Miller KF846342 Owner's manual

cover 5/94 − ST-130 895-E PRINTED IN USA

CC/DC Welding Generator

For SMAW Welding

250 Amperes, 40 Volts DC At 100% Duty Cycle

3 kVA/kW AC Auxiliary Power With Overload Protection

Optional 7.5/10 kVA/kW AC Auxiliary Power Plant

Deutz F3L-1011, Air/Oil-Cooled, Diesel Engine

Optional Low Oil Pressure/High Oil Temperature Shutdown System

For Options And Accessories, See Rear Cover

Read and follow these instructions and all

safety blocks carefully.

Have only trained and qualified persons

install, operate, or service this unit.

Call your distributor if you do not understand

the directions.

Give this manual to the operator.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

March 1995 Form: OM-480F

Effective With Serial No. KF846342

Big Blue™ 251D

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 Elec-

tric 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 workman-

ship. MILLER must be notified in writing within thirty (30) days of such defect or fail-

ure, at which time MILLER will provide instructions on the warranty claim proce-

dures 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 opera-

tion 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

purchase 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 replace-

ment will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER autho-

rized service facility as determined by MILLER. Therefore no compensation or re-

imbursement 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

WARRANTY, 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-480F − 3/95

EMF INFORMATION

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields −

Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large

volume of scientific findings based on experiments at the cellular

level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Volt-Ampere Curves 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

SECTION 3 − INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-2. Muffler Pipe Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3-5. Generator Auxiliary Power System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting And Preparing Weld Output Cables 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting To Weld Output Terminals 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Ether Cylinder (Optional Ether Starting Aid) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Optional Remote A/V Receptacle Information And Connections 11. . . . . . . . . . . . . . . . . . . . . .

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

SECTION 5 − OPERATING AUXILIARY EQUIPMENT 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. 120 Volt Duplex And Optional GFCI Receptacles 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-3. Connecting Optional Auxiliary Power Plant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Servicing Air Cleaner 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Oil And Fuel System Components 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Adjusting Engine Speed 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Replacing Battery Or Checking Battery Voltage 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Jump-Starting Welding Generator 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING (Continued)

6-7. Checking And Replacing Engine Belt 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Optional Ether Starting Aid Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Optional Overspeed Shutdown Valve Adjustment 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Overload Protection 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-11. Optional Spark Arrestor Inspection And Cleaning 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-12. Troubleshooting 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAM 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − RUN-IN PROCEDURE 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Run-In Procedure Using Load Bank 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Run-In Procedure Using Resistance Grid 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − AUXILIARY POWER GUIDELINES 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. How Much Power Does Equipment Require? 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. How Much Power Can Generator Supply? 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Connections To Supply Standby Power 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Selecting Extension Cord 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Figure 10-3. Switch, Range 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Terminal Assembly, Pwr Output 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-5. Generator 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-480 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/Direct Current (CC/DC)

Rated Weld Output NEMA Class I (100) − 250 Amperes, 40 Volts At 100% Duty Cycle (See Section 2-2)

Amperage Range 40-400 A

Max. Open-Circuit Voltage 95 Volts DC

Welding Process Shielded Metal Arc Welding (SMAW)

Engine Deutz F3L-1011, Air/Oil-Cooled, Three-Cylinder, Diesel Engine

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

Fuel Tank Capacity 11.3 gal (42.8 L)

Maximum Auxiliary Power From

Receptacles

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

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

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

Overall Dimensions See Figure 3-2

Weight Net: 1475 lb (670 kg); Ship: 1510 lb (685 kg)

OM-480 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-070 042-B

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION

WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.

• Do not weld at rated load longer than shown below.

warn7.1 8/93

Duty Cycle is percentage of 10

minutes that unit can weld at

rated load without overheating.

Continuous Welding

sb1.1 8/93 − SB-070 999-A

0

10

Minutes

100% Duty Cycle At 250 Amperes

Definition

Chart

Figure 2-2. Duty Cycle

OM-480 Page 3

2-3. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or power

loads.

rsb2.1 10/91 − SB-137 487

Figure 2-3. Fuel Consumption Curve

2-4. AC Auxiliary Power

The ac power curve shows the

auxiliary power in amperes available

at the 120 and 240 volt receptacles.

rsb3.1 2/92 − SB-109 365-B

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

OM-480 Page 4

2-5. Optional AC Power Plant Curves

rsb13.1 12/94 − SB-134 636 / SB-134 637

The ac power curves show the aux-

iliary power in amperes available at

the single-phase 120/240 volt or

three-phase 240 volt terminals.

A. 7.5 KVA/KW Single-Phase Auxiliary Power

Plant (No Weld Load)

B. 10 KVA/KW Three-Phase Auxiliary Power

Plant (No Weld Load)

Figure 2-5. AC Power Plant Curves

SECTION 3 − INSTALLATION

3-1. Selecting A Location And Moving Welding Generator

WARNING

ENGINE EXHAUST GASES can kill.

• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaust

outside and away from building air intakes.

ENGINE EXHAUST SPARKS can cause

fire.

• Use only U.S. Forestry Department approved spark

arrestor and comply with all local, state, and federal

laws.

• A spark arrestor is mandatory in all National Forests

and in grass, brush, or forest covered lands in

California, Oregon, and Washington. Check with

state and local authorities in other areas.

• Properly maintain the spark arrestor.

• Stop engine and allow exhaust system to cool down

before servicing spark arrestor.

• Service spark arrestor away from flammables.

HOT ENGINE EXHAUST AND EXHAUST

PIPE can cause fires.

• Keep exhaust and pipe away from flammables.

FALLING EQUIPMENT can cause

serious personal injury and equipment

damage.

• Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other heavy options,

accessories, or devices.

• Use equipment of adequate capacity to lift the unit.

TILTING OF TRAILER can result in

personal injury or equipment damage.

• Install unit properly on trailer (if applicable)

according to trailer manual.

rwarn1.1 3/93

OM-480 Page 5

Location And Airflow

OR

1

Movement

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

2

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

3 Trailer

Install unit on trailer according to

trailer manual.

Do not lift unit from end.

3

rsb20.2 5/94 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-130 895-D

Figure 3-1. Movement And Location Of Welding Generator

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

NOTE

Ref. ST-110 850-D

B

A

C

Inches Millimeters

A 36-1/2 927

B 24-5/8 625

C 55-1/2 1410

D 23-1/4 591

E 24-5/8 625

F 11/16 17

G 2-7/8 73

H 4-1/2 114

J 27 686

K 41-1/4 1048

L 51-1/8 1299

M 54 1372

N 21/32 Dia. 16.7 Dia.

4 Holes 4 Holes

P 1/2 Dia. 12.7 Dia.

6 Holes 6 Holes

D

E

F

G

H

J

L

M

N

P

K

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

OM-480 Page 6

S-0024-C

30°

Do not exceed operating angles while

running or engine damage will occur.

30

°

30°

Figure 3-3. Maximum Welding Generator Operating Angles

3-2. Muffler Pipe Installation

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

Stop engine and allow to cool.

Open and secure left side door.

1 Muffler Pipe

2 Exhaust Manifold

Install pipe over manifold so pipe

faces exactly as shown.

3 Clamp

Secure pipe with clamp.

Close door.

1/2 in

Tools Needed:

1

2

3

Top View

Do not blow exhaust toward

air cleaner or air intake.

1

Figure 3-4. Installing Muffler Pipe

3-3. Connecting The Battery

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

• Stop engine before disconnecting or connecting battery cables.

• Always wear a face shield and proper protective clothing when working on a battery.

• Do not allow tools to cause sparks when working on a battery.

rwarn2.1 9/91

ST-156 011-A / Ref. ST-142 560-A / S-0756

1 Engine Control Switch

Place switch in the Off position.

Open left side door.

2 Positive (+) Battery Terminal

3 Positive (+) Battery Cable

Connect positive cable first.

4 Negative (−) Battery Terminal

5 Negative (−) Battery Cable

Connect negative cable last.

Close side door.

If engine does not crank, check bat-

tery voltage according to Section

6-5.

Tools Needed:

1/2 in

1

4

2

+

−

5

3

Figure 3-5. Connecting The Battery

OM-480 Page 7

3-4. Engine Prestart Checks

ENGINE FUEL can cause fire or

explosion.

• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

USE OF GASOLINE will damage engine.

• Do not use gasoline.

Lack of lubrication in gasoline damages injector pump

and injectors.

REMOVE FUEL CAP SLOWLY; FUEL

SPRAY may cause injury; FUEL may be

under pressure.

• Turn fuel cap slowly and wait until hissing stops

before removing cap.

WARNING

rwarn3.1* 3/93

rsb4.2* 11/92 − ST-130 894-A / Ref. ST-155 966

FUEL

OIL

3

4

Full

1/2 in

(13 mm)

Check all fluids daily. Engine must

be cold and on a level surface.

Add fresh fuel before starting

engine the first time (see Figure

6-2).

1 Fuel Cap

Do not run out of fuel or air enters

fuel system and causes starting

problems.

2 Fuel Valve

Open valve.

3 Oil Dipstick

4 Oil Fill Tube

If oil is not up to full mark, add oil

(see Figure 6-2).

5 Muffler Pipe

Follow break-in procedure in

engine manual.

If unburned fuel and oil collect in

muffler pipe during break-in, see

Section 8.

Full

1

Valve Open

2

5

Figure 3-6. Checking Fluid Levels

OM-480 Page 8

3-5. Generator Auxiliary Power System

A. Selecting Equipment

WARNING

ELECTRIC SHOCK can kill.

• Use only grounded or double insulated equipment.

Ref. ST-156 024-B / ST-800 577

1 Auxiliary Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

1

OR

2

Be sure equipment has this

symbol and/or wording.

3

Figure 3-7. Equipment Grounding Connection

B. Grounding The Generator To A Truck Or Trailer Frame

S-0854

1 Generator Base

2 Metal Vehicle Frame

3 Equipment Grounding

Terminal

4 Grounding Cable

OR

1

2

Electrically bond generator

frame to vehicle frame by

metal-to-metal contact.

GND/PE

Use #10 AWG or

larger insulated

copper wire.

2

3 4

Figure 3-8. Grounding Methods

OM-480 Page 9

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

rsb5.1 8/93 − ST-800 576

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Water Meter

4 Metal Water Pipe

5 Driven Ground Rod

Ground generator to system earth

ground if supplying power to a

premises (home, shop, farm) wiring

system − see Section 9.

2 4 or 5

OR

GND/PE

1 2

4

Use metal water pipe or driven ground rod or

other means as stated in electrical codes.

5

3

Figure 3-9. Grounding When Supplying Building Systems

3-6. Selecting And Preparing Weld Output Cables

sb6.1 5/94 − 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, 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 3-10. Selecting And Preparing Weld Output Cables

OM-480 Page 10

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D

3-7. Connecting To Weld Output Terminals

WARNING

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Do not touch live electrical parts.

• Stop engine before making any weld output connections.

• Read Safety Precautions at beginning of this manual.

rwarn13.1 2/92

ST-800 162-A

Open left side door.

1 Bracket

Route weld cables through bracket.

2 Positive (+) Weld Output

Terminal

3 Negative (−) Weld Output Ter-

minal

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

connections.

If equipped with optional Polarity

switch, connect electrode holder

cable to Electrode (−) terminal and

work cable to Work (+) terminal.

Close door.

Tools Needed:

3/4 in

1

2

3

Weld output terminals are energized

whenever engine is running.

Figure 3-11. Weld Output Connections

OM-480 Page 11

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

WARNING

IMPROPER HANDLING OR EXPOSURE TO ETHER

can seriously harm your health.

• Follow manufacturer’s safety instructions on cylinder.

INJECTING ETHER WHILE ENGINE IS RUNNING

can damage engine.

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

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

particles settle to prevent atomizer plugging.

rsb15.1 6/92A − ST-153 382

Stop engine. Open side door(s) to

locate ether starting aid.

1 Ether Cylinder

Obtain cylinder.

2 Nozzle

Remove protective cover, and

clean nozzle and fitting area on

cylinder.

3 Clamp

4 Fitting

5 Cap

6 Valve

Remove valve cap, and clean 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 3-12. Installing Ether Cylinder

3-9. Optional Remote A/V Receptacle Information And Connections

Ref. ST-142 560-A

1 Remote A/ Receptacle RC3

2 Keyway

To connect to this receptacle, align

keyway, insert plug, and turn plug

clockwise.

1

2

Figure 3-13. Remote A/V Receptacle Connections

OM-480 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

ST-156 024-B / Ref. ST-800 162-A

1 Ampere Ranges Switch

2 Oil Temperature Gauge/

Switch (Optional)

3 Oil Pressure Gauge/Switch

(Optional)

4 Remote A/V Control Switch

(Optional)

5 DC Voltmeter (Optional)

6 Amperage/Voltage Adjustment

Control

7 DC Ammeter (Optional)

8 Polarity Switch (Optional)

9 Magnetic Shutdown Switch

(Optional)

10 Engine Control Switch

11 Ether Starting Aid Switch (Op-

tional)

12 Engine Hour Meter

13 Oil Pressure Warning Light

14 Battery Charging Light

12345

6

7

14

13

12

11

10

8

9

Figure 4-1. Controls

OM-480 Page 13

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet With Correct

Shade Of Filter (See ANSI

Z49.1)

sb3.1 1/94

123

Figure 4-2. Safety Equipment

1 Work Clamp

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

sb4.1 2/93

Tools Needed:

1

Figure 4-3. Work Clamp

CAUTION

ARCING can damage switch.

• Do not change Ampere Ranges switch position while welding.

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

rwarn6.1 2/93

Ref. ST-142 560-A

1 Ampere Ranges Switch

Use switch to select weld amper-

age range.

1

For best arc starts, use lowest

amperage range possible.

Figure 4-4. Ampere Ranges Switch

OM-480 Page 14

1 Amperage/Voltage Adjustment

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

Set Switch Weld Output = 158 A DCSet Range Set Percentage

Example Of Front Panel Amperage Control

(See Figure 4-6)

In Example:

Range = 90 to 225 A DC

Percentage Of Range = 50%

Weld Output = 158 A DC

(50% of 90 to 225)

Figure 4-5. Amperage/Voltage Adjustment Control

OM-480 Page 15

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

S-0774

1 Remote A/V Control Switch

Use switch to select way of control-

ling amperage and voltage.

For front panel control, place switch

in Panel position.

For remote control, place switch in

Remote position (see Section 3-9).

2 Remote Amperage Control

1

Min (90 A DC)

Max (158 A DC)

2

Set Switch Adjust Remote ControlSet Range Set Percentage

Example Of Combination Remote Amperage Control

Min = 90 A DC

Percentage Of Range = 50%

Max = 158 A DC (50% of 90 to 225)

In Example:

Figure 4-6. Remote A/V Control Switch (Optional)

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 − Ref. ST-142 560-A

1 Ether Starting Aid Switch

Push switch up and release while

cranking engine. Ether is sprayed

into engine manifold when switch is

released.

1

Figure 4-7. Ether Starting Aid Switch (Optional)

OM-480 Page 16

1 Engine Control Switch

Use switch to start engine, select

engine speed, and stop engine.

2 Magnetic Shutdown Switch

(Optional)

Use switch during start-up to by-

pass engine shutdown system.

Shutdown system stops engine if

oil pressure drops to between 15

and 20 psi (103 to 138 kPa) or oil

temperature rises to 250°F

(121°C).

To Start: turn engine control switch

to Start position while pressing

shutdown switch. Release both

switches when engine starts and

Oil Pressure light goes off. Do not

crank engine while flywheel is

turning.

In Run position, engine runs at

weld/power speed all the time.

In Run/Idle position (Optional), en-

gine runs at idle speed with no weld

or power load applied, and weld

speed with a load applied.

To Stop: turn switch to Off position.

3 Manual Shutoff Lever

Move lever counterclockwise to

stop engine if engine control switch

does not work.

3

Ref. ST-155 966 / Ref. ST-143 195-B

1 2

Nameplate Shown With

Automatic Idle Option

Figure 4-8. Engine Controls

1 Engine Hour Meter

Use meter to check total operating

hours (see Section 6-1). This meter

operates only when engine is

running.

1

rsb6.1 2/92

Figure 4-9. Engine Hour Meter

1 Oil Pressure Warning Light

Light goes on if engine oil pressure

drops to 7 psi (48 kPa). Stop engine

if light goes on. Do not run engine

until trouble is fixed.

If unit is equipped with optional au-

tomatic shutdown, light goes on

and engine stops when oil tempera-

ture rises to 250°F (121°C) or oil

pressure drops to between 15 and

20 psi (103 to 138 kPa).

2 Battery Charging Light

Light is off when engine is running

and battery is being charged. Light

goes on when battery is not being

charged. Stop engine if light comes

on. Do not run engine until trouble is

fixed.

Lights are always on when engine

control switch is in Run and engine

is stopped.

Stop engine if a light goes on.

1

2

Figure 4-10. Engine Lights

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