Miller Metro 300DXQ User manual

October 1996 Form: OM-156 368D
Effective With Serial No. KG212352
OWNER’S
MANUAL
cover_om 4/95 – Ref. ST-158 934-B PRINTED IN USA
1996 MILLER Electric Mfg. Co.
Metro300DXQ
CC/DC Welding Generator For SMAW And GTAW Welding
Rated Welding
Output Amperage
Range
Maximum
Open-Circu
it Voltage
DC
Auxiliary
Power Rating Engine Fuel Capacity Sound Power IP Rating
280 A, 31 V DC,
35% Duty Cycle
250 A, 30 V DC,
60% Duty Cycle
225 A, 29 V DC,
100% Duty Cycle
20 – 280 61
(Average)
Single-Phase/
3-Phase,
7/10 kVA/kW,
32/15 A,
220/380 V AC,
50 Hz
Ruggerini RD211
Air-Cooled,
Two-Cylinder, 20
HP Diesel Engine
11.8 US gal
(44.6 L) 98 Lwa 23

dec_con1 1/96
Declaration of Conformity for
European Community (CE) Products
ThisinformationisprovidedforunitswithCEcertification(seeratinglabelonunit).
NOTE
Manufacturer’s Name: Miller Electric Mfg. Co.
Manufacturer’s Address: 1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product: METRO300DXQ
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC,91/368/EEC, 93/C 133/04, 93/68/EEC
Noise Emission Directive: 79/113/EEC
Noise level of Welding Generators: 84/535/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1990
Rotating Electrical Machines – Part 1: Rating and Performance: IEC 34-1: 1994
Rotating Electrical Machines – Part 5: Classification of degrees of protection provided by enclosure of rotating
electrical machines (IP code): IEC 34-5: 1991
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and test: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
European Contact: Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone: [phone]
Fax: [phone]

OM-156 368D – 10/96
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Installation, Operation, And Maintenance Hazards 3. . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Welding Generator 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Activating The Dry Charge Battery 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Connecting Battery And Installing Exhaust Pipe 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Engine Prestart Checks 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Weld Output Terminals And Selecting Cable Sizes 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote 14 Receptacle RC1 Information 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATING THE WELDING GENERATOR 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle And Overheating 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote Amperage And Contactor Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATING AUXILIARY EQUIPMENT 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Auxiliary Power Receptacles 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MAINTENANCE & TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Maintenance Label 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Changing Engine Oil And Oil Filter 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Changing Fuel Filters 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Servicing Air Cleaner 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Adjusting Engine Speed 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Overload Protection 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Servicing Optional Spark Arrestor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – ELECTRICAL DIAGRAM 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – RUN-IN PROCEDURE 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Wetstacking 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Run-In Procedure Using Load Bank 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Run-In Procedure Using Resistance Grid 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – AUXILIARY POWER GUIDELINES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – PARTS LIST 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-156 368 Page 1
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible haz-
ards with this procedure! The possible hazards are
shown in the adjoining symbols.
YMarks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible ELEC-
TRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Con-
sultsymbolsandrelatedinstructionsbelowfornecessaryactionsto
avoid the hazards.
1-2. Arc Welding Hazards
YThe symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
seethesymbol,watchout,andfollowtherelatedinstructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
YDuringoperation,keepeverybody,especiallychildren,away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automaticwire welding,thewire,wirereel, driverollhousing,andall
metalpartstouchingtheweldingwireareelectricallylive.Incorrectly
installed or improperly grounded equipment is a hazard.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulateyourselffromworkandgroundusing dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
DDonotuseACoutputindampareas,ifmovementisconfined,orif
there is a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DDisconnectinput powerorstop enginebeforeinstallingorservic-
ing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
DProperly install and ground this equipment according to its Own-
er’s Manual and national, state, and local codes.
DAlways verify the supply ground – check and be sure that input
powercordgroundwireisproperlyconnectedtoground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
DWhen making input connections, attach proper grounding con-
ductor first – double-check connections.
DFrequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
DTurn off all equipment when not in use.
DDonotuseworn,damaged,undersized,orpoorlysplicedcables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
DDonottouchelectrodeifyouareincontactwiththework,ground,
or another electrode from a different machine.
DUseonlywell-maintainedequipment.Repairorreplacedamaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClampworkcable withgoodmetal-to-metalcontacttoworkpiece
or worktable as near the weld as practical.
DInsulateworkclampwhennot connectedtoworkpieceto prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
single weld output terminal.
Arc rays from the weldingprocess produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly offfrom the
weld.
ARC RAYS can burn eyes and skin.
DWearaweldinghelmetfittedwithapropershadeoffiltertoprotect
your face and eyes from arc rays and sparks when welding or
watching(seeANSIZ49.1andZ87.1listedinSafetyStandards).
DWear approved safety glasses with side shields under your hel-
met.
DUseprotectivescreensorbarrierstoprotectothersfromflashand
glare; warn others not to watch the arc.
DWearprotectiveclothingmadefromdurable,flame-resistantma-
terial (wool and leather) and foot protection.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMESAND GASES canbe hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use exhaust at the arc to re-
move welding fumes and gases.
DIf ventilation is poor, use an approved air-supplied respirator.
DRead the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
DWorkinaconfinedspaceonlyifitiswellventilated,orwhilewear-
inganair-suppliedrespirator.Alwayshaveatrainedwatchperson
nearby. Weldingfumes andgases candisplace airand lowerthe
oxygen level causing injury or death. Be sure the breathing air is
safe.
DDo not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
DDo not weld on coated metals, such as galvanized, lead, or cad-
mium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing
an air-supplied respirator. The coatings and any metals contain-
ing these elements can give off toxic fumes if welded.

OM-156 368 Page 2
Welding on closed containers, such as tanks,
drums,orpipes,cancausethemtoblowup.Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
causesparks,explosion,overheating,orfire.Checkandbesurethe
area is safe before doing any welding.
WELDINGcancausefireorexplosion.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Removeallflammables within 35 ft (10.7m)ofthe welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
Donotweld onclosedcontainers suchastanks,drums, orpipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Removestickelectrodefromholderorcutoffweldingwireatcon-
tact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
Welding,chipping,wirebrushing,andgrinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
MAGNETICFIELDScanaffectpacemakers.
Pacemaker wearers keep away.
Wearersshouldconsulttheirdoctorbeforego-
ingneararcwelding,gouging,orspotwelding
operations.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Sincegascylindersarenormallypartofthewelding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
Protectcompressedgascylindersfromexcessiveheat,mechan-
ical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keepcylindersawayfrom anyweldingorotherelectrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keepprotectivecapinplaceovervalveexceptwhencylinderisin
use or connected for use.
Readandfollowinstructionsoncompressedgascylinders,asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking
or adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank – allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
STEAMANDHOT COOLANT can burn.
Ifpossible,checkcoolantlevelwhenengineis
cold to avoid scalding.
If the engine is warm and checking is needed,
follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turncapslightlyandletpressureescapeslowlybeforecomplete-
ly removing cap.

OM-156 368 Page 3
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Haveonlyqualifiedpeopleremoveguardsorcoversformainte-
nance and troubleshooting as necessary.
Topreventaccidentalstartingduringservicing,disconnectneg-
ative (–) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Beforeworkingongenerator,removesparkplugsorinjectorsto
keep engine from kicking back or starting.
Blockflywheelso thatitwillnotturn whileworkingongenerator
components.
BATTERY EXPLOSION can BLIND.
Alwayswear afaceshield,rubbergloves,and
protective clothing when working on a battery.
Stop engine before disconnecting or connect-
ing battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
Disconnect negative (–) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-venti-
lated areas.
If used in a closed area, vent engine exhaust
outside and away from any building air in-
takes.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combus-
tible surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor
in required areas – see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear,gascylinders,trailer,oranyother acces-
sories.
Useequipmentofadequatecapacitytoliftand
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shapetungsten electrodeonlyongrinder with
properguardsin a safelocationwearingprop-
er face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERHEATING can damage motors.
Turnofforunplugequipmentbeforestartingor
stopping engine.
Do not let low voltage and frequency caused
by low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz recep-
tacle where applicable.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE han-
dling boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.

OM-156 368 Page 4
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
UseonlygenuineMILLERreplacementparts.
Perform engine maintenance and service ac-
cordingtothismanualandtheenginemanual.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Haveonlyqualifiedpersonsfamiliarwith elec-
tronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the equip-
ment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as com-
puters and computer-driven equipment such
as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
Besurethisweldingmachineisinstalledandgroundedaccord-
ing to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. Principal Safety Standards
Safety in Welding and Cutting , ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards , OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cuttingof ContainersThatHaveHeldHazardousSubstances
,Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code , NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders , CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Weldingand Cutting , CSA Standard W117.2, from
CanadianStandardsAssociation,StandardsSales,178RexdaleBou-
levard, Rexdale, Ontario, Canada M9W 1R3.
S
afePracticesForOccupationAndEducationalEyeAndFaceProtec-
tion
, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes , NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Weldingcurrent,asitflowsthroughwelding cables,willcauseelectro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
yearsofresearch,aspecialblueribboncommitteeof theNationalRe-
search Council concluded that: “The body of evidence, in the
committee’sjudgment,hasnot demonstratedthatexposuretopower-
frequency electric and magnetic fields is a human-health hazard.”
However,studiesarestillgoingforthand evidencecontinuestobe ex-
amined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following proce-
dures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as pos-
sible.
About Pacemakers:
Pacemakerwearersconsultyourdoctorfirst.Ifclearedbyyourdoctor,
then following the above procedures is recommended.

OM-156 368 Page 5
SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
3/96
1 1.1 1.2 1.3
3 3.1 3.2 3.3
4 4.1
S-176 105-A
+
2 2.1 2.2
+5 +
7 7.1 7.2
2.3
+
6 6.1 6.2 6.3
+ =
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Become trained and read the in-
structions before working on the
machine or welding.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Weardryinsulatinggloves.Do
not touch electrode with bare
hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Do not work on unit if engine
is running. Stop engine first.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Do not remove or paint over
(cover) the label.
6 Engine fuel plus flames or
sparks can cause fire.
6.1 Do not smoke while fueling or
if near fuel.
6.2 Stop engine before fueling.
6.3 Do not fuel a hot engine.
7 Engine exhaust gases can kill.
7.1 Vent exhaust outside.
7.2 Use unit outside.

OM-156 368 Page 6
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away
from battery.
3 Sparks can cause battery
gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 Battery acid can burn skin. Do
not spill acid.
5 Read Owner’s Manual.
6 Wear rubber gloves.
7 Dead battery
8 Engine block
9 Fully charged battery
10 Do not connect last negative
cable to dead battery –
connect instead to engine
block.
11 Jumper cables – observe
polarityandmakeconnections
in numbered sequence
shown.
12 Once dead battery is charged,
disconnect cables in
sequence shown.
1
S-176 108
+–
+–
14
23
–+
+–
+–
41
32
2 3 4 5 6
10
11
7
89 12
S-176 106
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury.Keepawayfrommoving
parts.
1
2

OM-156 368 Page 7
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
1
S-176 230
2
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Engine fuel plus flames or
sparks can cause fire.
3 Do not smoke while fueling or
if near fuel.
4 Stop engine before fueling.
5 Do not fuel a hot engine.
6 Use Diesel Fuel only.
S-176 103
DIESEL
+
1
2
4
3
5
6

OM-156 368 Page 8
S-176 104
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Falling equipment can cause
serious injury and damage.
3 Use lifting eye to lift or move
unit only. Use proper
equipment when lifting.
4 Donot use lifting eye to lift and
supportunitandtrailerorother
heavy devices or accessories.
1
2 3 4
3/96
1 Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
2 Read Owner’s Manual. Read
labels on unit.
3 Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
4 Check oil level. Add oil if
necessary.
5 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
During the first 50 hours of
operation, do not exceed 225
amperes of weld output or 7
kVA of auxiliary power output.
6 Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
+
2
1+
4
DIESEL
6
API CD-MIL L 2104D,
SF/CD, CC/CD
2.4 qt (2.3 L)
50 – 50 h Std
0 – 225A 275A
3 ∼50 Hz 0 – 7kVA 10kVA
3
S-176 107-A

OM-156 368 Page 9
3/96
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Ether will damage engine. Do
not use ether as a starting
aid.
3 Read Owner’s Manual.
4 Use glow plugs for 10–25
seconds to aid starting in cold
weather.
1
S-176 109
10 – 25 s
23
4
2-2. Manufacturer’s Rating Label For CE Products
 Rating label shown includes op-
tional 24/48 volt receptacle infor-
mation.

OM-156 368 Page 10
2-3. Symbols And Definitions
Stop Engine Fast
(Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle)
Start Engine Glow Plug Temperature Fuel
Engine Oil 14 Remote 14 Panel/Local On
Check Injectors/
Pump Check Valve Clearance Battery (Engine) VVolts
AAmperes Shielded Metal Arc
Welding (SMAW) Arc Force (DIG) Gas Tungsten Arc Welding (TIG)
G
Engine-Driven,
Single-Phase
Alternator With
Rectifier Engine Read Operator’s
Manual Circuit Breaker
Positive Negative Alternating Current
(AC) Direct Current (DC)
Certified/Trained
Mechanic Time Protective Earth (Ground) Input
Output U0Rated No Load
Voltage (Average) U2Conventional Load Voltage I2Rated Welding Current
nRated Load
Speed n0Rated No Load Speed n1Rated Idle Speed XDuty Cycle
ICurrent PPower 3Three Phase 1Single Phase
hHours sSeconds

OM-156 368 Page 11
SECTION 3 – INSTALLATION
3-1. Installing Welding Generator
install1 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
1
2
Electricallybondgeneratorframeto
vehicle frame by metal-to-metal
contact.
GND/PE
34
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding
Terminal
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI
receptacles, use GFCI-pro-
tected extension cord.
2
OR
OR
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm) 18 in
(460 mm)
18 in
(460 mm)
OR
Movement Airflow Clearance Location
Grounding
3-2. Dimensions, Weights, And Operating Angles
ADimensions
Height 41 in (1041 mm)
Width 30 in (762 mm) Do not exceed operating angles while
r nning or engine damage will occ r
Depth 54-1/2 in (1384 mm) running or engine damage will occur.
Donotmoveoroperateunitwhereitcould
ti
p
.
B
A29 in (737 mm)
tip
.
BB36-3/4 in (933 mm)
C9/16 in (14 mm) Dia. 25°
Weight 25°
15°
C
4 Holes
960 lb (435 kg) 15°
ST-158 938
4
H
o
l
es
angles1 3/96

OM-156 368 Page 12
3-3. Fuel Consumption
SA-175 807

OM-156 368 Page 13
3-4. Activating The Dry Charge Battery
Remove battery from unit.
1 Eye Protection – Safety
Glasses Or Face Shield
2 Rubber Gloves
3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
5 Well
Filleachcellwithelectrolytetobot-
tom of well (maximum).
Do not overfill battery cells.
Wait ten minutes and check elec-
trolytelevel.Ifnecessary,addelec-
trolyte to raise to proper level. Re-
install vent caps.
6 Battery Charger
Read and follow all instruc-
tions supplied with battery
charger.
Chargebatteryfor12minutesat30
amperes or 30 minutes at 5 am-
peres.Disconnectchargingcables
and install battery.
 When electrolyte is low, add
only distilled water to cells to
maintain proper level.
3
Tools Needed:
1
2
4
6
30 A For 12 Minutes
5 A For 30 Minutes
OR
+
–
5
drybatt1 2/96 – S-0886

OM-156 368 Page 14
3-5. Connecting Battery And Installing Exhaust Pipe
ST-801 079-A / Ref. ST-175 920-B
7/16, 1/2 in
+
–
Connect (–)
cable last.
Tools Needed:
Stop engine.
 Installation of exhaust pipe is
optional.
3-6. Engine Prestart Checks
Ref. ST-159 219-D
Check all fluids daily. Unit must be
cold and on a level surface.
Engine stops if oil pressure is low.
Heavy loading during first
50 hours will damage en-
gine. Keep load less than
225A(weld)or7kVA(power)
for first 50 hours.
1 Exhaust Pipe
If unburned fuel and oil collect in
exhaust pipe during run-in, see
Section 8.
Full
Full
1
Diesel