cover 8/92 − ST-134 686-B 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
August 1992 Form: OM-481A
Effective With Serial No. KC227524
CC/CV, DC Multiprocess 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-481A - 8/92
TABLE OF CONTENTS
SECTION 1 − SAFETY SIGNAL WORDS 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 Curves 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. Engine Prestart Checks 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. 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 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Maintenance Lights 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Oil And Fuel System Components 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Servicing Air Cleaner 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Adjusting Engine Speed 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Checking Battery Voltage Or Replacing Battery 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Overload Protection 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Checking And Replacing Engine Belt 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Optional Ether Starting Aid Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − RUN-IN PROCEDURE
8-1. Run-In Procedure Using Load Bank 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Run-In Procedure Using Resistance Grid 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − AUXILIARY POWER GUIDELINES
9-1. How Much Power Does Equipment Require? 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. How Much Power Can Generator Supply? 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Typical Connections To Supply Standby Power 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Selecting Extension Cord 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST
Figure 10-1. Main Assembly 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2. Panel, Front w/Components 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-3. Panel, Front Lower w/Components 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-4. Control Box 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-5. Generator 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-481 Page 1
SECTION 1 − SAFETY SIGNAL WORDS
mod1.1 9/91
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions.
WARNING
WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.
CAUTION
CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.
IMPORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2 − SPECIFICATIONS
Table 2-1. Welding Generator
Specification Description
Type Of Output Direct Current/Constant Current (DC/CC) Or Direct Current/Constant Voltage (DC/CV)
Rated Weld Output 600 Amperes, 44 Volts DC At 100% Duty Cycle (See Section 2-2)
Amperage Range 45-800A
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
Optional Auxiliary Power Plant Three-Phase, 5 kVA/kW, 240 Volts AC, 12 Amperes, 60 Hz
Engine Deutz F4L912 Air-Cooled, Diesel Engine
Engine Speed (No Load) Weld/Power Speed: 1850 rpm
Fuel Tank Capacity 19 U.S. Gal. (72L)
Overall Dimensions See Figure 3-2
Weight Net: 2250 lbs. (1021 kg); Ship: 2380 lbs. (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
EXCEEDING DUTY CYCLE RATINGS will damage unit.
• Do not exceed indicated duty cycles.
warn7.1 2/92
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 100% duty cycle
allowing continuous operation at
rated load.
sb1.1 2/92 − SB-134 397-A
Figure 2-2. Duty Cycle Chart
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 Curves
The ac power curves show the auxil-
iary power in amperes available at
the 120 and optional 240 volt recep-
tacles.
rsb3.1* 10/91 - 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 12/91
ST-156 470-A
1 18 in. (457 mm) Open Space
On All Sides For Good Airflow
2 Lifting Eye
Use lifting eye to move unit.
3 Exhaust Pipe
Install according to Section 3-2
4 Lifting Forks
If using lifting forks, be sure forks
are at least 42 in. (1097 mm) long.
Front
Left
To p
Right
Rear
Lift only from engine end.
1
3
2
4
Figure 3-1. Location And Movement Of Welding Generator
OM-481 Page 5
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 16.7
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°
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.
Close door.
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
Generator neutral connected to
frame. Connect equipment ground-
ing terminal to proper earth ground.
Meet National Electrical Code and
all other code requirements.
2 Remote 14 Receptacle
(Section 3-8)
3 Positive (+) Weld Output
Terminals (Section 3-7)
4 Negative (−) Weld Output Ter-
minals
5 Bar
Route all cables under bar.
Close door.
Tools Needed:
3/8 in., 1/2 in.
1
2
34 5
Figure 3-6. Lower Front Panel
OM-481 Page 7
3-5. 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* 9/91
rsb4.2* 4/92 − Ref. ST-156 467
1 Fuel Cap
Add fresh fuel before starting
engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
fuel level on a cold engine before
use each day.
Do not run out of fuel or air enters
fuel system and causes starting
problems.
2 Oil Dipstick
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see
Figure 6-2).
3 Oil Fill Cap
Engine stops if oil pressure gets too
low or oil temperature gets too high
(see Figure 4-9).
Follow run-in procedure in engine
manual.
If unburned fuel and oil collect in ex-
haust pipe during run-in, see Sec-
tion 8.
Close door.
1
2
3
Figure 3-7. Checking Oil And Fuel
S-0007-B
OM-481 Page 8
3-6. Selecting And Preparing Weld Output Cables
sb6.1 12/91 − S-0653
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 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 3-8. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
100 ft. (30 m) Or Less
150 ft.
(45 m)
200 ft.
(60 m)
250 ft.
(70 m)
300 ft.
(90 m)
350 ft.
(105 m)
400 ft.
(120 m)
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 not more than 300 circular mils per ampere. Use weld cable with
insulation rating equal to or greater than the open-circuit voltage of the unit.
OM-481 Page 9
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
Ref. ST-134 687-A / ST-145 043
1 POSITIVE (+) Weld Output
Terminals
2 NEGATIVE (−) Weld Output
Terminals
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 in., 7/8 in.
12
Figure 3-9. Weld Output Connections
3-8. Remote 14 Receptacle Or Terminal Strip Connections
A. Remote 14 Receptacle
sb7.1* 4/92 − Ref. ST-145 043 / Ref. S-0004-A / S-0628
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, B Contact closure completes the 24 volts ac contactor con-
trol circuit. Protected by circuit breaker CB4.
I, J Contact closure completes the 115 volts ac contactor con-
trol circuit. Protected by circuit breaker CB3.
G Circuit common for 24/115 volts ac circuit.
Remote Amperage/Voltage Control
C Command reference; +10 volts dc.
D Control circuit common.
E Input command signal (potentiometer wiper or 0-10 volts
dc source); 0 to +10 volts dc.
K Chassis common.
The remaining sockets are not used.
Tools Needed:
3/8 in.
Figure 3-10. 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 re-
lief.
2 Terminal Strip 3T
3 Label
Connect leads to 3T using terminal
information shown in Figure 3-10.
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 3-11. Terminal Strip 3T Connections
OM-481 Page 11
3-9. 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 3-12. 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 Start Switch (Optional)
5 Service Engine Air Cleaner
Light (Section 6-4)
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 Ampere Gauge
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
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
sb4.1 5/92
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 9/91
1 Ampere Ranges Switch
Use switch to select range of weld
output.
1
Figure 4-5. Ampere Ranges Switch
OM-481 Page 14
1 Amperage And Voltage Ad-
justment Control
Use control to adjust amperage or
voltage within range selected by
AMPERE RANGES switch (see
Figure 4-5).
The numbers are a percentage of
the range selected and not an ac-
tual value.
Control may be adjusted while
welding.
1
Figure 4-6. Amperage And Voltage Adjustment Control
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
3-8).
2 Amperage/Voltage Control
Switch
Use switch to select way of control-
ling amperage and voltage adjust-
ment.
For front panel control, place switch
in PANEL position.
For remote control, place switch in
REMOTE position (see Section
3-8).
Weld output terminals are energized when OUTPUT
(CONTACTOR) switch is ON and engine is running.
1
2
Figure 4-7. Remote Controls
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 posi-
tion 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 equipped with optional overspeed
shutdown kit, engine stops auto-
matically when speed exceeds nor-
mal 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 Ampere Gauge
Use gauge to check amperage out-
put to the battery. The gauge reads
near 0 (zero) when the engine is
running. If gauge is at a negative
number, the battery is discharging.
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 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 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 Regulator/Flowmeter
4 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off.
Close valve on cylinder when fin-
ished welding.
sb5.1* 6/92 − S-0621-C
1
23
4
Figure 4-11. Shielding Gas
Install &
Connect
Equipment
Select
Electrode
Put On
Personal Safety
Equipment
Set Controls Start Engine
Turn On
Auxiliary
Equipment
Insert
Electrode
Into Holder
Begin Welding
rsb8.1 4/92
Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Put On
Personal Safety
Equipment
Set Controls
Turn On
Shielding Gas Start Engine
Turn On
Auxiliary
Equipment
Turn On
Wire Feeder
rsb7.1 4/92
Begin Welding
Figure 4-13. Sequence Of Gas Metal Arc Welding (GMAW)
OM-481 Page 17
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Put On
Personal Safety
Equipment
Set Controls
Turn On
Wire Feeder
Turn On
Auxiliary
Equipment
Start Engine
Begin
Welding
Figure 4-14. Sequence Of Flux Cored Arc Welding (FCAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Install & Prepare
Flux System
Put On
Personal Safety
Equipment
Turn On Feeder
Start EngineSet Controls
Turn On
Flux System Begin Welding
Figure 4-15. Sequence of Submerged Arc Welding (SAW)
Install &
Connect
Equipment
Connect
Compressed Air
Supply
Select
Carbon
Electrode
Put On
Personal Safety
Equipment
Set Controls
Start Engine
Turn On
Auxiliary
Equipment
Begin
Cutting Or
Gouging
Insert Electrode
Into Torch
Turn
On Air
Supply
Figure 4-16. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A)
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