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Connecting The Battery 1/2 in ST-156 011-A / Ref. ST-188 448 / S-0756 + – Connect Negative (–) Cable Last. Tools Needed: OM-480 Page 15 4-3. Installing Muffler Pipe exh_pipe2 12/96 – ST-154 089-A / ST-154 611 / Ref. ST-188 448 Stop engine and let cool. Do not blow exhaust toward air cleaner or air intake. Top View 1/2 in Tools Needed: 4-4. Engine Prestart Checks Ref. ST-800 159-D Full 1/2 in (13 mm) Full Diesel Valve Open Check all fluids daily. Engine must be cold and on a level surface. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 9. Fuel Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Open fuel shut-off valve. Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Your unit may have the optional low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. To improve cold weather starting: Keep battery in good condition. Store battery in warm area off concrete 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. 4-5. Installing Ether Cylinder (Optional Ether Starting Aid) 5 4-6. Connecting To Weld Output Terminals . Stop engine. . Improper handling or exposure to ether can harm your health. Follow manufacturer’s safety instructions on cylinder. 1 . Do not use Ether Starting Aid while engine is running. Open side door(s). 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle. 2 3 Clamp 4 Fitting 5 Cap 6 Valve 3 Remove cap and clean fitting. 4 Install cylinder on fitting. Tighten clamp. . After installing cylinder, wait at least 10 minutes before using 6 to let ether particles settle and prevent atomizer plugging. Put cap on fitting when cylinder is removed. ether1 12/96 – ST-153 382-A / Ref. ST-188 448 Ref. ST-800 162-A Open left side door. 1 Bracket Route cables through bracket. 2 Positive (+) Weld Output Terminal 3 Negative (–) Weld Output Terminal For Stick welding Direct Current Electrode Positive (DCEP), connect work cable to (–) terminal and electrode holder cable to (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections. If equipped with optional polarity switch, connect electrode holder cable to Electrode (–) terminal and work cable to Work (+) terminal. For FCAW welding, connect work cable to (–) terminal and wire feeder cable to (+) terminal. Close door. Tools Needed: 3/4 in 1 2 3 OM-480 Page 16 4-7. Selecting Weld Cable Sizes Welding Amperes AmperesAmperes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0 Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E OM-480 Page 17 OM-480 Page 18 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (See Section 5-2) Ref. ST-188 448 / ST-800 162-A / ST-800 159-D 1 2 12 13 5 3 4 7 6 10 11 9 8 14 15 5-2. Description Of Front Panel Controls (See Section 5-1) This unit has a max OCV control circuit that resets the Amperage/Voltage Control to maximum when the arc breaks. When an arc is struck, weld output control returns to the front panel or remote control setting. The Amperage/voltage Control adjusts amperage only when welding and does not adjust open-circuit voltage. 1 Ampere Range Switch Use switch to select weld amperage range. For most welding applications, use lowest amperage range possible to prevent arc outages. Do not switch under load. 2 Amperage/Voltage Control Control adjusts amperage within range selected by Ampere Range switch. Weld output would be 140 A DC with controls set as shown (50% of 90 to 190 A). 3 DC Voltmeter (Optional) 4 DC Ammeter (Optional) 5 Remote A/V Switch And Receptacle (See Section 5-3) 6 Magnetic Shutdown Switch (Optional) Use switch during start-up to bypass optional engine shutdown system. System stops engine if oil pressure is too low or oil temperatur...