Professional Documents
Culture Documents
Miller 320 Diesel
Miller 320 Diesel
2008−10
Processes
Stick (SMAW) Welding
Description
Mil_Thank 4/05
TABLE OF CONTENTS
Protect yourself and others from injury — read and follow these precautions.
BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
D Shut off shielding gas supply when not in use.
D Wear approved ear protection if noise level is
D Always ventilate confined spaces or use ap- high.
proved air-supplied respirator.
MAGNETIC FIELDS can affect Implanted
ARC RAYS can burn eyes and skin. Medical Devices.
BATTERY EXPLOSION can BLIND. HOT PARTS can cause severe burns.
D Always wear a face shield, rubber gloves, and D Do not touch hot parts bare handed.
protective clothing when working on a battery. D Allow cooling period before working on equip-
D Stop engine before disconnecting or connect- ment.
ing battery cables or servicing battery. D To handle hot parts, use proper tools and/or
D Do not allow tools to cause sparks when working on a battery. wear heavy, insulated welding gloves and
clothing to prevent burns.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and −) on batteries.
D Disconnect negative (−) cable first and connect it last.
STEAM AND HOT COOLANT can burn.
FUEL can cause fire or explosion. D If possible, check coolant level when engine is
cold to avoid scalding.
D Stop engine and let it cool off before checking or D Always check coolant level at overflow tank, if
adding fuel. present on unit, instead of radiator (unless told
D Do not add fuel while smoking or if unit is near otherwise in maintenance section or engine
any sparks or open flames. manual).
D Do not overfill tank — allow room for fuel to expand. D If the engine is warm, checking is needed, and there is no over-
D Do not spill fuel. If fuel is spilled, clean up before starting engine. flow tank, follow the next two statements.
D Dispose of rags in a fireproof container. D Wear safety glasses and gloves and put a rag over radiator cap.
D Always keep nozzle in contact with tank when fueling. D Turn cap slightly and let pressure escape slowly before
completely removing cap.
D Before working on hydraulic system, turn off and D Before working on hydraulic system, turn off and lockout/tagout
lockout/tagout unit, release pressure, and be sure unit, release pressure, and be sure hydraulic pressure cannot be
hydraulic pressure cannot be accidentally applied. accidentally applied.
D Relieve pressure before disconnecting or con- D Have only qualified people remove guards or covers for maint-
necting hydraulic lines. enance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when servicing is
D Check hydraulic system components and all con- finished and before starting engine.
nections and hoses for damage, leaks, and wear
before operating unit.
HOT PARTS AND FLUID can cause severe
D Wear protective equipment such as safety burns.
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic D Do not touch hot parts bare handed or allow hot
system. fluid to contact skin.
D Use a piece of paper or cardboard to search for leaks−−never use D Allow cooling period before working on equip-
bare hands. Do not use equipment if leaks are found. ment.
D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics D To handle hot parts, use proper tools and/or wear heavy, insu-
near sparks or flames; do not smoke near hydraulic fluid. lated welding gloves and clothing to prevent burns.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
D If ANY fluid is injected into the skin, it must be surgically removed READ INSTRUCTIONS.
within a few hours by a doctor familiar with this type of injury or gan-
grene may result. D Read Owner’s Manual before installing, oper-
ating, or servicing unit.
MOVING PARTS can injure. D Use only genuine replacement parts from the
manufacturer.
D Keep away from fans, belts and rotors. D Perform maintenance and service according to the Owner’s
D Keep all doors, panels, covers, and guards Manuals, industry standards, and national, state, and local
closed and securely in place. codes.
D Do not exceed the rated output or capacity of the compressor or D Check compressed air system components
any equipment in the compressed air system. Design com- and all connections and hoses for damage,
pressed air system so failure of any component will not put people leaks, and wear before operating unit.
or property at risk. D Do not direct air stream toward self or others.
D Before working on compressed air system, turn off and lockout/ D Wear protective equipment such as safety glasses, hearing pro-
tagout unit, release pressure, and be sure air pressure cannot be tection, leather gloves, heavy shirt and trousers, high shoes, and
accidentally applied. a cap when working on compressed air system.
D Do not work on compressed air system with unit running unless D Use soapy water or an ultrasonic detector to search for leaks−−
you are a qualified person and following the manufacturer’s in- never use bare hands. Do not use equipment if leaks are found.
structions.
D Reinstall doors, panels, covers, or guards when servicing is
D Do not modify or alter compressor or manufacturer-supplied finished and before starting unit.
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system. D If ANY air is injected into the skin or body seek medical help im-
mediately.
D Use only components and accessories approved by the manu-
facturer.
BREATHING COMPRESSED AIR can in-
D Keep away from potential pinch points or crush points created by
jure or kill.
equipment connected to the compressed air system.
D Do not work under or around any equipment that is supported D Do not use compressed air for breathing.
only by air pressure. Properly support equipment by mechanical
D Use only for cutting, gouging, and tools.
means.
D Keep away from fans, belts and rotors. D Do not touch hot compressor or air system
D Keep all doors, panels, covers, and guards parts.
closed and securely in place. D Let system cool down before touching or ser-
vicing.
D To handle hot parts, use proper tools and/or wear heavy, insu-
D Keep hands, hair, loose clothing, and tools away from moving lated welding gloves and clothing to prevent burns.
parts.
D Before working on compressed air system, turn off and lockout/ HOT METAL from air arc cutting and
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
gouging can cause fire or explosion.
D Have only qualified people remove guards or covers for maint- D Do not cut or gouge near flammables.
enance and troubleshooting as necessary. D Watch for fire; keep extinguisher nearby.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
READ INSTRUCTIONS.
TRAPPED AIR PRESSURE AND WHIPPING D Read Owner’s Manual before installing, oper-
HOSES can injure. ating, or servicing unit.
D Use only genuine replacement parts from the
D Release air pressure from tools and system be- manufacturer.
fore servicing, adding or changing attach-
D Perform maintenance and service according to the Owner’s
ments, or opening compressor oil drain or oil fill
Manuals, industry standards, and national, state, and local
cap.
codes.
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
LES FUMÉES ET LES GAZ peu- D Déplacer toutes les substances inflammables à une distance de
vent être dangereux. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Le soudage génère des fumées et des gaz. Leur D Ne pas souder dans un endroit là où des étincelles peuvent tomber
inhalation peut être dangereux pour votre santé. sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
D Eloigner votre tête des fumées. Ne pas respirer les fumées. de métal chaud.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Des étincelles et des matériaux chauds du soudage peuvent
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé. D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les D Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou D Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
un surveillant dûment formé de se tenir à proximité. Des fumées et préparés correctement conformément à AWS F4.1 (voir les nor-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau mes de sécurité).
d’oxygène provoquant des blessures ou des accidents mortels. D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
S’assurer que l’air de respiration ne présente aucun danger. peurs inflammables (vapeur d’essence, par exemple).
D Ne pas souder dans des endroits situés à proximité d’opérations D Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for- longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants. quant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- lées.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit D En cas de non utilisation, enlever la baguette d’électrode du porte-
bien ventilé, et en portant un respirateur à alimentation d’air. Les électrode ou couper le fil à la pointe de contact.
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage. D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
LES ACCUMULATIONS DE GAZ ris- revers, des chaussures hautes et un couvre chef.
quent de provoquer des blessures ou D Avant de souder, retirer toute substance combustible de vos po-
même la mort. ches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
D Fermer l’alimentation du gaz protecteur en cas
ce d’étincelles incandescentes ni de flammes.
de non utilisation.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
D Veiller toujours à bien aérer les espaces confinés ou se servir
Ne pas augmenter leur puissance; ne pas les ponter.
d’un respirateur d’adduction d’air homologué.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
LES RAYONS DE L’ARC peuvent extincteur à proximité.
provoquer des brûlures dans les
yeux et sur la peau. LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage Le bruit des processus et des équipements peut
génère des rayons visibles et invisibles intenses affecter l’ouïe.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Porter des protections approuvés pour les
soudage. oreilles si le niveau sonore est trop élevé.
Les ÉQUIPEMENTS HYDRAULIQUES D Pour intervenir sur un circuit hydraulique, porter un équipement
peuvent provoquer des blessures ou de protection tel que des lunettes de sécurité, des gants de cuir,
même la mort. une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
D Une installation ou une utilisation incorrecte D Pour rechercher des fuites, utiliser un morceau de papier ou
de cet appareil pourrait conduire à des dégâts de carton, jamais les mains nues. En cas de détection de fuite,
matériels ou corporels. Seul un personnel qualifié ne pas utiliser l’équipement.
est autorisé à installer, faire fonctionner et réparer
cet appareil conformément à son manuel D Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas
d’utilisation, aux normes industrielles et aux intervenir sur des composants hydrauliques à proximité
codes nationaux, d’état ou locaux. d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.
D Ne pas dépasser le débit nominal ou la capacité de la pompe D Remettre les portes, panneaux, recouvrements ou dispositifs
hydraulique ou de tout équipement du circuit hydraulique. de protection quand l’entretien est terminé et avant de mettre
Concevoir le circuit hydraulique de telle sorte que la défaillance en marche l’appareil.
d’un composant hydraulique ne risque pas de provoquer D En cas de pénétration d’un QUELCONQUE liquide dans la peau,
un accident matériel ou corporel. celui−ci doit être retiré chirurgicalement sous quelques heures par
D Avant d’intervenir sur le circuit hydraulique, couper l’alimentation un médecin familiarisé avec ce type de blessure, faute de quoi
électrique, verrouiller et étiqueter l’appareil, détendre la pression la gangrène pourrait apparaître.
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance. Les PIÈCES MOBILES peuvent causer
D Ne pas intervenir sur le circuit hydraulique lorsque l’appareil des blessures.
fonctionne. Seul un personnel qualifié et appliquant les consignes
du fabricant est autorisé le faire. D Rester à l’écart des ventilateurs, courroies
et rotors.
D Ne pas modifier ou altérer la pompe hydraulique ou D Maintenir fermés et verrouillés les portes,
les équipements fournis par le fabricant. Ne pas débrancher, panneaux, recouvrements et dispositifs
désactiver ou neutraliser les équipements de sécurité du circuit de protection.
hydraulique.
D Utiliser uniquement des composants et accessoires homologués D Ne pas approcher les mains, cheveux, vêtements lâches et outils
par le fabricant. des organes mobiles.
D Se tenir à l’écart de tout point présentant un danger de pincement D Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
ou d’écrasement créé par l’équipement raccordé au circuit électrique, verrouiller et étiqueter l’appareil, détendre la pression
hydraulique. et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.
D Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression hydraulique. Soutenir l’équipement D Demander seulement à un personnel qualifié d’enlever
de façon appropriée par un moyen mécanique. les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
D Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
Le LIQUIDE HYDRAULIQUE risque de de mettre le moteur en marche.
provoquer des blessures ou même la mort.
D Avant d’intervenir sur le circuit hydraulique, Les PIÈCES ET LIQUIDES CHAUDS peuvent
couper l’alimentation électrique, verrouiller provoquer des brûlures graves.
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut D Ne pas toucher les pièces chaudes à main nue
être remis sous pression par inadvertance. ni laisser des liquides chauds entrer en contact
D Détendre la pression avant de débrancher ou avec la peau.
de brancher des canalisations hydrauliques. D Prévoir une période de refroidissement avant d’intervenir
D Avant d’utiliser l’appareil, contrôler sur l’équipement.
les composants du circuit hydraulique, D Ne pas toucher aux pièces chaudes, utiliser les outils
les branchements et les flexibles en recherchant recommandés et porter des gants de soudage et des vêtements
tout signe de détérioration, de fuite et d’usure. épais pour éviter les brûlures.
Un ÉQUIPEMENT PNEUMATIQUE risque D Pour rechercher des fuites, utiliser de l’eau savonneuse ou
de provoquer des blessures ou même un détecteur à ultrasons, jamais les mains nues. En cas
la mort. de détection de fuite, ne pas utiliser l’équipement.
D Remettre les portes, panneaux, recouvrements ou dispositifs
D Une installation ou une utilisation incorrecte de de protection quand l’entretien est terminé et avant de mettre
cet appareil pourrait conduire à des dégâts en marche l’appareil.
matériels ou corporels. Seul un personnel D En cas d’injection d’air dans la peau ou le corps, demander
qualifié est autorisé à installer, utiliser et immédiatement une assistance médicale.
entretenir cet appareil conformément à son
manuel d’utilisation, aux normes industrielles et L’INHALATION D’AIR COMPRIMÉ risque
aux codes nationaux, d’état ou locaux. de provoquer des blessures ou même
D Ne pas dépasser le débit nominal ou la capacité du compresseur la mort.
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance D Ne pas inhaler d’air comprimé.
d’un composant ne risque pas de provoquer un accident D Utiliser l’air comprimé uniquement pour
matériel ou corporel. découper ou gouger ainsi que pour l’outillage
D Avant d’intervenir sur le circuit d’air comprimé, couper pneumatique.
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance. Les PIÈCES MOBILES peuvent causer
D Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil des blessures.
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant. D Rester à l’écart des ventilateurs, courroies
et rotors.
D Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou D Maintenir fermés et verrouillés les portes,
neutraliser les équipements de sécurité du circuit d’air panneaux, recouvrements et dispositifs
comprimé. de protection.
D Utiliser uniquement des composants et accessoires D Ne pas approcher les mains, cheveux, vêtements lâches et outils
homologués par le fabricant. des organes mobiles.
D Se tenir à l’écart de tout point présentant un danger de pincement D Avant d’intervenir sur le circuit d’air comprimé, couper
ou d’écrasement créé par l’équipement raccordé au circuit d’air l’alimentation électrique, verrouiller et étiqueter l’appareil,
comprimé. détendre la pression et s’assurer que le circuit d’air ne peut être
D Ne pas intervenir sous ou autour d’un équipement qui n’est mis sous pression par inadvertance.
soutenu que par la pression pneumatique. Soutenir l’équipement D Demander seulement à un personnel qualifié d’enlever
de façon appropriée par un moyen mécanique. les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
D Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
Une PRESSION D’AIR RÉSIDUELLE
L’AIR COMPRIMÉ risque de provoquer ET DES FLEXIBLES QUI FOUETTENT
des blessures ou même la mort. risquent de provoquer des blessures.
D Avant d’intervenir sur le circuit d’air comprimé, D Détendre la pression pneumatique des outils et
couper l’alimentation électrique, verrouiller circuits avant d’entretenir, ajouter ou changer
et étiqueter l’appareil, détendre la pression des accessoires et avant d’ouvrir le bouchon
et s’assurer que le circuit d’air ne peut être mis de vidange ou de remplissage d’huile
sous pression par inadvertance. du compresseur.
D Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
D Avant d’utiliser l’appareil, contrôler DES PIÈCES CHAUDES peuvent
les composants du circuit d’air comprimé, provoquer des brûlures graves.
les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure. D Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
D Ne pas diriger un jet d’air vers soi−même ou vers autrui. D Laisser refroidir le circuit avant de toucher
ou entretenir des pièces.
D Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir, D Ne pas toucher aux pièces chaudes, utiliser les outils
une chemise et un pantalon en tissu résistant, des chaussures recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.
montantes et une coiffe.
OM-217 454 Page 11
Le MÉTAL CHAUD provenant du LIRE LES INSTRUCTIONS.
découpage ou du gougeage à l’arc risque
de provoquer un incendie ou une explosion. D Lire le manuel d’utilisation avant d’installer,
d’utiliser ou d’intervenir sur l’appareil.
D Ne pas découper ou gouger à proximité D N’utiliser que les pièces de rechange
de produits inflammables. recommandées par le constructeur.
D Attention aux risques d’incendie: tenir un extincteur à proximité. D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
Fast Fast/Slow
Stop Engine Slow (Idle)
(Run, Weld/Power) (Run/Idle)
Start Engine
Read Operator’s
Manual A Amperes
V Volts
Alternating Current
Positive Negative Output
(AC)
s
Protective Earth
h
Hours Seconds Time
(Ground)
Circuit Protector
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, and Engine Specifications
. Also see Performance Data in Section 12.
Rated Maximum Weld
Welding Generator Fuel
Welding Open-Circuit Output Engine
Mode Power Rating Capacity
Output Voltage Range
280 A, 25 V, 100%
CC/DC 50 10 − 300 A Continuous: 9.5 kVA/ Kubota D722
Duty Cycle
kW, 80/40 A, Water-Cooled,
300 A, 25 V, 100% 13 − 35 V, 120/240 V AC, 60 Hz, 12 gal
Three-Cylinder,
CV/DC 35 Single-Phase, (45 L)
Duty Cycle 10−325 A Four-Cycle,
Tank
Peak: 11 kVA/kW 18.8 HP
200 A, 25 V, 60% Diesel Engine
CC/AC 50 30 − 225 A (w/Weld Contactor Off)
Duty Cycle
20°
20° 20°
20°
.105
13.500
16.500
51.500
32.750
Locate Rear Cross
Support Under Engine
Minimum Gage − 12
2.000 Minimum Width − 3 in.
5.250 Locate Front Cross Support
Approximately 1 in. Behind 803 572 / Ref 232 770
Mounting Holes
OM-217 454 Page 16
. A complete Parts List is available at www.MillerWelds.com
4-3. Dimensions For Units With Optional Running Gear
Dimensions
C
Protective Cage Width:
A
26 in. (660 mm)
D
B
Running Gear Length:
D
45−1/2 in. (1156 mm)
Notes
18 in. 18 in.
(460 mm) (460 mm)
Mounting
1
install2 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
Tools Needed:
1/2 in. 804 196-A / Ref 216 171-B
+ −
Tools Needed:
1/2 in.
804 197-A / Ref 216 171 / Ref. S-0756-D
Notes
10
9
4 5 Tools Needed:
3/4 in.
9
6
Weld Output 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
Terminals
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
! Turn off power be-
fore connecting to 2 ea. 2/0 2 ea. 2/0
weld output termi- 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
nals.
! Do not use worn, 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
damaged, under- (2x70) (2x95) (2x95)
sized, or poorly
spliced cables. 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**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.
( ) = mm2 for metric use S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
A 24 volts AC.
24 VOLTS AC B Contact closure to A completes 24 volt AC
contactor control circuit and keeps engine at Run
speed in MIG mode. Protected by supplementary
protector CB4.
A J
K I
B I 115 volts AC. Protected by supplementary protec-
115 VOLTS AC tor CB3.
C L N H
D M G J Contact closure to I completes 115 volts AC
E F contactor control circuit.
=
Speed) Continuous.
Use in welding applications where
high speed is needed for better
arc starting and in TIG
applications using a high
frequency arc starter.
Any
= No Load: 2450 rpm (Idle Speed)
Load: 3750 rpm max (weld/Power
Speed)
position.
70°F (21°C)
t
0 seconds
32°F (0°C) 10 seconds
−4°F (−20°C) 20 seconds
Do not use glow plugs longer than
20 seconds.
Do not use ether to start engine.
Using ether voids warranty. 1
3
Ref. 240 604
1 Engine Control Switch 2 Speed Lock Switch To Start: Use glow plug switch if necessary
Use switch to lock engine in idle or weld/power (see item 3 and glow plug table). Turn engine
Use switch to start engine, select speed, and speed when Engine Control switch is in the control switch to Start. Release engine control
stop engine. In Run/Idle position, engine runs Speed Lock position. The Speed Lock switch switch when engine starts.
at idle speed at no load, and weld/power speed is not needed at start-up. The engine always
under load. In Speed Lock position, engine starts at idle speed. . If the engine does not start, let the engine
speed is determined by position of Speed Lock come to a complete stop before attempt-
With switch in the Idle position and Engine
switch (see item 2 and engine speed table ing restart.
Control switch in Speed Lock, the engine runs
above).
at idle speed. With switch in Run position and To Stop: Turn Engine Control switch to Off
Engine Control switch in Speed Lock, engine position.
. Place Engine Control switch in Speed runs at weld/power speed.
Lock position and Speed Lock switch in
Run position for TIG (GTAW) welding us-
Speed Lock switch does not affect engine . Close fuel valve to stop engine if Engine
speed when Engine Control switch is in Run/ Control switch does not work (see Section
ing a high frequency device. Idle position. (Engine speed changes with 5-6).
load.)
4 Fuel Level Indicator
. In MIG mode, the unit will not return to idle 3 Glow Plug Switch
speed when the remote contactor is on If necessary, push switch down before start- With Engine Control switch in the Speed Lock
(closure between pins A and B or I and J up to activate glow plug. See glow plug table or Run/Idle position, LED’s indicate fuel level
on remote receptacle). above for operating information. left in tank.
1 2 3 4 5 6
1 Process/Contactor Switch If displays read: HLP_001, and engine does When a remote voltage/amperage control is
See Section 6-3 for Process/Contactor switch not return to idle, check throttle solenoid. Turn connected to the Remote receptacle, the Auto
information. Engine Control switch to OFF to reset shut- Sense Remote feature automatically switches
2 And 3 Displays down. voltage/amperage control to the remote con-
trol (see Sections 5-9 and 6-6).
Displays can show weld process information 4 Voltage/Amperage Control
(voltage and amperage) or engine and main- With remote voltage/amperage control con-
tenance information. Use control to select weld voltage or nected, weld output in CC mode is determined
amperage. Control may be adjusted while by a combination of front panel and remote
Meter Weld Functions: In Wire modes, Volt- welding.
meter displays preset weld voltage when not control voltage/amperage settings. In CV
welding. Meters display actual voltage and With Process/Contactor switch in any Stick or mode, weld output is controlled through re-
amperage when welding and for five seconds TIG setting, use control to adjust amperage. mote control only.
after welding has stopped. With Process/Contactor switch in any Wire If no remote voltage/amperage control is con-
In Stick and TIG modes, Voltmeter reads ON position, use control to adjust voltage. When a nected to the Remote receptacle, the front
and Ammeter displays preset amperage when remote voltage/amperage control is con- panel Voltage/Amperage control adjusts volt-
the contactor is on and not welding. The Volt- nected to Remote receptacle RC4, control age and amperage.
meter reads 0 (zero) when in remote with the sets the maximum amperage in Stick and TIG
contactor off. Meters display actual voltage modes, but has no effect in MIG modes. 6 DC Polarity/AC Switch
and amperage when welding and for five sec-
onds after welding has stopped. 5 Remote Receptacle NOTICE − Do not switch while welding.
Meter Engine And Maintenance Functions: Use receptacle to connect remote control or Use switch to select AC weld output or polarity
See inset from maintenance label. wire feeder. of DC weld output.
1 Process/Contactor Switch descriptions following (reading L to R): Medium Arc - This setting provides me-
dium dig/arc force for open root vertical up
! Weld output terminals are energized Soft Arc (E 7018) - This setting provides a joints or joints that do not require additional
when Process/Contactor switch is low dig/arc force setting for smooth weld current for fit up inconsistencies.
in an Electrode Hot position and the performance. A stable weld puddle with
engine is running. little arc “snap” gives excellent weld bead Stiff Arc (E6010) - This setting provides a
appearance with minimal spatter. high dig/arc force for open root vertical
. The unit will not return to idle speed down joints where additional current is
when Process/Contactor switch is in a Medium Soft Arc - This setting provides a needed to compensate for tight joint fit up
Wire position and the remote contactor low to medium dig/arc force that gives a without the need to increase overall welding
is on (closure between pins A and B on slightly more fluid weld puddle, more arc current. This setting is recommended for
remote receptacle). “snap”, and reduces the potential for those who prefer a very stiff arc with 6010
electrode sticking at shorter arc lengths. electrodes.
Use switch to select weld process and weld
output on/off control (see table below and Medium Stiff Arc - This setting provides The dig circuit is disabled when switch is in
Section 5-9). medium dig/arc force for open root vertical Wire or TIG positions.
up joints or joints that do not require TIG Positions:
Place switch in Remote positions to turn additional current for fit up inconsistencies.
weld output on and off with a device con- TIG − Remote On/Off − Use this position for
nected to the remote receptacle. Stiff Arc (E6010) - This setting provides a AC or DC TIG welding using remote on/off
high dig/arc force for open root vertical control.
Place switch in Electrode Hot positions for down joints where additional current is
weld output to be on whenever the engine needed to compensate for tight joint fit up Electrode Hot − Lift-Arc™ w/Auto Crater™
is running. without the need to increase overall welding TIG (DC only) - With switch in this position,
current. This setting is recommended for a low voltage (10 V DC) is present between
Wire Positions: the electrode and workpiece preventing
those who prefer a very stiff arc with 6010
Use Wire positions for MIG welding using a electrodes. overheating, sticking, or contamination of
voltage sensing wire feeder (Electrode Hot) the electrode (see Section 6-5) as the arc is
or wire feeder using remote control. Stick Remote On/Off: struck.
Stick Positions: When switch is in a Stick Remote On/Off End the arc using the Auto-Crater feature
mode, select one of three settings to pro- (see Section 6-5).
Use Stick positions for stick (SMAW) and
vide additional amperage during short arc Electrode Hot − Lift-Arc™ w/Auto Stop™
air carbon arc (CAC-A) cutting and
length conditions and help prevent elec- TIG (DC only) - With switch in this position,
gouging. trodes from “sticking”. See Stick position a low voltage (10 V DC) is present between
Stick Electrode Hot: descriptions following (readingR to L): the electrode and workpiece preventing
overheating, sticking, or contamination of
When switch is in a Stick Electrode Hot Soft Arc (E7018) - This setting provides a
the electrode (see Section 6-5) as the arc is
mode, select one of four dig settings to pro- low to medium dig/arc force that gives a
struck.
vide additional amperage during short arc slightly more fluid weld puddle, more arc
length conditions and help prevent elec- “snap”, and reduces the potential for End the arc using the Auto-Stop feature
trodes from “sticking”. See Stick position electrode sticking at shorter arc lengths. (see Section 6-5).
Stick (SMAW)
Electrode Hot − Stick Electrode Hot
Select Preferred Dig
Electrode Hot − Lift Arc w/Auto-Crater TIG (GTAW) Lift Arc w/Auto-Crater (GTAW) (DC Only) Electrode Hot
Electrode Hot − Lift Arc w/Auto-Stop TIG (GTAW) Lift Arc w/Auto-Stop (GTAW) (DC Only) Electrode Hot
TIG − Remote On/Off GTAW With HF Unit Or Remote Control (AC or DC) At Remote Receptacle
Stick − Remote On/Off Stick (SMAW) With Remote On/Off At Remote Receptacle
WM Marketing
In Example:
Process = Stick (Using Remote On/Off)
Min = 25 A CC/DC
Max = 160 A CC/DC
Connect Remote Select Polarity By Set V/A Control Adjust Remote V/A Control
V/A Control To Using DC Polarity/AC (Mid-Range: About 160 A) (Stick Welding Only)
Remote Switch Or By
Receptacle RC4 Changing Cable
Connections
240V 6
Tools Needed:
2
3
4
240V
6 5
240 V
AC
120 V 120 V
AC AC
Recycle engine
. See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.
~ Air Cleaner Element n Air Cleaner Hoses n Belt Tension ~ Battery Terminals
Z Oil
Every Engine
200 Manual,
Hours Section 8-4
n Valve Clearance*
Every Section 8-3
2000
Hours
Blow Inspect
3
1
! Stop engine and let cool. Install new filter as shown. Add engine coolant as follows:
Oil And Fuel 5 Fuel Filter
8 Thermostat Housing Plug
1 Oil Drain Valve Replace filter according to engine manual.
Remove thermostat housing plug. Add cool-
2 Oil Filter Wipe up any spilled fuel. ant to radiator until coolant is at bottom of fill-
Start engine, and check for fuel leaks. er neck and coolant trickles out of thermo-
Change engine oil and filter according to en-
stat housing plug hole. This ensures all air is
gine manual. ! Stop engine, tighten connections as purged from the system.
. Close valve and valve cap before ad- necessary, and wipe up fuel.
ding oil and running engine. Reinstall plug and radiator cap. Check cool-
Coolant
ant level in overflow bottle.
Fill crankcase with new oil to full mark on dip- 6 Radiator Cap
stick (see Section 5-6). Engine coolant is a mixture of water and
7 Radiator Drain Cocks (One located on
3 Fuel Lines ethylene glycol base antifreeze. A solution
bottom of radiator)
of 50% antifreeze and 50% water must be
Replace fuel lines if cracked or worn.
Drain engine coolant according to proce- used in this engine. Do not use 100% anti-
4 Inline Fuel Filter dure in engine manual. freeze or severe damage will occur.
If the engine runs properly but the speeds are incorrect, do not adjust the solenoids. Adjust the engine speed according to the instructions in
Section C.
! Stop engine.
Tools Needed:
If the engine does not start and stop when
using the Engine Control switch, check
7/16 in. the position of the fuel solenoid.
10, 14 mm Adjusting Fuel Solenoid Position
3 1 Fuel Solenoid
2 Stop Screw
Verify mounting 3 Fuel Solenoid Mounting Screws
bracket is recessed
from edge of engine. . Stop screw is factory-set and should
not be adjusted.
1 2 When properly adjusted, the solenoid
bracket is slightly recessed from the edge
of the engine block and the solenoid link-
age easily travels between the stop screw
and the fuel solenoid internal stop.
If adjustment is necessary, loosen the so-
lenoid mounting screws and push the so-
lenoid bracket back toward engine as far
Tighten mounting screws when as possible.
solenoid is in correct position. Continue pushing on solenoid bracket in
a clockwise direction while tightening
mounting screws.
4 Shutdown Lever
5 Stop screw
6 Stop Screw Jam Nut
7 Fuel Solenoid Jam Nut
8 Plunger
. Stop screw is factory-set and should
not be adjusted.
Hold throttle solenoid in idle (energized)
position. If shutdown lever is touching or
within 1/16 in. of stop screw, fuel solenoid
is properly adjusted.
If lever is more than 1/16 in. from stop
screw, check for clearance between jam
nut and fuel solenoid. If there is clearance
8 between jam nut and solenoid, loosen nut
and turn plunger clockwise until lever
touches stop screw. Retighten nut.
If there is no clearance between jam nut
6 5 and solenoid, loosen the solenoid mount-
7 ing screws and reposition the solenoid as
described at the beginning of this section.
4
! Stop engine.
If the engine does not stay at idle
speed, verify the the throttle sole-
noid and linkage is installed proper-
ly.
Adjusting Throttle Solenoid
1 Throttle Solenoid
2 Jam Nut
3 Solenoid Link
4 Shoulder Bolt
5 Throttle Lever
6 Solenoid Rod
1 2 3 5 7 Throttle Solenoid Mounting
Screw
Loosen jam nut, remove shoulder
bolt, and remove link from throttle
lever. Install link 5/8 in. (16 mm) on
solenoid rod. Reconnect link to
shoulder bolt and throttle lever.
4
Push solenoid rod into idle (ener-
gized) position and check for non-
binding lateral movement of throttle
link at throttle lever. If link binds,
6 loosen solenoid mounting screws.
Move the solenoid slightly until the
link moves freely with solenoid in
relaxed and energized positions.
Tighten screws.
Tighten jam nut.
Tools Needed:
Tools Needed:
3/8, 7/16 in.
10, 14 mm
Ref. 804 197-A / 801 963
. Supplementary protectors
CB1 and CB3 protect the stator
winding supplying 115 volt ac
output to Remote Receptacle
RC4 (see Section 5-9).
Press button to reset.
2 Circuit Breaker CB7
CB7 protects the engine glow plug
circuit. If CB7 opens, the glow plug
does not heat. CB7 automatically
resets when the fault is corrected.
3 Supplementary Protector CB8
CB8 protects the engine battery cir-
cuit. If CB8 opens, the engine will
not crank. CB8 automatically re-
sets when the fault is corrected.
Trouble Remedy
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-2 and 6-6).
Check and secure connections to Remote receptacle RC4 (see Sections 5-9).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Increase front panel and/or remote voltage/amperage control settings (see Sections 6-2 and 6-6).
Clean and/or replace fuel filter and inline fuel strainer as necessary (see Section 8-3)
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Weld output cannot be adjusted. Have Factory Authorized Service Agent check field current control board PC2.
Check shielding gas, ensure proper shielding gas coverage while welding.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
No remote voltage/amperage control. Check and tighten connections to Remote receptacle RC4 (see Section 5-9). Check and secure lead
connections to remote control.
No front panel voltage/amperage con- Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
trol. 5-9).
No 24 volt ac power output at Remote Reset supplementary protector CB4 (see Section 8-5).
receptacle RC4.
No 115 volt ac power output at Remote Reset supplementary protector(s) CB1 and/or CB3 (see Section 7-1).
receptacle RC4.
Lack of high frequency; difficulty in Use proper size tungsten for welding amperage.
establishing Gas Tungsten Arc Weld-
ing arc.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld.
B. Generator
Trouble Remedy
No power output. Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 7-1).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Clean and/or replace fuel filter and inline fuel strainer as necessary (see Section 8-3)
High power output. Check engine speed, and adjust if necessary (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
C. Engine
Trouble Remedy
Engine does not crank. Supplementary protector CB8 may be open (see Section 8-5). Wait and retry.
Check plug Engine Control switch and engine wiring harness connections.
Have Factory Authorized Service Agent check Engine Control switch S2 or circuit breaker CB8.
Engine cranks but does not start. Check fuel level (see Section 6-1).
Service inline fuel strainer and fuel filter (see Section 8-3).
Have Factory Authorized Service Agent check glow Plug switch S6, glow plug, and control relay CR3.
Engine starts but stops when Engine Check oil level (see Section 5-6). Engine will not start if oil pressure is too low.
Control switch S2 returns to Run/Idle
position.
Check coolant level and fan belt (see Section 5-6 and engine manual). Engine will not start if engine
temperature is too high.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Sec-
tion 5-6).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem-
perature switch S4.
Engine does not stop. Stop engine by closing fuel valve (see Section 5-6). Adjust shutdown solenoid (see Section 8-4).
Engine stopped during normal Check fuel level (see Section 6-1).
operation.
Check oil level (see Section 5-6). Engine stops if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual). Engine stops if engine temper-
ature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem-
perature switch S4.
Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.
Replace battery.
Engine does not return to idle speed Remove all weld and generator power loads.
when load is removed with Engine
Control switch in Run/Idle position.
Have Factory Authorized Service Agent check current transformer CT1, idle lock switch S7, throttle
solenoid TS1, and Engine Control switch S2.
Engine does not remain at weld/power Check for obstructed movement of solenoid linkage (see Section 8-4).
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Have Factory Authorized Service Agent check control relay CR2, control relay CR4, current trans-
former CT1, and throttle solenoid TS1.
Engine does not remain at idle speed Check for obstructed movement of solenoid linkage (see Section 8-4).
with Engine Control switch in Speed
Lock position and Idle Lock switch in
Idle position.
Have Factory Authorized Service Agent check control relay CR2, control relay CR4, Idle Lock switch
S7, and throttle solenoid TS1.
Engine uses oil during run-in period; Dry engine (see Section 11).
wetstacking occurs.
Dia. Part
Mkgs. No. Description Quantity
Notes
1.00
Weld
0.75 3600
RPM
0.50
0.25 Idle
0.00
0 50 100 150 200 250 300
DC Weld Ampers At 100% Duty Cycle
1.20
1.00
US Gal./Hr.
0.80
0.60
0.40
Idle
0.20
0.00
0 1 2 3 4 5 6 7 8 9 10
Auxiliary Power Kilowatts At 100% Duty Cycle
300 150
250 125
200 100
AC Volts
150 75
100 50
50 25
0 0
0 20 40 60 80 100 120 140
AC Amperes At 120 V
0 10 20 30 40 50 60 70
AC Amperes At 240V
226 760-A
207 925
70
60
50
Volts
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500
Amps
80
70
60
50
Volts
40
30
20
10
0
0 50 100 150 200 250 300 350
Amps
90
80
70
60
50
Volts
40
30
20
10
0
0 50 100 150 200 250 300
Amps
60
50
40
Volts
30
20
10
0
0 50 100 150 200 250 300 350
Amps
30
25
Volts
20
15
10
0
0 100 200 300 400 500 600 700
Amps
226 757-A
OR
800 652-D
1 Equipment Grounding
1 2 Terminal
GND/PE 2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
. Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
2 3 power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
3 sistive load and requires approxi-
VOLTS 115 mately six times more power while
2 AMPS 4.5 starting the motor than when running
1 Hz 60 (see Section 13-8).
3 Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
3 Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
. Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
5
ages.
1 Utility Electrical Service
Essential
Loads 2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 13-4).
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
WELD JOINT
TYPES
GROOVE FILLET
WELD POSITION:
FLAT
BUTT
1G
T−JOINT
1F
HORIZONTAL
BUTT
2G
T−JOINT
2F
VERTICAL
BUTT
3G
T−JOINT
3F
OVERHEAD
BUTT
4G
T−JOINT
4F
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.