cover 8/92 − ST-130 895-C PRINTED IN USA
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
April 1993 Form: OM-480C
Effective With Serial No. KC288497
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
Big Blue™ 251D
OM-480C − 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS
2-1. Volt-Ampere Curves And Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Fuel Consumption 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. AC Auxiliary Power Curve 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Optional AC Power Plant Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION
3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Muffler Pipe Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting The Battery 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Engine Prestart Checks 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Grounding The Generator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Selecting And Preparing Weld Output Cables 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting To Weld Output Terminals 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Installing Ether Cylinder (Optional Ether Starting Aid) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Optional Remote A/V Receptacle Information And Connections 9. . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATING THE WELDING GENERATOR 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATING AUXILIARY EQUIPMENT
5-1. 120 Volt Duplex Receptacles 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Optional 240 Volt Duplex Receptacle 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Connecting Optional Auxiliary Power Plant 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Maintenance Lights 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Servicing Air Cleaner 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Oil And Fuel System Components 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Adjusting Engine Speed 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Replacing Battery Or Checking Battery Voltage 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Checking And Replacing Engine Belt 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Optional Ether Starting Aid Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Optional Overspeed Shutdown Valve Adjustment 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Optional Low Oil Pressure/High Oil Temperature Shutdown System Fuse F 26. . . . . . . . . . . .
6-11. Troubleshooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − RUN-IN PROCEDURE
8-1. Run-In Procedure Using Load Bank 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Run-In Procedure Using Resistance Grid 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − AUXILIARY POWER GUIDELINES
9-1. How Much Power Does Equipment Require? 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. How Much Power Can Generator Supply? 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Typical Connections To Supply Standby Power 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Selecting Extension Cord 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST
Figure 10-1. Main Assembly 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2. Panel, Front w/Components 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-3. Switch, Range 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-4. Generator 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-5. Terminal Assembly, Pwr Output 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 2-1)
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 U.S. gal (42.8L)
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
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: 1475 lb (670 kg); Ship: 1510 lb (685 kg)
Options See Rear Cover
OM-480 Page 2
2-1. Volt-Ampere Curves And Duty Cycle
CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
• Do not exceed indicated duty cycles.
warn7.1 2/92
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.
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.
rsb1.1 10/91 − SB-070 042-B / sb1.1 2/92 − SB-070 999-A
A. Volt-Ampere Curves
B. Duty Cycle
Figure 2-1. Volt-Ampere Curves And Duty Cycle Chart
2-2. Fuel Consumption
The fuel consumption curve shows
typical fuel use under weld or power
loads.
rsb2.1 10/91 − SB-137 487
Figure 2-2. Fuel Consumption Curve
OM-480 Page 3
2-3. AC Auxiliary Power Curve
The ac power curve shows the auxil-
iary power in amperes available at
the 120 and 240 volt receptacles.
rsb3.1 10/91 − SB-109 365-B
Figure 2-3. AC Power Curve For 120 And 240 Volt Receptacles
2-4. Optional AC Power Plant Curves
rsb13.1 3/92 − 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 2-4. AC Power Plant Curves
OM-480 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-155 965
1 18 in (457 mm) Open Space
On All Sides For Good Airflow
2 Lifting Eye
Use lifting eye to move unit.
3 Muffler Pipe
Install according to Section 3-2.
4 Lifting Forks
If using lifting forks, extend forks out
opposite side of base.
Front
Left
To p
Right
Rear
1
2
3
4
Figure 3-1. Location And Movement Of Welding Generator
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 5
1 Trailer Hitch
Install unit onto trailer according to
trailer manual.
S-0024-B
1
30°
30°
30°
30°
Engine
End
Figure 3-3. Maximum Welding Generator Tilt 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 / 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
6-6.
Tools Needed:
1/2 in
1
4
2
+
−
5
3
Figure 3-5. Connecting The Battery
OM-480 Page 6
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* 9/91
rsb4.2* 11/92 − ST-130 894 / 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 7
3-5. Grounding The Generator
rsb5.1 1/93 − Ref. ST-156 024-A / Ref. ST142 560
1 Equipment Grounding
Terminal
Tools Needed:
1/2 in
Connect To Earth Ground
According To Codes
1
The generator auxiliary power neutral
is connected to the machine frame.
Figure 3-7. Equipment Grounding Connection
3-6. Selecting And Preparing Weld Output Cables
sb6.1 11/92 − 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 3-8. Selecting And Preparing Weld Output Cables
OM-480 Page 8
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 not more than 300 circular mils per ampere. S-0007-C
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-133 520
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
Figure 3-9. Weld Output Connections
OM-480 Page 9
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 3-10. Installing Ether Cylinder
3-9. Optional Remote A/V Receptacle Information And Connections
Ref. ST-142 560
1 Remote A/V Receptacle RC3
2 Keyway
To connect to this receptacle, align
keyway, insert plug, and turn plug
clockwise.
1
2
Figure 3-11. Remote A/V Receptacle Connections
OM-480 Page 10
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-A
1 Ampere Ranges Switch
2 Oil Temperature Gauge
(Optional)
3 Oil Pressure Gauge
(Optional)
4 Remote A/V Control Switch
(Optional)
5 Voltmeter (Optional)
6 Amperage/Voltage Adjustment
Control
7 Ammeter (Optional)
8 Polarity Switch (Optional)
9 Low Oil Pressure/High Oil
Temperature Shutdown Sys-
tem Switch (Optional)
10 Engine Control Switch
11 Ether Starting Aid Switch (Op-
tional)
12 Engine Hour Meter
13 Low Oil Pressure Light
(Section 6-2)
14 Engine Battery Light
(Section 6-2)
12345
6
7
14
13
12
11
10
8
9
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-480 Page 11
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
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
Ref. ST-142 560
1 Ampere Ranges Switch
Use switch to select weld amper-
age range.
1
Figure 4-4. Ampere Ranges Switch
1 Amperage/Voltage Adjustment
Control
Use control to adjust amperage
within range selected by Ampere
Ranges switch. Numbers around
control are for reference only.
1
Figure 4-5. Amperage/Voltage Adjustment Control
OM-480 Page 12
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 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 3-9).
2 Remote Amperage Control
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:
1
Figure 4-6. Remote A/V Control (Optional)
OM-480 Page 13
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. SD-118 111-B
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)
1 Engine Control Switch
Use switch to start engine, select
engine speed, and stop engine.
To start, turn switch to Start position
and release as soon as engine
starts. Do not engage starter while
flywheel is rotating.
In Run position, engine runs at
weld/power speed all the time.
To stop engine, turn switch to Off
position.
2 Low Oil Pressure/High Oil
Temperature Shutdown Sys-
tem Switch (Optional)
Use switch during start-up to by-
pass engine shutdown system.
Shutdown system stops engine if
oil pressure drops between 15 and
20 psi (103 to 138 kPa) or oil tem-
perature 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.
1
2
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 run-
ning.
1
rsb6.1 2/92
Figure 4-9. Engine Hour Meter
OM-480 Page 14
CAUTION
ARCING can damage switch.
• Do not change Polarity switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail.
rwarn6.1* 9/91
1 Polarity Switch
Use switch to select polarity of weld
output (see Section 3-7).
+()
ELECTRODE
POSITIVE
()
ELECTRODE
NEGATIVE
DC
110 501
DC
110 500
1
Figure 4-10. Polarity Switch (Optional)
1 Oil Temperature Gauge/Shut-
down Switch
Use gauge/switch to check oil tem-
perature. If oil temperature rises to
250°F (121°C), the engine stops
(see Section 6-10).
2 Oil Pressure Gauge
Use gauge to check oil pressure. If
oil pressure drops between 15 and
20 psi (103 to 138 kPa) the engine
stops (see Section 6-10).
3 Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not nec-
essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
4 Ammeter
Ammeter displays dc amperage
output of the unit.
1 2
3 4
Figure 4-11. Gauges And Meters (Optional)
Insert
Electrode
Into Holder
rsb8.1 9/92
Install &
Connect
Equipment
Select
Electrode
Put On
Personal Safety
Equipment
Set Controls Start Engine
Turn On Auxiliary
Equipment
Begin Welding
Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)
OM-480 Page 15
SECTION 5 − OPERATING AUXILIARY EQUIPMENT
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine before making internal inspection or
reconnection.
• Ground generator according to all applicable
national, state, and local codes.
• Connect equipment grounding terminal to a proper
earth ground.
• Do not connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and grounding procedure are
employed (see Section 9).
MOVING PARTS can cause serious
injury.
• Keep away from moving parts such as fans, belts,
and rotors.
• Keep all doors, panels, covers, and guards closed
and securely in place.
ELECTRIC SPARKS can cause fire.
• If using auxiliary power only and not welding,
disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
• Watch for fire.
• Keep a fire extinguisher nearby, and know how to
use it.
The weld output terminals are electrically energized
when the engine is running and the contactor, if
applicable, is energized.
LOW VOLTAGE AND FREQUENCY can
damage electrical equipment.
• Turn off or unplug all electrical equipment connected
to auxiliary power receptacles before starting or
stopping the engine.
When starting or stopping, the engine has low speed
which causes low voltage and frequency.
rwarn8.1 10/92
5-1. 120 Volt Duplex Receptacles
Ref. ST-142 560
1 120 V 15 A AC Duplex Re-
ceptacle RC1
2 120 V 15 A AC Duplex Re-
ceptacle RC2
These receptacles supply 60 Hz
single-phase power at weld/power
speed. Maximum output from each
receptacle is 3 kVA/kW.
3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 protects RC1 and CB2 pro-
tects RC2 from overload. If CB1 or
CB2 opens, the receptacle does
not work. Press button to reset
breaker.
5 Total Auxiliary Power Output
Combined output of all receptacles
limited to 3 kVA/kW output of the
generator.
EXAMPLE: If 15 A is drawn from a
120 V receptacle, only 10 A is avail-
able at the other receptacle:
(120 V x 15 A) + (120 V x 10 A) = 3.0
kVA/kW
Auxiliary power is not affected by
weld output.
12
3
4
5
Figure 5-1. Auxiliary Power Receptacles And Circuit Breakers
OM-480 Page 16
5-2. Optional 240 Volt Duplex Receptacle
Ref. ST-142 560 / ST-140 864
1 240 V 13 A AC Duplex Re-
ceptacle RC1
This receptacle supplies 60 Hz
single-phase power at weld/power
speed. Maximum output is 3 kVA/
kW.
2 120 V 15 A AC Duplex Re-
ceptacle RC2
See Figure 5-1 for description.
3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 and CB2 protect the 120 V and
240 V receptacles from overload. If
CB1 or CB2 opens, the 240 V re-
ceptacle and half of the 120 V re-
ceptacle will not work. Press button
to reset breaker.
5 Total Auxiliary Power Output
Combined output of all receptacles
limited to 3 kVA/kW output of the
generator.
EXAMPLE: If 10 A is drawn from a
240 V receptacle, only 5 A is avail-
able at the 120 V receptacle:
(240 V x 10 A) + (120 V x 5 A) = 3.0
kVA/kW
Auxiliary power is not affected by
weld output.
12
3
4
5
Figure 5-2. Optional 240 Volt Duplex Receptacle And Circuit Breakers
Place Engine
Control Switch In
Run Position
See Section 9
Auxiliary Power
Guidelines
Install &
Connect
Equipment
Start Engine
Turn On
Auxiliary
Equipment
Begin Operation
rsb11.1 4/92
Figure 5-3. Sequence Of Auxiliary Equipment Operation
5-3. Connecting Optional Auxiliary Power Plant
WARNING
ELECTRIC SHOCK can kill.
• Stop engine before making or changing connections
or changing fuses.
• Keep junction box cover in place while engine is
running.
• Do no connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and grounding procedure are
employed.
• Ground in accordance with NEC, state, and local
codes; be sure that a proper ground is connected to
the Equipment Grounding Terminal provided on the
equipment frame.
INCORRECT CONNECTIONS or
IMPROPER VOLTAGE OR FREQUENCY
can damage equipment and cause fire.
• Read all equipment instruction manuals before
making connections.
• Use only equipment suitable for operation on 60 or
50/60 Hz power.
• Switch off electrical equipment before starting or
stopping engine.
• Have only a qualified electrician make or change
connections.
ELECTRIC SPARKS can cause fire.
• If using auxiliary power only and not welding,
disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
• Watch for fire.
• Keep a fire extinguisher nearby, and know how to
use it.
The weld output terminals are electrically energized
when using auxiliary power.
MOVING PARTS can cause serious
injury.
• Keep away from moving parts such as fans, belts,
and rotors.
• Keep all doors, panels, covers, and guards closed
and securely in place.
INCORRECT FUSES can cause
equipment damage.
• Use only fuses of correct size, type, and rating (see
Parts List).
• Set Engine Control switch to Run position.
• Rotate Amperage & Voltage Adjustment control to
100 for power.
OM-480 Page 17
240V
120V120V
240V
240V
240V
1 3
F3
F2
F1
93
92
91
rsb14.1 2/93A − S-160 622-A
Have only qualified persons make
this installation.
Stop engine. Open right side door.
1 Lead 42 (Circuit Grounding
Lead)
2 Lead 90 (Neutral)
3 Isolated Neutral Terminal
4 Jumper Lead 42
5 Grounding Terminal
Jumper lead 42 may be discon-
nected from neutral to meet appli-
cable codes, such as National
Electrical Code.
6 Strain Relief
7 User-Supplied Conductors
Strip back cord jacket approximate-
ly 12 in (305 mm). Strip 3/4 in (19
mm) insulation from ends of leads.
Route cord through strain relief.
8 Load Terminals
Connect leads to proper load termi-
nals as shown in connection dia-
gram. Tighten connections and
strain relief.
9 Fuses F1, F2, And F3 (see
Parts List for rating)
F1, F2, and F3 protect each load
line from overload. If output from the
power plant stops, a fuse may be
open.
Reinstall cover, and close side
door.
Tools Needed:
Generator Windings
(See Section 7 For Complete Circuit)
6
7
89
Volts
Amps
KVA/KW
Single
120/240
31
7.5
Three
240
24
10
60 HzFrequency
Engine Speed
Max. Fuse Size 35 Amperes
1850 RPM
AC
Phase
1
Phase
3
Output
1. Set Engine Control switch to RUN.
2. Set AMPERAGE & VOLTAGE ADJUST-
MENT control to 100.
Lead 42 connects to GROUND stud on front of unit.
Jumper 42 is connected to 90 at factory.
93
91
90
92
Power and weld outputs
are live at the same time.
Disconnect or insulate
unused cables.
Front
Of
Unit
3451
2
Figure 5-4. Auxiliary Power Plant Connections And Overload Protection
See Section 9
Auxiliary Power
Guidelines
Install & Connect
Welding
Generator
Connect Auxiliary
Equipment To
Power Plant
Place Engine
Control Switch In
Run Position
Start Engine
Turn On
Auxiliary
Equipment
Turn Amperage &
Voltage Control
To 100
Begin Operation
Figure 5-5. Sequence Of Operating Auxiliary Equipment From Power Plant
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