A-5
INSTALLATION
CROSS COUNTRY 300
ELECTRICAL CONNECTIONS
Machine Grounding
Because this portable engine driven welder creates its own power, it
is not necessary to connect its frame to an earth ground, unless the
machine is connected to premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment to which this
engine driven welder supplies power must:
• Be grounded to the frame of the welder using a
grounded type plug.
• Be double insulated.
• Do not ground the machine to a pipe that carries
explosive or combustible material.
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When this welder is mounted on a truck or trailer, its frame must be
electrically bonded to the metal frame of the vehicle. Use a #8 or
larger copper wire connected between the machine grounding stud
and the frame of the vehicle. When this engine driven welder is
connected to premises wiring such as that in a home or shop, its
frame must be connected to the system earth ground. See
further connection instructions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal water pipe going into the ground for at least ten feet
and having no insulated joints, or to the metal framework of a building
which has been effectively grounded.
The National Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding stud marked
with the symbol is provided on the front of the welder.
Welding OUTPUT Cables
With the engine off connect the electrode and work cables to the
output studs. The welding process dictates the polarity of the
electrode cable. These connections should be checked periodically
and tightened with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths for rated current
and duty cycle. Length refers to the distance from the welder to the
work and back to the welder. Cable diameters are increased for long
cable lengths to reduce voltage drops.
TABLE A.1
Cable Installation
Install the welding cables to your CROSS COUNTRY 300
as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals
3. Connect the electrode holder and work cables to the weld
output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the “work”) is
properly connected to the work clamp and cable.
6. Check and tighten the connections periodically.
WARNING
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
2 / 0 AWG
3 / 0 AWG
