OM-945 Page 20
5-8. Connecting To Weld Output Terminals
803 778-A / Ref. 226 427-A
Tools Needed:
4
2
3
Do not place
anything between
Correct Installation
Incorrect Installation
1
weld cable terminal
and copper bar.
3/4 in
!
Stop engine.
!
Failure to properly connect
weld cables may cause ex-
cessive heat and start a fire,
or damage your machine.
1
Weld Output Terminal
2
Supplied Weld Output
Terminal Nut
3
Weld Cable Terminal
4
Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per bar.
Do not place anything
between weld cable terminal
and copper bar. Make sure that
the surfaces of the weld cable
terminal and copper bar are
clean.
5-9. Selecting Weld Cable Sizes*
Weld Cable Size** and 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)
Weld Output
Terminals
Welding
Amperes
10
−
60%
Duty
Cycle
60
−
100%
Duty
Cycle
10
−
100% Duty 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)
!
Stop engine before
connecting to weld
output terminals.
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120) 2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
!
Do not use worn, dam-
aged, undersized, or
l li d bl
output terminals.
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120) 2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
g ,
,
poorly spliced cables.
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120) 2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120) 2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
*
This chart is a general guideline and may not suit all applications. If cable overheating occurs, 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.
( ) = mm
2
for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 1-800-332-3281.
