Miller AIR PAK Owner's manual

cover 5/94 − ST-121 575-B 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

May 1995 Form: OM-478J

Effective With Serial No. KF824571

CC/CV AC/DC Welding Generator

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

400 Amperes, 36 Volts DC At 100% Duty Cycle

10 Or 15 kVA/kW AC Auxiliary Power Plant With Overload Protection

3 kVA/kW AC Auxiliary Power With Overload Protection

Deutz F4L912, Air-Cooled, Diesel Engine

Battery Charge/Jump Start Option Available

For Options And Accessories, See Rear Cover

Miller Air Pak

miller_war1 6/95

MILLER’S TRUE BLUE LIMITED WARRANTY

Effective January 1, 1995

(Equipment with a serial number preface of “KD” or newer)

This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions below, MILLER Electric

Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new

MILLER equipment sold after the effective date of this limited warranty is free of de-

fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-

RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-

NESS.

Within the warranty periods listed below, MILLER will repair or replace any war-

ranted parts or components that fail due to such defects in material or workmanship.

MILLER must be notified in writing within thirty (30) days of such defect or failure, at

which time MILLER will provide instructions on the warranty claim procedures to be

followed.

MILLER shall honor warranty claims on warranted equipment listed below in the

event of such a failure within the warranty time periods. All warranty time periods

start on the date that the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American distributor or eighteen

months after the equipment is sent to an International distributor.

1. 5 Years Parts − 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Robots

3. 2 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

* Air Compressors

4. 1 Year — Parts and Labor

* Motor Driven Guns

* Process Controllers

* IHPS Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Spot Welders

* Load Banks

* SDX Transformers

* Running Gear/Trailers

* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

* Tecumseh Engines

* Deutz Engines (outside North America)

* Field Options

(NOTE: Field options are covered under True Blue

for the remaining

warranty period of the product they are installed in, or for a minimum of

one year — whichever is greater.)

5. 6 Months — Batteries

6. 90 Days — Parts and Labor

* MIG Guns/TIG Torches

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts

MILLER’S True Blue Limited Warranty shall not apply to:

1. Items furnished by MILLER, but manufactured by others, such as engines or

trade accessories. These items are covered by the manufacturer’s warranty, if

any.

2. Consumable components; such as contact tips, cutting nozzles, contactors

and relays or parts that fail due to normal wear.

3. Equipment that has been modified by any party other than MILLER, or equip-

ment that has been improperly installed, improperly operated or misused

based upon industry standards, or equipment which has not had reasonable

and necessary maintenance, or equipment which has been used for operation

outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-

CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies

shall be, at MILLER’S option: (1) repair; or (2) replacement; or, where authorized in

writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-

ment at an authorized MILLER service station; or (4) payment of or credit for the pur-

chase price (less reasonable depreciation based upon actual use) upon return of the

goods at customer’s risk and expense. MILLER’S option of repair or replacement

will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized ser-

vice facility as determined by MILLER. Therefore no compensation or reimburse-

ment for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN

ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE

LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL

DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-

TRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-

RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL

THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-

CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty

lasts, or the exclusion of incidental, indirect, special or consequential damages, so

the above limitation or exclusion may not apply to you. This warranty provides spe-

cific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties

or remedies other than as stated herein, and to the extent that they may not be

waived, the limitations and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may be available, but may

vary from province to province.

WHO DO I CONTACT?

For help,

H contact your distributor

For additional information, such as

Technical Manuals (Service And Parts)

Engine Manuals

Circuit And Wiring Diagrams

Process Handbooks

User’s Guides

Distributor Directories

H contact your distributor

To file a claim for loss or damage during

shipment,

H contact the delivering carrier

For assistance in filing or settling claims,

H contact your distributor and/or equipment

manufacturer’s Transportation

Department

Miller Electric Mfg. Co.

H CALL:

414-735-4505

H FAX:

800-637-2348 (in USA), or

414-735-4136 (outside USA)

H WRITE:

Miller Electric Mfg. Co.

P.O. Box 1079

Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

OM-478J − 5/95

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. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-3. Volt-Ampere Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. AC Auxiliary Power Curves 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Air Compressor Output Curve 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3-2. Installing Precleaners, Exhaust Pipe, And Rain Cap 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-4. Engine Prestart Checks 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Grounding The Generator Auxiliary Power System And Lower Panel Components 8. . . . . .

3-6. Selecting And Preparing Weld Output Cables 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting To Weld Output Terminals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Remote 14 Receptacle Or Terminal Strip Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Air Compressor Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Installing Ether Cylinder (Optional Ether Starting Aid) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION 5 − OPERATING AUXILIARY EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Auxiliary Power Receptacles And Circuit Breakers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Connecting To Auxiliary Power Plant 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING OPTIONAL BATTERY CHARGER 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Maintenance Lights And Air Tank Drain Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Oil And Fuel System Components 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Servicing Air Cleaner 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Adjusting Engine Speed 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Adjusting Air Pressure 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Overload Protection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Replacing Battery Or Checking Battery Voltage 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Checking And Replacing Engine Belt 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Optional Spark Arrestor Inspection And Cleaning 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − RUN-IN PROCEDURE 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Run-In Procedure Using Load Bank 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Run-In Procedure Using Resistance Grid 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − AIR COMPRESSOR TABLES 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − AUXILIARY POWER GUIDELINES 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. How Much Power Does Equipment Require? 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. How Much Power Can Generator Supply? 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Typical Connections To Supply Standby Power 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-4. Selecting Extension Cord 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − TUNGSTEN ELECTRODE 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Selecting Tungsten Electrode 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-2. Preparing Tungsten 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-1A. Main Assembly (Part 1) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-1B. Main Assembly (Part 2 of 2) 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-2. Panel, Front w/Components 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-3. Panel, Front Lower w/Components 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-4. Control Box 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-5. Compressor, Air 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 13-6. Generator 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-478 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

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each

symbol shown.

7 NOTE

Special instructions for best

operation − 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 CC/CV AC/DC Multiprocess Welding Generator

Rated Weld Output 400 Amperes, 36 Volts DC At 100% Duty Cycle (See Section 2-1)

Amperage Range 45-500 A DC; 40-300 A AC

Max. Open-Circuit Voltage 95 Volts DC; 80 Volts AC

Welding Processes Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), And Gas Tungsten

Arc Welding (GTAW); Air Carbon Arc Cutting And Gouging (CAC-A)

Engine Deutz F4L912 Air-Cooled, Diesel Engine (See Engine Manual)

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

Fuel Tank Capacity 19 gal (72 L)

Auxiliary Power Plant Single-Phase 10 kVA/kW, 120/240 Volts AC, 42 Amperes, 60 Hz Or Three-Phase 15 kVA/kW, 240

Volts AC, 36 Amperes, 60 Hz

Maximum Auxiliary Power From

Receptacles

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

Overall Dimensions See Figure 3-2

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

OM-478 Page 2

Table 2-2. Air Compressor

Specification Description

Pressure Output 40 scfm (1.1 scmm), 90 psig (620 kPa), 100% Duty Cycle

Air Tank Capacity 21 gal (79 L)

Tank Pressure Rating 150 psig (1034 kPa)

Safety Relief Valve Rating 130 psig (896 kPa)

Air Control Valve Setting Loads At 90 psig (620 kPa); Unloads At 115 psig (793 kPa)

2-1. 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-121 571-A

0

10

Minutes

100% Duty Cycle At 400 Amperes

Definition

Chart

Figure 2-1. Duty Cycle

2-2. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or power

loads.

rsb2.1 10/91 − SB-121 494

Figure 2-2. Fuel Consumption Curve

OM-478 Page 3

2-3. 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-121 492 / SB-121 493 / SB-121 491

A. For AC Mode

B. For Constant Current (CC) DC Mode

C. For Constant Voltage (CV) DC Mode

Figure 2-3. Volt-Ampere Curves

OM-478 Page 4

2-4. AC Auxiliary Power Curves

The ac power curve shows the auxil-

iary power in amperes available at

the 120 and optional 240 volt recep-

tacles, and the single-phase

120/240 volt or three-phase 240

volts terminals.

rsb3.1* 2/92 / rsb13.1 3/92 − SB-109 365-B / SB-121 506 / SB-121 505

A. AC Power Curve For Receptacles

B. 10 KVA/KW Single-Phase Auxiliary Power

Plant (No Weld Load)

C. 15 KVA/KW Three-Phase Auxiliary Pow-

er Plant (No Weld Load)

Figure 2-4. AC Power Curves

2-5. Air Compressor Output Curve

SB-121 490

The air output curve shows the vol-

ume and pressure of air available

from the air compressor.

Figure 2-5. Air Compressor Output Curve

OM-478 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-800 652 / Ref. ST-800 477-A / ST-121 575-B

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

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. Location And Movement Of Welding Generator

OM-478 Page 6

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

NOTE

G

ST-153 650

B

A

C

Inches Millimeters

A 58 1473

B 32 813

C 68 1727

D 1-1/16 27

E 29-7/8 759

F 6-1/8 156

G 9-3/4 248

H 13-3/4 349

J 28-3/16 716

K 36 914

L 46-1/2 1181

M 50-1/2 1283

N 62-3/8 1584

P 21/32 Dia 16.7 Dia

16 Holes 16 Holes

D

E

F

H

J

K

L

M

N

P

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

Ref. S-0024-B

17.5°

20°

15°

Engine

End

Do not exceed operating

angles while running or en-

gine damage will occur.

Figure 3-3. Maximum Welding Generator Operating Angles

3-2. Installing Precleaners, Exhaust Pipe, And Rain Cap

Stop engine and allow to cool.

Remove rear, left side panel.

1 Air Cleaner

2 Precleaner

Remove tape from air cleaner

openings. Install precleaners onto

air cleaners.

3 Exhaust Pipe

4 Muffler Extension

Remove tape from extension. In-

stall exhaust pipe over extension.

Secure exhaust pipe to top cover

using supplied hardware.

5 Rain Cap

Install cap so it opens toward front

of unit.

Reinstall side panel or go to Section

3-3.

rsb19.4* 5/92 − ST-153 652

Do not blow exhaust toward

air cleaner or air intake.

1

2

3

5

4

Tools Needed:

1/2 in

Figure 3-4. Installing Precleaners, Exhaust Pipe, And Rain Cap

OM-478 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

ST-153 654-B / Ref. ST-118 111-C / Ref. S-0756-B

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 will not crank, check

battery voltage according to

Section 7-8.

Tools Needed:

1/2 in

1

4

−

+

3

5

2

Figure 3-5. Connecting The Battery

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.

• Rotate fuel cap slowly and wait until hissing stops

before removing cap.

WARNING

rwarn3.1* 3/93

rsb4.2* 11/92 − Ref. ST-153 653

Check all fluids daily. Engine must

be cold and on a level surface.

Add fresh fuel before starting

engine the first time (see

Figure 7-2).

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 7-2).

Follow break-in procedure in

engine manual.

If unburned fuel and oil collect in ex-

haust pipe during break-in, see

Section 9.

Tools Needed:

3/8 in

OIL

2

Full

FUEL

Full

1/2 in

(13 mm)

1

3

Figure 3-6. Checking Fuel And Oil

OM-478 Page 8

3-5. Grounding The Generator Auxiliary Power System And Lower Panel Components

3/8, 1/2 in

rsb5.1* 8/93 − Ref. ST-121 578-C

Open lower front door.

1 Jump Start/Battery Charge

Receptacle (Optional)

(Section 6)

2 Remote Terminal Strip

(Section 3-8)

3 Remote 14 Receptacle

(Section 3-8)

4 Equipment Grounding

Terminal

5 Electrode Weld Output

Terminal (Section 3-7)

6 Work Weld Output Terminal

(Section 3-7)

7 Bar

Route all cables under bar.

8 Air Compressor Fitting

(Section 3-9)

Close door.

Tools Needed:

12

3

56

7

8

Connect To Earth Ground

If Required By National

Or Local Codes

The generator auxiliary power neutral

is connected to the machine frame.

4

Figure 3-7. Equipment Grounding Connection And Lower Panel Components

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

5 GTAW Torch

Install according to manufacturer’s

instructions.

6 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

6

3

2

54

OR OR

Figure 3-8. Selecting And Preparing Weld Output Cables

OM-478 Page 9

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

*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.

• Do not touch live electrical parts.

• Stop engine before making any weld output connections.

• Do not let torch cable adapter hit screwheads, access door, case, or any parts.

• Install adapter as shown in Figure 3-9.

rwarn9.1* 3/94

1

2

1 Work Weld Output Terminal

2 Electrode Weld Output Terminal

3 Torch Cable Adapter

Adapter connects power and water to

torch and cooling system or drain.

4 Access Door

Connect cables as shown.

Close and secure access door.

Tools Needed:

3/8, 3/4 in

SMAW Connections GTAW Connections

Work

OR

Use only a proper torch cable

adapter positioned so it does

not hit frame, hardware, or

door during operation.

sb9.1 12/94 − Ref. ST-121 578-C / Ref. ST-150 972-A / ST-800 578

Location of Terminals

Gas Or

Water Hose

1

2

3

1

2

4

Figure 3-9. Weld Output Connections

OM-478 Page 10

3-8. Remote 14 Receptacle Or Terminal Strip Connections

A. Remote 14 Receptacle Connections

sb7.1 5/94 − Ref. ST-800 729 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B

1 Remote 14 Receptacle RC3

(See Table 3-2)

Remove cover from receptacle.

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

Figure 3-10. Remote 14 Connections

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*

OM-478 Page 11

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.

Ref. ST-150 972-A

Stop engine.

Remove plug from remote control

cord.

1 Terminal Strip 3T

Remove clear plate from 3T.

Connect leads to 3T using terminal

information shown in Table 3-2.

Reinstall clear plate. Close door.

Tools Needed:

3/8 in

1

Figure 3-11. Terminal Strip 3T Connections

3-9. Air Compressor Connections

ST-800 727

Air compressor operates whenever

engine is running.

1 1/2 in NPT Air Compressor

Fitting

Obtain and connect quick-

disconnect and air hose to fitting.

2 Air Shutoff Valve

Be sure valve is in open position

when using air compressor.

Open Position Closed Position

2

1

Figure 3-12. Air Compressor Connections

OM-478 Page 12

3-10. 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 Valve 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

Figure 3-13. Installing Ether Cylinder

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

OM-478 Page 13

1 Voltmeter

2 Ammeter

3 Amperage And Voltage

Adjustment Control

4 Ether Starting Aid Switch

(Optional)

5 Battery Check Light (Optional)

6 Battery Voltage Selector Switch

(Optional)

7 Amperage & Voltage Control

Switch

8 CC/CV Switch

9 Output (Contactor) Switch

10 Battery Charge/Jump Start

Switch (Optional)

11 Service Engine Air Cleaner

Light (Section 7-2)

12 Engine Control Switch

13 Check Cooling System/

Alternator Light (Section 7-2)

14 Service Compressor Air

Cleaner Light (Section 7-2)

15 Fuel Gauge

16 Air Pressure Gauge

17 Battery Ampere Gauge

18 Air Tank Moisture Drain Control

(Section 7-2)

19 Oil Pressure Gauge/Switch

20 Oil Temperature Gauge/Switch

21 Engine Hour Meter

22 Output Selector Switch

23 Ampere Ranges Switch

Ref. ST-121 578-C

12 3 456789

10

11

12

13

14

15

16

17

18

23 22 21 20 19

Figure 4-1. Controls

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

OM-478 Page 14

1 CC/CV Switch

Use switch to select type of weld

output.

Use constant current (CC) position

for SMAW, GTAW, and CAC-A.

Use constant voltage (CV) position

for GMAW and FCAW process.

When using CV position, place Am-

pere Ranges switch in CV position

(see Figure 4-6).

Ref. ST-118 111-C

1

Figure 4-4. CC/CV Switch

WARNING

WARNING: ELECTRIC SHOCK can kill.

• Do not use AC output in damp areas, if movement is

confined, or if there is a danger of falling.

• Use AC output ONLY if required for the welding

process.

• If AC output is required, use remote output control.

• Read Safety Precautions at beginning of this

manual.

ARCING can damage switch.

• Do not change Output Selector switch position while

welding.

Arcing inside switch can damage contacts, causing

switch to fail.

warn6.3 4/92 / rwarn6.1* 2/93

1 Output Selector Switch

Use switch to select polarity of weld

output.

For Direct Current Electrode

Negative (DCEN), use Electrode

Negative position.

For Direct Current Electrode

Positive (DCEP), use Electrode

Positive position.

For alternating current (AC), use

AC position.

1

Figure 4-5. Output Selector Switch

OM-478 Page 15

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 range of weld

output.

If Output Selector switch is in

Electrode Negative or Electrode

Positive position, set switch

according to DC scale.

If Output Selector switch is in the

AC position, set switch according to

AC scale.

1

For best arc starts, use

lowest amperage range

possible.

Figure 4-6. Ampere Ranges Switch

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

controlling unit output.

For weld output, place switch in On

position.

For remote output control, place

switch in Remote position (see

Section 3-8).

Weld output terminals are

energized when switch is

On and engine is running.

1

Figure 4-7. Output (Contactor) Control Switch

OM-478 Page 16

1 Amperage And Voltage

Adjustment Control

Use control to adjust amperage or

voltage within range selected by

Ampere Ranges switch (see

Figure 4-6). Numbers around

control are for reference only.

1

Example Of Front Panel Amperage And Voltage Control

Set Range Set Percentage Weld Output = 82.5 A DC

In Example:

Range = 55 to 110 A DC

Percentage Of Range = 50%

Weld Output = 82.5 A DC

(50% of 55 to 110)

Figure 4-8. Amperage And Voltage Adjustment Control

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