts dc).

K Chassis common.

The remaining sockets are not used.

3/8 in

Tools Needed:

Figure 3-11. Remote 14 Connections

OM-481 Page 10

B. Terminal Strip 3T

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.

ST-134 839-A

Stop engine.

Remove plug from remote control

cord.

Open right side door.

1 Strain Relief

Route cord leads through strain

relief.

2 Terminal Strip 3T

3 Label

Connect leads to 3T using terminal

information shown in Figure 3-11.

Secure cord in strain relief.

Close door.

15A

0-10VDC

0-1 k

Circuit Common

Equipment

S-138 042

24VAC

A

B

C

D

E

G

I

K

J

Contactor

Output

Ground

Feeder

115VAC

Contactor

24VAC 10A Feeder Power

3T

Power

115VAC

Remote

A/V

Ω

2

Tools Needed:

1

3

Figure 3-12. Terminal Strip 3T Connections

OM-481 Page 11

3-10. Installing Optional Ether Cylinder

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 fitting

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

Tools Needed:

Figure 3-13. Installing Ether Cylinder

OM-481 Page 12

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-134 687-A

1 DC Voltmeter

2 DC Ammeter

3 Amperage And Voltage Ad-

justment Control

4 Ether Starting Aid Switch (Op-

tional)

5 Service Engine Air Cleaner

Light (Section 6-2)

6 Amperage/Voltage Control

Switch

7 CC/CV Switch

8 Output (Contactor) Switch

9 Check Cooling System/Alter-

nator Light (Section 6-2)

10 Engine Control Switch

11 Engine Hour Meter

12 Fuel Gauge

13 Battery Ammeter

14 Oil Pressure Gauge/Switch

15 Oil Temperature Gauge/

Switch

16 Ampere Ranges Switch

12 3 45678

9

10

11

12

16 15 14 13

Figure 4-1. Controls

1 Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet

Wear dry insulating gloves, safety

glasses with side shields, and a

welding helmet with a correct shade

of filter (see ANSI Z49.1).

sb3.1 10/91

123

Figure 4-2. Safety Equipment

OM-481 Page 13

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

Ref. ST-131 784-A

1 CC/CV Switch

Use switch to select type of weld

output.

Use constant current (CC) position

for SMAW and CAC-A.

Use constant voltage (CV) position

for wire feeding processes, GMAW,

SAW, and FCAW. When using CV

position, place Ampere Ranges

switch in CV position (see

Figure 4-5).

1

Figure 4-4. CC/CV Switch

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 output

range.

2 Amperage And Voltage Ad-

justment 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 ac-

tual value.

Control may be adjusted while

welding.

1

2

Example Of Front Panel Amperage Control

Set Range Set Percentage Weld Output = 90 A DC

In Example:

Range = 55 to 125 A DC

Percentage Of Range = 50%

Weld Output = 90 A DC (50% of 55 to 125)

Figure 4-5. Amperage Controls

OM-481 Page 14

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Do not touch weld output terminals when engine is running.

• Do not touch electrode and work clamp at the same time.

rwarn7.1 9/91

1 Output (Contactor) Switch

Use switch to select way of control-

ling unit output.

For front panel control, place switch

in On position.

For remote control, place switch in

Remote position (see Section 3-9).

Weld output terminals are energized when Output

(Contactor) switch is On and engine is running.

1

Figure 4-6. Remote Controls

1 Amperage/Voltage Control

Switch

Use switch to select way of control-

ling amperage and voltage

adjustment.

For front panel control, place switch

in Panel position.

For remote control, place switch in

Remote position.

2 Remote Foot Control

3 Remote Amperage Control

See example below.

1

Example Of Combination Remote Amperage Control

Set Switches

Adjust Remote Control

Set Percentage

Min = 55 A DC/CC

Percentage Of Range = 50%

Max = 90 A DC/CC (50% of 55 to 125)

In Example:

3

S-0774 / S-0769

Set Range

Min (55 A DC/CC)

Max (90 A DC/CC)

2

Figure 4-7. Amperage/Voltage Control Switch

OM-481 Page 15

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 Engine Control Switch

Use switch to start and stop engine.

To start, turn switch to Start position

and release as soon as engine

starts. Do not engage starter while

flywheel is rotating.

In Run position, engine runs at weld

speed all the time.

To stop engine, turn switch to Off

position.

If unit has optional overspeed shut-

down kit, engine stops automatical-

ly when speed exceeds normal

rpm.

2 Ether Starting Aid Switch

Push switch up and release while

cranking engine. Ether is sprayed

into engine manifold when switch is

released.

12

Figure 4-8. Engine Control Switch And Optional Ether Starting Aid Switch

1 Engine Hour Meter

Use meter to check total operating

hours (see Section 6-1).

2 Fuel Gauge

Use gauge to check fuel level in fuel

tank.

3 Battery Ammeter

Use ammeter to check amperage

output to the battery. The ammeter

reads near 0 (zero) when the en-

gine is running. If ammeter is at a

negative number, the battery is dis-

charging. Stop engine, and do not

run until problem is fixed.

4 Oil Pressure Gauge/Shut-

down Switch

Use gauge/switch to check oil pres-

sure. Normal operating pressure is

about 50 psi (345 kPa). If oil pres-

sure drops to 30 psi (207 kPa),

switch closes and engine stops.

5 Oil Temperature Gauge/Shut-

down Switch

Use gauge/switch to check oil tem-

perature. Normal operating temper-

ature is about 225°F (107° C). If oil

temperature rises to 250°F (121°

C), switch closes and engine stops.

rsb6.1* 2/92

12

345

Figure 4-9. Engine Hour Meter And Gauges

OM-481 Page 16

1 DC Voltmeter

Voltmeter displays voltage at the

weld output terminals, but not nec-

essarily the welding arc due to

cable resistance, poor connec-

tions, etc.

2 DC Ammeter

Ammeter displays amperage out-

put of unit.

1

2

Figure 4-10. Voltmeter And Ammeter

WARNING

BUILDUP OF SHIELDING GAS can harm health or kill.

• Shut off shielding gas supply when not in use.

warn1.1 9/91

1 Shielding Gas Cylinder

2 Valve

3 Gun Trigger

4 Foot Control

Open valve on cylinder just before

welding.

Gun trigger or foot control turns

weld output and gas flow on and off.

Close valve on cylinder when fin-

ished welding.

sb5.2 2/92 − S-0621-C

2

1

3

4

OR

Figure 4-11. Shielding Gas

Insert

Electrode

Into Holder

rsb8.1 9/92

Install &

Connect

Equipment

Select

Electrode

Put On

Personal Safety

Equipment

Set Controls Start Engine

Turn On Auxiliary

Equipment

Begin Welding

Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)

Turn On Auxiliary

Equipment

rsb7.1 9/92

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Put On

Personal Safety

Equipment

Set Controls

Turn On

Shielding Gas Start Engine

Turn On

Wire Feeder Begin Welding

Figure 4-13. Sequence Of Gas Metal Arc Welding (GMAW)

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