Big Blue 300 D PRO 300 D: OM-236 949A Processes
Big Blue 300 D PRO 300 D: OM-236 949A Processes
Big Blue 300 D PRO 300 D: OM-236 949A Processes
2008−02
Processes
Stick (SMAW) Welding
Description
PRO 300 D
Mil_Thank 2005−04
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.
Shut off shielding gas supply when not in use.
Wear approved ear protection if noise level is
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. STEAM AND HOT COOLANT can burn.
Always wear a face shield, rubber gloves, and If possible, check coolant level when engine is
protective clothing when working on a battery. cold to avoid scalding.
Stop engine before disconnecting or connect- Always check coolant level at overflow tank, if
ing battery cables or servicing battery. present on unit, instead of radiator (unless told
Do not allow tools to cause sparks when working on a battery. otherwise in maintenance section or engine
manual).
Do not use welder to charge batteries or jump start vehicles.
If the engine is warm, checking is needed, and there is no over-
Observe correct polarity (+ and −) on batteries. flow tank, follow the next two statements.
Disconnect negative (−) cable first and connect it last. Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
FUEL can cause fire or explosion. completely removing cap.
Do not use compressed air for breathing. Release air pressure from tools and system be-
Use only for cutting, gouging, and tools. fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
Porteur de simulateur cardiaque ou autre im- Tenir les bouteilles éloignées des circuits de soudage ou autres
plants médicaux, rester à distance. circuits électriques.
Les porteurs d’implants doivent d’abord consulter leur médecin Ne jamais placer une torche de soudage sur une bouteille à gaz.
avant de s’approcher des opérations de soudage à l’arc, de sou- Une électrode de soudage ne doit jamais entrer en contact avec
dage par points, de gougeage, du coupage plasma ou de chauf- une bouteille.
fage par induction.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
Si des BOUTEILLES sont endomma- tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
gées, elles pourront exploser.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
Des bouteilles de gaz protecteur contiennent du gaz bouteille.
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de gaz font Maintenir le chapeau de protection sur la soupape, sauf en cas
normalement partie du procédé de soudage, les manipuler avec d’utilisation ou de branchement de la bouteille.
précaution. Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Lire et suivre les instructions sur les bouteilles de gaz comprimé,
des chocs mécaniques, des dommages physiques, du laitier, des l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
flammes ouvertes, des étincelles et des arcs. Association) mentionné dans les principales normes de sécurité.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en DES PIÈCES CHAUDES peuvent
dernier lieu. provoquer des brûlures graves.
Ne pas toucher à mains nues les parties chau-
LE CARBURANT MOTEUR peut pro- des.
voquer un incendie ou une explosion. Prévoir une période de refroidissement avant de
Arrêter le moteur avant de vérifier le niveau de travailler à l’équipement.
carburant ou de faire le plein. Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
Ne pas faire le plein en fumant ou proche d’une source d’étincel- dés et porter des gants de soudage et des vêtements épais pour
les ou d’une flamme nue. éviter les brûlures.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion. LA VAPEUR ET LE LIQUIDE DE
Faire attention de ne pas renverser de carburant. Nettoyer tout
REFROIDISSEMENT CHAUD peuvent
carburant renversé avant de faire démarrer le moteur. provoquer des brûlures.
Jeter les chiffons dans un récipient ignifuge. Il est préférable de vérifier le liquide de refroi-
Toujours garder le pistolet en contact avec le réservoir lors du dissement une fois le moteur refroidi pour éviter
remplissage. de se brûler.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
tilly, VA 20151 (téléphone : 703-788-2700, site Internet : and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
www.cganet.com). tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
Code for Safety in Welding and Cutting, CSA Standard W117.2, de ne de la région 5, Chicago, est 312-353-2220, site Internet :
Canadian Standards Association, 5060 Mississauga, Ontario, Canada www.osha.gov).
+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 0 − 200A
50 h Std.
Notes
Certified/Trained
Positive Negative Welding Arc
Mechanic
A Amperes
V Volts Panel/Local Remote
Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature
h s 1
Time Hours Seconds Single Phase
3
Read Operator’s Do Not Switch
Three Phase Circuit Protector
Manual While Welding
Engine-Driven,
Electrode
Connection
Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz
n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current
Weight
D F
With fuel: 1290 lb (585 kg) E
No fuel: 1208 lb (548 kg)
70
60
Max
DC Volts
50
40
30 Min
20
10
0
0 100 200 300 400 500
DC Amperes
B. MIG Mode
100
90
80
70
60
DC Volts
50
Max
40
30
20
Min
10
0
0 100 200 300 400 500
DC Amperes
C. TIG Mode
100
90
80
70
60
DC Volts
Max
50
40
30 Min
20
10
0
0 100 200 300 400 500
DC Amperes
2.00
1.75
1.50
U.S. GAL/HR.
1.25
1.00
0.75
0.50
Idle
0.25
0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE
237 299
1000
800
600
WELD AMPERES
500
400
CC
300 CV
250
200
150
100
10 15 20 25 30 40 50 60 80 100
% DUTY CYCLE
217 515
75 150
50 100
25 50
0 0
0 20 40 60 80
AC AMPERES IN 240 V MODE
0 40 80 120 160
AC AMPERES IN 120 V MODE
237 303
Location/Airflow Clearance
OR OR
18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)
18 in
18 in (460 mm)
(460 mm)
install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
2 3
Tools Needed:
9/16 in
install3 2008--01 803 274 / 200 864-A / 803 231
Tools Needed:
1/2 in 803 582 / Ref. 217 357-A
Notes
+
6
−
Tools Needed: 30 A
drybatt 12008−01 − S-0886
Tools Needed:
1/2 in
Full
Full
Diesel
Capacity:
6 qt (5.7 L)
Hot Full
Cold Full
Full
805 177-A
Check all engine fluids daily. Engine stops if fuel level is low. freeze to mixture if using the unit in tempera-
tures below −34° F (−37° C).
Engine must be cold and on a level surface. Oil
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if Keep radiator and air intake clean and free
After fueling, check oil with unit on level sur- of dirt.
oil pressure is too low or coolant tempera- face. If oil is not up to full mark on dipstick,
ture is too high. add oil (see maintenance label).
NOTICE − Incorrect engine temperature
This unit has a low oil pressure shut- can damage engine. Do not run engine with-
down switch. However, some condi- Coolant
out a properly working thermostat and ra-
tions may cause engine damage before diator cap.
the engine shuts down. Check oil level Check coolant level in radiator before start-
often and do not use the oil pressure ing unit the first time. If necessary, add cool-
shutdown system to monitor oil level. ant to radiator until coolant level is at bottom To improve cold weather starting:
of filler neck.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust Use Preheat switch (see Section 6-1).
Check coolant level in recovery tank daily.
pipe during run-in, see Section 10.
If necessary, add coolant to recovery tank Keep battery in good condition. Store
Fuel until coolant level is between Cold Full and battery in warm area.
NOTICE − Do not use gasoline. Gasoline Hot Full levels. If recovery tank coolant level
will damage engine. was low, also check coolant level in radiator. Use fuel formulated for cold weather
The unit is shipped with enough fuel to pre- Add coolant if level is below bottom of radia- (diesel fuel can gel in cold weather).
vent air from entering fuel system. Add fresh tor filler neck. Contact local fuel supplier for fuel in-
diesel fuel before starting (see engine main- formation.
tenance label for fuel specifications). Leave Unit is shipped with an engine coolant mix-
filler neck empty to allow room for ture of water and ethylene glycol base anti- Use correct grade oil for cold weather
expansion. freeze rated to −34° F (−37° C). Add anti- (see Section 8-2).
! Stop engine.
1 Work/Negative (−) Weld Output Terminal
2 CV (wire) Weld Output Terminal
3 CC (Stick/TIG) Weld Output Terminal
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
4 Weld Output Terminal
5 Supplied Weld Output Terminal Nut
6 Weld Cable Terminal
7 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur- 2
faces of the weld cable terminal and cop- 3
per bar are clean. 1
Tools Needed:
3/4 in
1 2 3
7
4
Do not place
anything between
weld cable terminal
and copper bar.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Stop engine before
connecting to weld
output terminals. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
! Do not use worn, dam- (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
aged, undersized, or
poorly spliced cables.
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
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.
Notes
Notes
Welding Symbols
Ref. AWS/ANSI A2.4
8 9
5
6 7 1 2 3 4
Engine Starting Controls To check fuel level or engine hours when en- 6 Process/Contactor Switch
1 Preheat Switch gine is not running, turn Engine Control switch See Section 6-3 for Process/Contactor
to Run position. switch information.
Use switch to energize starting aid for cold
weather starting (see starting instructions fol- 4 Engine Indicator Light 7 Voltage/Amperage Control
lowing). Light goes on and engine stops if fuel is low, With Process/Contactor switch in any Stick or
2 Engine Control Switch engine temperature exceeds 230° F (110° C) TIG setting, use control to adjust amperage.
or engine oil pressure is below 10 psi (69 With Process/Contactor switch in any Wire
Use switch to start engine, select engine kPa).
speed (if unit has auto idle option), and stop (MIG) position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Re-
engine. Normal engine temperature is 180 - 203 mote position, control limits the remote am-
In Run position, engine runs at weld/power F (82 - 95 C). Normal oil pressure is 30 perage in Stick or TIG mode, but has no effect
speed. In Auto position (optional), engine - 60 psi (207 - 414 kPa). in Wire (MIG) modes.
runs at idle speed at no load and weld speed
with load applied. NOTICE − Do not run engine until trouble is Weld Meters
fixed.
To Start: Weld meters also work in combination to
Weld Controls display troubleshooting help codes (see
NOTICE − Do not use ether.
5 Remote Control Receptacle Section 8-10).
If engine does not start, let engine come 8 DC Voltmeter
to a complete stop before attempting re- Use receptacle to connect remote controls,
start. wire feeders, and tools. Voltmeter displays preset voltage (MIG weld-
ing) with contactor off, and actual output volt-
Above 325 F (05 C): turn Engine Control When a remote control is connected to the age with the contactor on. Voltmeter displays
switch to Start. Release Engine Control Remote receptacle, the Auto Sense Remote voltage at the weld output terminals, but not
switch when engine starts. feature automatically switches voltage/am- necessarily the welding arc due to resistance
perage control to the remote control (see Sec- of cable and connections.
Below 325 F (05 C): turn engine control switch tion 5-11).
to Auto position. Push Preheat switch up for To set voltage, turn contactor off and turn Pro-
6 seconds. Turn Engine Control switch to With remote control connected, weld output is cess/Contactor switch to Wire position. Turn
Start. Release Engine Control switch and determined by a combination of front panel V/A control until desired voltage is displayed
Preheat switch when engine starts. and remote control voltage/amperage set- on Voltmeter. When welding is finished, volt-
tings. meter displays weld voltage and then defaults
Do not operate Preheat switch for more to preset voltage.
than 60 seconds at a time. If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am- 9 DC Ammeter
To Stop: turn Engine Control switch to Off perage control adjusts voltage and amper-
position. age. Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
Engine Gauges, Meters, And Lights
If a remote device connected to Remote output amperage when welding.
See Section 6-6 for complete fuel/hour Receptacle RC14 is faulty or is discon- To set amperage, turn Process/Contactor
gauge information. nected during operation, the meters dis- switch to Stick or TIG position. Turn V/A con-
play Help 25 (see Section 8-10). Clear trol until desired amperage is displayed on
3 Fuel/Hour Gauge
fault by stopping and restarting the unit or Ammeter. When welding is finished, ammeter
Use gauge to check fuel level, total engine op- by turning Process/Contactor switch to displays weld amperage and then defaults to
erating hours, or hours to oil change. another position. preset amperage.
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Stick (SMAW),
Weld Terminals Always On −
Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
Stick
And Gouging
OR
1 2 3
WM Marketing
In Example:
Min = 20 A DC
Max = 205 A DC
1 2 3 4 5 6
217 357-A
1 120 V 20 A AC (shown)
Receptacle RC5 and/or GFCI1
At least once a month, run engine at overload. If CB5 opens, the receptacles do
not work. Place CB5 switch in On position
weld/power speed and press test but-
2 120 V 20 A AC GFCI (shown) to reset circuit breaker.
ton to verify GFCI is working properly.
Receptacle RC6 and/or GFCI2
RC11 supplies 60 Hz single-phase power If a supplementary protector continues
3 240 V 50 A AC at weld/power speed. Maximum output to open, contact Factory Authorized
Receptacle RC11 from RC11 is 10 kVA/kW. Service Agent.
RC5 / 6 and GFCI1 / 2 supply 60 Hz single-
phase power at weld/power speed. Recep-
4 Supplementary Protector CB4 Generator power decreases as weld
tacle configuration varies depending on 5 Supplementary Protector CB6 output increases.
machine model and serial number.
6 Supplementary Protector CB5 Combined output of all receptacles is limit-
Maximum output from these receptacles is ed to the 10 kVA/kw rating of the generator.
2.4 kVA/kW. CB4 protects RC6 / GFCI2 and CB6 pro-
tects RC5 / GFCI1 from overload. If a sup- EXAMPLE: If 15 A is drawn from each 120
If a ground fault is detected, GFCI Reset plementary protector opens, the receptacle V receptacle , only 26 A is available at the
button pops out and receptacle does not does not work. Press button to reset. 240 V receptacle:
work. Check for faulty equipment plugged
in receptacle. Press button to reset GFCI Supplementary protector CB5 protects re- 2 x (120 V x 15 A) + (240 V x 26 A) =
receptacle. ceptacles and the generator winding from 10.0 kVA/kW
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.
Weld Terminals
Every Section 8-3
100
Hours
Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor
Every
500
Hours
Slip Rings*
Brushes*
Every
2000
Hours
Injectors*
! Stop engine.
NOTICE − Do not run engine without air
1 3 4 cleaner or with dirty element. Engine
2
damage caused by using a damaged ele-
ment is not covered by the warranty.
aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A
805 177-A
1
805 177-A / 802 490 / Ref. 801 434
! Stop engine.
5 6
Replace
Damaged Brushes
NOTICE − Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with adjustments may affect engine
warranty.
Notes
MATERIAL THICKNESS REFERENCE CHART
HL.P 21
ry Authorized Service Agent check
PC1, PC2, and the wiring between
PC1 and PC2.
2 Help 21 Display
3
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
25
before restarting. If problem contin-
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).
A. Welding
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles. On/Off Switch Required position and turn remote contactor on (see Section 5-11).
Reset supplementary protector CB7 or CB8 (see Section 8-7). Check for faulty remote device connected
to RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 5-11).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.
Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit.
Erratic weld output. Check and tighten connections inside and outside unit.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.
Low weld output. Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.
Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the rotor.
Low open-circuit voltage. Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-11).
No 24 volt or 115 volt ac output at Re- Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 8-7).
mote receptacle RC14.
Trouble Remedy
No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1).
tacles; weld output okay.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check field
excitation circuit.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Have Factory Authorized Service Agent check field excitation circuit.
ceptacles.
Low output at generator power ac recep- Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.
tacles.
Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the rotor.
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-7).
Have Factory Authorized Service Agent check engine wiring harness and components.
Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel
pump.
Engine hard to start in cold weather. Use Preheat switch (see Section 6-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-2).
Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.
Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-8 ).
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-7).
Reset supplementary protector CB2 (see Section 8-7). Have Factory Authorized Service Agent check
engine alternator, engine harness, fuel valve, and the fuel pump.
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-
grated rectifier SR2, fuel valve, and the fuel pump.
Check engine air and fuel filters (see Sections 8-3 and 8-6).
Battery discharges between uses. Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Engine idles, but does not come up to Have Factory Authorized Service Agent check fuel/hour gauge and current transformer CT1.
weld speed (units with idle option only).
Engine does not run at idle speed Have Factory Authorized Service Agent check fuel/hour gauge, and control relay CR4.
(units with idle option only).
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.
Notes
10-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
1
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
S-0683
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
6
! Keep exhaust and pipe away
from flammables.
2
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
1 Resistance Grid
Use grid sized for generator rated
1 output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
4 current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
+ Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
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 11-8).
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 11-4).
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)
6
7 16
15
8 17
18
9
10 19
11 26
5 20
12 25
14 21
13
22 23 24
4 (Fig.15−5)
3
2
1
100
101
110 102
103
105
104
106
35 37
41
27 36
40
39
76
77 38
73
78 75 45
72
74 47
48 49 46
50
87 51
59
79 (Fig 12−4) 70 58
63 52
71 64 53
69 65 62 57
88 86 68
61 56 54
85 60
80
66
67
84 55
83 81
82
805 178-A
11
10
12
8 9
13
7 14
15
5 16
25
4 23 24
17
24
3 26
1 2 18 27
22
37
36 19
20
35 21
28
29
30
31
34
32
33
803 684-C
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
1
8
10
805 180-A
11
Figure 12-3. Control Panel
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
8
9
10
11
12
13
14
20 19 18
17
16 805 179-A
15
3
2
10
9
803 685-A
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 949 Page 67
Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.
Wiring Harnesses
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.