Campbell Hausfeld Welder/Generator User manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
IN952501AV 4/01
Operating Instructions
Welder/Generator
BUILT TO LAST
TM
These units are powered by air-cooled
four cycle engines and designed to run
at maximum RPM and give a
continuous wattage as rated. On
certain models, a low-oil level shutoff
is provided to protect the engine. This
feature is usually associated with
extended run models. The alternator is
thermostatically protected. To operate
this unit as a generator or welder, set
the switch on the front panel
accordingly
When unpacking, inspect carefully for
any damage that may have occurred
during transit. Make sure any loose
fittings, bolts, etc., are tightened
before putting unit into service. Report
any missing items by calling 1-800-746-
5641.
Danger alerts you
to a hazard that
WILL result in death or serious injury
Warning alerts you
to a hazard that
COULD result in death or serious
injury.
Caution alerts you
to a hazard that
MAY result in minor injury.
Notice alerts you
to important
information that will help you prevent
damage to equipment.
●Before starting or
servicing any
welder/generator, read
and understand all
instructions. Failure to
follow safety precautions or
instructions can cause equipment
damage and or serious personal
NOTICE
!
CAUTION
!
WARNING
!
DANGER
injury or death. Engine instructions
for these units are contained in a
separate manual. Retain all manuals
for future reference.
●Never use this welder/generator for
any application other than that
specified by the manufacturer.
Never operate this welder/generator
under conditions not approved by
the manufacturer. Never attempt to
modify this welder/generator to
perform in any manner not
intended by the manufacturer.
●For maintenance and repairs, use
only products and parts
recommended by the manufacturer.
●Be sure that the welder/generator is
properly grounded to an external
ground path prior to operation.
Refer to the section entitled
"Grounding Instructions" for proper
grounding procedures.
●Be sure that the welder/generator is
operated only by persons who have
read and understand these
instructions.
●Be sure that the welder/generator is
placed on a flat level surface prior
to and during operation. The
welder/generator must not slide or
shift during operation.
●Keep all persons away from the
welder/generator during operation.
●Do not allow persons wearing loose
clothing or jewelry to start or
operate the welder/generator.
Loose clothing or jewelry may
become entangled in moving
components, causing equipment
damage and or personal injury.
●Keep all persons away from parts
that move or become hot during
operation.
●Be sure all powered devices are shut
off prior to connecting them to the
welder/generator.
●Keep the welder/generator clean
and well maintained at all times.
Never operate this
welder/generator in an
explosive or flammable
atmosphere or poorly ventilated area.
●Be sure that all tools and appliances
are in good repair and are properly
grounded. Use devices that have
three prong power cords. If an
extension cord is used, be sure that
it has three prongs for proper
grounding.
Do not operate this
welder/generator
on wet surfaces or in the rain.
Shut off the
engine and
disconnect the spark plug wire before
performing any service or maintenance
to the unit.
●Use only unleaded fuel. Do not refill
the fuel tank while the engine is
running. Use precautions to prevent
fuel spillage during refills. Be sure
the fuel tank cap is securely in place
before starting the engine. Clean up
any spilled fuel before starting the
engine. Allow engine to cool for at
least two minutes before refueling.
●This welder/generator may be used
for emergency stand-by service. In
such cases, a manual transfer switch
must be installed between the
electric utilities meter and the
electrical distribution box. This
switch should be installed by a
licensed electrician.
Never mix oil with
gasoline for this
engine. This is a four cycle engine
designed to run on pure gasoline. Oil is
used for engine lubrication purposes
only.
Always keep a fire
extinguisher accessible while
performing arc welding
operations.
!
WARNING
!
CAUTION
!
DANGER
!
WARNING
!
WARNING
MANUAL
© 2001 Campbell Hausfeld For parts, product & service information
visit www.chpower.com or call 1-800-746-5641
Description
Unpacking
General Safety

2
Operating Instructions
●All installation, maintenance, repair
and operation of this equipment
should be performed by qualified
persons only in accordance with
national, state, and local codes.
Improper use of electric
arc welders can cause
electric shock, injury, and
death! Take all precautions
described in this manual to reduce the
possibility of electric shock.
●Verify that all components of the
arc welder are clean and in good
condition prior to operating the
welder. Be sure that the insulation
on all cables, electrode holders, and
power cords is not damaged.
Always repair or replace damaged
components before operating the
welder. Always keep welder panels,
shields, etc. in place when operating
the welder.
●Always wear dry protective clothing
and welding gloves, and insulated
footwear.
●Always operate the welder in a
clean, dry, well ventilated area. Do
not operate the welder in humid,
wet, rainy, or poorly ventilated
areas.
●Be sure that the work piece is
properly supported and grounded
prior to beginning any electric arc
welding operation.
●Coiled welding cable should be spread
out before use to avoid overheating
and damage to insulation.
Never immerse the
electrode or
electrode holder in water. If the welder
becomes wet for any reason, be
absolutely certain that it is completely
clean and dry prior to attempting use!
●Always shut the equipment off prior
to moving the unit.
●Always attach the work lead first.
● Verify that the work piece is
securely grounded.
●Always shut off electric arc welding
equipment when not in use and
remove the electrode from the holder.
●Never allow any part of the body to
touch the electrode and ground or
grounded work piece at the same time.
!
DANGER
!
WARNING
●Awkward welding conditions and
positions can be electrically hazardous.
When crouching, kneeling or at
elevations, be sure to insulate all
conductive parts, wear appropriate
protective clothing, and take
precautions to prevent injury from falls.
●Never attempt to use this
equipment at current settings or
duty cycles higher than those
specified on the equipment labels.
●Never use an electric arc welder to
thaw frozen pipes.
Flying sparks and hot metal
can cause injury. As welds
cool, slag can be thrown
off. Take all precautions described in
this manual to reduce the possibility of
injury from flying sparks and hot metal.
●Wear ANSI approved face shield or
safety glasses with side shield
protection when chipping or
grinding metal parts.
●Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ears.
Electric arc welding
operations produce intense
light and heat and
ultraviolet (UV) rays. This
intense light and UV rays can cause
injury to eyes and skin. Take all
precautions described in this manual to
reduce the possibility of injury to eyes
and skin.
●All persons operating this
equipment or in the area while
equipment is in use must wear
protective welding gear including:
welding helmet or shield with at
least shade 10, flame resistant
clothing, leather welding gloves,
and full foot protection.
Never look at arc
welding operations
without eye protection as described
above. Never use a shade filter lens
that is cracked, broken, or rated below
number 10. Warn others in the area not
to look at the arc.
Electric arc welding
operations cause sparks
and heat metal to
temperatures that can cause severe
burns! Use protective gloves and
clothing when performing any metal
working operation. Take all precautions
!
WARNING
!
WARNING
!
WARNING
!
WARNING
described in this manual to reduce the
possibility of skin and clothing burns.
●Make sure that all persons in the
welding area are protected from
heat, sparks, and ultraviolet rays.
Use additional face shields and
flame resistant barriers as needed.
●Never touch work pieces until
completely cooled.
Heat and sparks produced
during electric arc welding
and other metal working
operations can ignite
flammable and explosive materials!
Take all precautions described in this
manual to reduce the possibility of
flames and explosions.
●Remove all flammable materials
within 35 feet (10.7 meters) of
welding arc. If removal is not
possible, tightly cover flammable
materials with fire proof covers.
●Take precautions to be sure that
flying sparks and heat do not cause
flames in hidden areas, cracks,
behind bulkheads, etc.
Fire hazard! Do not weld on
containers or pipes that
contain or have contained
flammable materials or
gaseous or liquid combustibles.
Arc welding closed
cylinders or containers such
as tanks or drums can cause
explosion if not properly
vented! Verify that any cylinder or
container to be welded has an
adequate ventilation hole, so that
expanding gases can be released.
Do not breathe fumes that
are produced by the arc
welding operation. These
fumes are dangerous. If the welding
area cannot be adequately ventilated,
be sure to use an air-supplied
respirator.
●Keep the head and face out of the
welding fumes.
●Do not perform electric arc welding
operations on metals that are
galvanized or cadmium plated, or
contain zinc, mercury, or beryllium
without completing the following
precautions:
!
WARNING
!
WARNING
!
WARNING
!
WARNING
General Safety
(Continued)
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3
a. Remove the coating from the
base metal.
b. Make sure that the welding area
is well ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created
when these metals are heated.
The electromagnetic field
that is generated during
arc welding may interfere
with the operation of
various electrical and electronic devices
such as cardiac pacemakers. Persons
using such devices should consult with
their physician prior to performing any
electric arc welding operations.
● Route the electrode and work
cables together and secure with
tape when possible.
● Never wrap arc welder cables
around the body.
●Always position the electrode and
work leads so that they are on the
same side of the body.
●Exposure to electromagnetic fields
during welding may have other
health effects which are not known.
Always be sure
that the welding
area is secure and free of hazards
(sparks, flames, glowing metal or slag)
prior to leaving. Be sure that
equipment is turned off and electrode
is removed. Be sure that cables are
loosely coiled and out of the way. Be
sure that all metal and slag has cooled.
ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
Safety and Health Standards
OSHA 29 CFR 1910, from
Superintendent of Documents, U.S.
Government Printing Office,
Washington, D.C. 20402
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
Highway, Suite 501, Arlington, VA
22202
Code for Safety in Welding and
Cutting
!
WARNING
!
WARNING
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
Cutting And Welding Processes
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269
Safe Practices For Occupational And
Educational Eye And Face Protection
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
Refer to the Material Safety Data
Sheets and the manufacturers
instructions for metals, electrodes,
coatings and cleaners.
LOCATION
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
●For best results locate the
welder/generator in an
environment that is clean and dry.
Dust and dirt in the unit retain
moisture and increase wear of
moving parts.
●Store electrodes in a clean, dry
location with low humidity to
preserve the flux coating.
PRE-OPERATION
1. Check engine oil level. Oil is NOT
mixed with the gasoline, however
adequate oil supply is necessary for
proper engine lubrication. Refer to
the Engine Manual for SAE, API and
fill quantity specifications. Unit is
shipped without oil in engine.
2. Use of a Ground Fault Interrupter
(GFI) is strongly recommended.
Ground Fault Interrupters can
significantly reduce the possibility of
injury if an electrical short occurs. In
order to install a GFI, the
welder/generator neutral wire must
be internally grounded to the
welder/generator frame, and the
frame must be properly grounded
to the earth.
A Ground Fault
Interrupter may
not be effective if used on a
welder/generator that is not grounded!
Refer to the section entitled Grounding
for proper steps to ground the
welder/generator.
!
WARNING
3. When installing a GFI, be sure to
follow all national and local
regulations. If not sure of
regulations or procedures, obtain
assistance from a qualified (licensed
or certified) electrical technician.
GROUNDING
1. Use the ground terminal and wing
nut on the welder/generator frame
to connect the unit to a suitable
ground source. Securely fasten the
end terminal of the ground wire to
the ground terminal on the
welder/generator frame. Tighten
the washer and wing nut on top of
the ground wire end terminal.
2. The ground wire should be made of
#8 gauge wire. Do not use wire with
a higher gauge number. Higher
gauge numbers indicate thinner
wire, which may not provide an
adequate ground path.
3. The other end of the ground wire
must be securely fastened to an
approved ground source.
The following are ground sources
approved by the National Electric Code.
Other ground sources may be
acceptable. Refer to the National Electric
Code and local regulations for further
ground source information. If not sure
of regulations or procedures, obtain
assistance from a qualified (licensed or
certified) electrical technician.
a. An underground water pipe at
least ten feet in length
b. A non-corrosive underground
pipe at least eight feet in length
and 3/4 inch diameter
c. A steel or iron underground rod
at least eight feet in length and
5/8 inch diameter
d. A non-ferrous rod at least eight
feet in length, 1/2 inch in
diameter, and approved for
grounding purposes
Any rod or pipe used for grounding must
be driven to eight feet deep or buried in
the deepest possible trench.
STARTING
1. Remove all electrical loads from the
welder/generator.
General Operations
General Safety
(Continued)
Welder/Generator
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4
Operating Instructions
2. Rotate fuel shut-off valve counter
clockwise to enable fuel flow.
3. Rotate the engine switch to the ON
position.
4. Adjust the choke lever as follows:
a. For cold engine, move the choke
lever as far as possible to the left,
choke fully ON, position.
b. For warm/hot engine, move the
choke lever midway between the
choke and run positions.
5. Pull the starter rope with a brisk,
smooth motion.
NOTE: Some models may be equipped
with an electric starter. For models
equipped with an electric starter, turn
the key.
6. After each start up, allow the engine
to run for 2-3 minutes with no load.
7. As the engine warms up and
stabilizes, adjust the choke lever to
the right, until the lever is positioned
at the RUN label.
Engine speed is
preset to provide
proper output voltage. Never attempt to
modify or adjust engine speed or output
voltage.
ENGINE BREAK-IN
After initial start-up, the engine should
be broken in according to the
manufacturer's instructions. Refer to the
engine manual for the proper break-in
procedure.
SHUT OFF
1. Shut off and remove all electrical
load devices from the welder/
generator.
2. Allow the engine to run for 2-3
minutes with no electrical loads.
3. Rotate the engine switch to the OFF
position.
4. Verify that the welder/generator has
completely stopped.
5. Close the fuel supply valve.
6. Allow the unit to cool before
installing any covers.
!
CAUTION
LOW OIL SHUTDOWN
A low oil shutdown switch is provided to
protect the engine and welder/generator
on most extended run models. When
engine oil level drops too low for proper
engine operation, the low oil shutdown
switch causes the engine to shut off. If oil
level is low when attempting to start the
welder/generator engine, the low oil
level shutdown switch prevents the
engine from starting. If engine does not
start, check oil level.
NOTE: It is important to keep the
welder/generator unit on a level surface.
The oil level shutdown switch can
prevent the engine from starting even if
oil level is sufficient, when the
welder/generator unit is placed on an
uneven surface.
(FRONT PANEL SWITCH MUST BE SET
TO GENERATOR)
LOAD DEVICES
1. All load devices and extension cords
should use three prong terminals.
Refer to Table 2 for extension cord
and cable size requirements.
2. Allow the engine to run for 2-3
minutes before applying any
electrical loads.
3. The 120 volt receptacles are rated
for 20 amps and may be used in any
combination of 120 volt loads and
also with 240 volt loads through the
240 volt receptacles.
The 240 volt receptacles, found
on some units, are rated for 20
amps and may be used in any
combination of 240 volt loads and
also with 120 volt loads through the
120 volt receptacles.
The 120/240 volt twist lock
receptacle, found on some units, is
rated for 20 amps and may be used
in any combination of 120 volt and
240 volt loads.
4. Individual receptacles should not be
loaded beyond the amperage
rating.
5. Total combined load through any
combination of receptacle must not
exceed the rated load limits of the
welder/generator. Refer to the
identification plate on the
welder/generator for amp and
wattage specifications.
6. Always shut off and remove loads
before starting or shutting off the
welder/generator engine.
7. When plugging multiple electrical
load devices into the
welder/generator receptacles, be
sure to connect and activate the
highest power draw item first.
Allow the welder/generator engine
to stabilize, then connect and
activate the next highest power
draw device. The smallest power
draw device should be connected to
the receptacle and activated last.
Radio 50-200
Refrigerator 190-2000
Skillet 1200
Space heater 600-4800
Sump pump 400-3000
Television 200-500
Toaster 900-1700
Vacuum cleaner 200-300
Water pump 1000-3000
Water heater 1000-5000
Small hand saw 1000-2000
Large hand saw 1500-2500
Air conditioner 2000-3000
Automatic washer 150-1500
Brooder 100+
Clothes dryer 5000-10,000
Coffee maker 400-700
Electric drill (small) 225-1000
Electric drill (large) 500-1000
Fan 40-200
Freezer 300-500
Hot plate 330-1100
Iron 500-1500
Light bulb As Rated
Load Device Watts Load Device Watts
TABLE 1 - ESTIMATED POWER USAGE (WATTS)
General Operations
(Continued)
Generator Operations
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5
2.5 300 600 1000 600 375 250
5 600 1200 500 300 200 125
7.5 900 1800 350 200 125 100
10 1200 2400 250 150 100 50
15 1800 3600 150 100 65
20 2400 4800 175 125 75 50
25 3000 6000 150 100 60
30 3600 7200 125 65
40 4800 9600 90
Amps Watts Watts #8 #10 #12 #14 #16
120 V 240 V Wire Wire Wire Wire Wire
TABLE 2 - EXTENSION CORDS
MAXIMUM RECOMMENDED LENGTHS (IN FEET)
NOTE: Power draw can be calculated
by multiplying volts and amps. The
resulting number is wattage.
Never exceed the posted maximum
wattage for the welder/generator or any
individual receptacle. Refer to owner's
manuals and product tags to determine
the wattage of all electrical load devices.
If actual watt ratings are not available,
the Power Usage Chart, see Table 1,
may be used as a general guideline.
Remember that devices which generate
heat during operation such as heaters,
incandescent light bulbs, motors and
hair dryers have a higher power draw
than devices which generate little heat
during operation such as florescent
bulbs, radios, and clocks.
Long power cords and extension cords
also draw additional power. Keep cords
at minimum possible length.
Refer to Table 2 for maximum limits for
lengths of extension cords.
8. Circuit protection is provided by a
circuit breaker. The circuit breaker
opens when the welder/generator
load exceeds its maximum capacity or
a short circuit occurs. If the circuit
breaker opens, perform the following
procedures to correct the problem:
a. Shut off and disconnect all
electrical loads.
b. Attempt to determine the cause
of the electrical problem -
overloading or short circuit.
c. Do not use any devices that have
short circuits. Avoid overloading
the welder/generator.
d. Press the circuit breaker
pushbutton to reset the circuit
breaker.
Repeated cycling
of the circuit
breaker indicates a problem and may
cause damage to the welder/generator
or load devices. Do not operate the
welder/generator if repeated cycling of
the circuit breaker occurs.
Installation for Stand-by Use
Precautions must be taken to prevent
electrical back feeding into utility
systems. This requires isolation of the
electrical system. To isolate the
electrical system, perform the following
procedures:
1. Turn off the main electrical system
switch prior to connecting the
welder/generator.
2. In accordance with national and
local standards, a double throw
transfer switch must be installed in
the system.
Always shut off
main power prior
to temporary connection of the
welder/generator to a building
electrical system.
!
WARNING
!
CAUTION
Installation of the
welder/generator
as a backup electrical source must be
performed by a qualified (licensed or
certified) electrical technician.
(FRONT PANEL SWITCH MUST BE SET
TO THE WELDING POSITION)
Welding Lead Assemblies
Welding leads assemblies are not
included with all units. Use copper
welding cables in the size specified in
Table 3.
GROUND CLAMP (SEE FIGURE 1)
1. Strip 1/2” of insulation from the end
of one of the welding cables.
2. Loosen hex nuts on work clamp.
3. Insert the end of the welding cable
through clamp handle and slide the
bare wire under the clamp block.
4. Tighten the hex nuts, securing the
cable in place.
ELECTRODE HOLDER (SEE FIGURE 2)
1. Strip 1” of insulation from the end
of the other welding cable.
Separate the strands of the cable
into two sections and twist.
2. Loosen the setscrew a few turns. Do
not remove it completely. Pull
the insulated handle off of the
electrode holder, and slide it over
the welding cable.
!
WARNING
Generator Operations
(Continued)
Welder Operations
Welder/Generator
Figure 1 - Work Clamp Assembly
Figure 2 - Electrode Holder Assembly
Shim
Cable Bolt Welding
Cable
Electrode
Holder Set Screw
Handle
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Total Cable Length* 0-20 ft (0-6 m) 20-40 ft (6-12 m) 40-60 ft (12-18 m)
Maximum Welding
Current Recommended Sizes of Copper Welding Cables
6
3. Loosen the bolt on the top of the
electrode holder.
4. Slide the bare wires from the cable
between the shim and the brass
body of the electrode holder.
5. Tighten the bolt to secure the cable
in place.
6. Slide the insulated handle onto the
electrode holder and tighten the
setscrew. Do not overtighten the
setscrew. Overtightening will
damage the insulated handle.
DINSE PLUGS (SEE FIGURE 3)
1. Strip 1/2”of insulation from the
opposite end of the welding cable.
2. Insert this end of the welding cable
through the dinse plug boot and
slide the bare wire into the wire
sleeve.
3. Insert the welding cable/wire sleeve
assembly into the back of the dinse
plug.
4. Tighten the set screw, securing the
cable in place.
5. Slide the boot over the hex portion
of the dinse plug.
6. Repeat for the other lead.
Welding
1. Verify that the surfaces of metals to
be joined are free from dirt, rust,
paint, oil, scale or other
contaminants. These contaminants
make welding difficult and cause
poor welds.
All persons
operating this
equipment or in the area while
equipment is in use must wear protective
welding gear including: eye protection
with proper shade (minimum shade 10),
flame resistant clothing, leather welding
gloves, and full foot protection.
!
WARNING
If heating, welding,
or cutting materials
that are galvanized, zinc plated, lead, or
cadmium plated refer to the General
Safety Information Section for
instructions. Extremely toxic fumes are
created when these metals are heated.
2. Connect the work clamp to the
work piece. Make sure the contact is
on bare metal and not obstructed
by paint, varnish, corrosion, or non-
metallic materials.
3. Insert the exposed part of the
electrode (the end with no flux) into
the jaws of the electrode holder.
4. Set the amperage adjustment knob
to the proper amperage for the
electrode diameter. Refer to the
chart on the front panel for proper
electrode current settings.
The electrode
holder and rod are
electrically “live” (current potential)
when the engine is running.
5. Position the electrode to begin
weld, lower the welding helmet or
position the hand shield, and strike
an arc. Adjust weld amperage as
needed.
6. When finished welding, turn engine
off and store unit properly.
DUTY CYCLE/THERMOSTATIC
PROTECTION
Welder duty cycle is the percentage of
actual weld time that can occur in a ten
minute interval. For example, at a 10%
duty cycle, actual welding can occur for
one minute, then the welder must cool
for nine minutes.
Internal components of this welder are
!
WARNING
!
WARNING
Welder Operations
(Continued)
100 A 6 AWG (15 mm2) 6 AWG (15 mm2) 4 AWG (20 mm2)
150 A 6 AWG (15 mm2) 3 AWG (25 mm2) 2 AWG (35 mm2)
200 A 4 AWG (20 mm2) 2 AWG (35 mm2) 1 AWG (40 mm2)
250 A 3 AWG (25 mm2) 2 AWG (35 mm2) 1/0 AWG (55 mm2)
* Total cable length is the sum of the ground and electrode cable lengths
protected from overheating with an
automatic thermal switch.
INFREQUENT USAGE
If the welder/generator is used
infrequently, starting difficulty may
occur. To help prevent this, the
welder/generator should be run for
approximately 30 minutes per week.
STORAGE
If the welder/generator is not to be
used for extended periods of time, the
following pre-storage procedures
should be performed:
1. Make sure engine oil is filled to the
proper level.
2. Drain all fuel from the tank, lines,
carburetor and fuel valve.
3. Remove the spark plug, and pour
approximately one teaspoon of oil
into the spark plug hole.
4. Pull the starter cord several times to
spread the oil throughout the
cylinder.
5. Slowly pull the starter cord, until
resistance is felt. This indicates that
the piston is moving upward on the
compression cycle, and the intake
and exhaust valves are closed. (The
piston pushes a small amount of air
from the spark plug hole on
compression.)
6. Use of fuel stabilizers or anti-
gumming agents in the fuel system
can help prevent the build up of
gum and varnish.
Whenever the welder/generator is
stored, be sure that the fuel shut-off
Operating Instructions
Figure 3 - Dinse Plug Assembly
Set
Screw Boot Welding
Cable
Wire
Sleeve
Dinse Plug
TABLE 3 - WELDING CABLES
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Maintenance

7
General
This line of welding machines utilizes a
process known as Shielded Metal-Arc
Welding (SMAW). This process is used to
bond metals by heating them with an
electric arc created between the
electrode and the work piece.
Electrodes used for shielded metal arc
welding have two parts. The inner core is
a metal rod or wire that should be similar
in composition to the base metal. The
outer coating is called flux. Various types
of flux exist. Each coating is used for a
particular welding situation.
While the metal is molten, it can be
contaminated by elements in the air. This
contamination could weaken the weld.
The flux coating creates a protective
barrier called slag that protects the
molten metal from contaminants.
When current (amperage) flows through
the circuit to the electrode, an arc is
formed between the end of the electrode
and the work piece. The arc melts the
electrode and the work piece. The melted
metal of the electrode flows into the
molten crater and forms a bond with the
work piece as shown in Figure 4.
NOTE: Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder.
STRIKING AN ARC
Place the bare end of the electrode in the
holder. Grip the holder lightly to reduce
tiring of the hand and arm.
NOTE: Always keep the jaws of the
holder clean to insure good electrical
contact with the electrode.
Be careful not to
touch the work
piece or welding bench with the
electrode as this causes arc flashes.
The best method of striking an arc is the
scratching method. Drag the electrode at
an angle along the surface much like
striking a match. Upon contact with the
plate, lift the electrode approximately
1/16”off the surface or it will stick (See
Figure 5).
NOTE: Should the electrode stick to the
work piece, break it loose by quickly
twisting or bending at the holder while
pulling upward. If the electrode does not
break loose, disengage the electrode by
releasing it from the holder.
!
WARNING
ELECTRODE TYPE AND SIZE
Four types of electrodes are
recommended for this welder. The
electrodes are commonly known by the
AWS (American Welding Society)
designation as follows:
1. E-6011 DEEP PENETRATING
•Flat bead with deep penetrating arc.
•For rusted or dirty mild steel general
repair work.
2. E-6013 GENERAL PURPOSE
•All position, smooth deposit rod with
low spatter.
•For all mild steel and general purpose
work.
3. E-7014 FAST FILL
•Smooth bead and fast deposition
•Ideal for joints with poor fitup and
general repair work.
4. E-7018-AC HIGH STRENGTH
•Ideal for pipes and structural
applications.
•Low hydrogen reduces porosity for a
strong weld.
NOTE: Only the E-7018-AC electrode is
recommended for use with these
welders. Other E-7018 electrodes are
designed for use with higher open
circuit voltages than these welders are
capable of producing. Recommended
electrode diameter is 3/32”or 1/8”.
Arc Welding Basics
Four basic techniques affect weld
quality. These are: amperage setting,
weld angle, arc length, and travel
speed. Proper use of these techniques is
necessary for good weld quality.
Slag
Weld
Wire
Flux
Work
Piece
Crater
Figure 4 - Weld Components
1/16"
Same as Electrode Diameter
Figure 5 - Scratching Method
Welding Guidelines
Welder/Generator
Maintenance
(Continued)
valve is in the closed position.
Refer to the engine manual that
accompanies this unit for instructions
regarding maintenance of engine
components.
Never tamper with
engine speed
settings or welder/generator frequency
settings. Any governor adjustments
should be made by qualified personnel
only.
WELD CABLES
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
!
WARNING
2. Check condition of electrode holder
insulating pieces and immediately
replace cracked or missing parts.
Every 3 months:
Replace any unreadable labels on the
welder. Use compressed air to blow all
dust and lint from the ventilation
openings.
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8
Normal Amps, Arc Length, Speed
Amperage Too Low
Amperage Too High
Arc Length Too Short
Arc Length Too Long
Speed Too Slow
Speed Too Fast
Workpiece
NOTE: Weld bead width (W)
should be approximately
twice the diameter for the
electrode rod used.
W
Figure 7 - Weld Appearance
AMPERAGE SETTING
The correct amperage involves the
adjustment of the welding machine to
the required amp setting. This is
regulated by a knob on the welder. The
amperage required depends on the size
(diameter) of electrode used and the
thickness of the work piece.
Consult specifications listed on the
welder. Excessive amps burn through
light metals and the weld bead is flat
and porous (See Figure 7). The bead
appears high and irregular if the
amperage is too low.
WELD ANGLE
Weld angle is the angle at which the
electrode is held during the welding
process. Using the correct angle ensures
proper penetration and bead
formation. Electrode angle involves
two positions - travel angle and work
angle (See Figure 6).
Travel angle is the angle in the line of
welding and may vary from 5ºto 45º
from the vertical, depending on
welding conditions.
Work angle is the angle from
horizontal, measured at right angles to
the line of welding.
For most applications, a 45ºtravel
angle and 45ºwork angle is sufficient.
For specific applications, consult an arc
welding handbook.
NOTE: Right handed welders should
weld from left to right. Left handed
welders should weld from right to left.
The electrode should always point into
the weld puddle as shown.
ARC LENGTH
Arc length is the distance from the
work piece to the tip of the electrode,
the distance which the arc must travel.
A proper arc length is essential to
generate the heat needed for welding
(See Figure 7). An arc that is too long
produces an unstable arc, reduces
penetration, increases spatter, and
causes flat and wide beads. Too short
an arc does not create enough heat to
melt the work piece, the electrode has
a tendency to stick, penetration will be
poor, and uneven beads with irregular
ripples result. A proper arc should be
no longer than the diameter of the rod.
The sound of a proper arc is a steady,
crisp sizzle, similar to bacon frying.
TRAVEL SPEED
The travel speed is the rate at which
the electrode is moved across the weld
area (See Figure 7). When the speed is
too fast, the bead is narrow and bead
ripples are pointed as shown. When the
speed is to slow, the weld metal piles
up and the bead is high and wide. To
control travel speed, watch the width
of the weld bead (not the arc) when
welding. The weld bead is the orange,
molten metal behind the arc. The width
should be approximately twice the
diameter of the welding rod. Control
travel speed to obtain a consistent
bead width.
Welding Guidelines (Continued)
Operating Instructions
Figure 6 - Weld Angle
5o - 45o
Travel Angle
Work Angle
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9
SLAG REMOVAL
Wear ANSI
approved safety
glasses (ANSI Standard Z87.1) and
protective clothing when removing
slag. Hot, flying debris can cause
personal injury to anyone in the area.
After completing the weld, wait for the
welded sections to cool. A protective
coating called slag now covers the weld
bead which prevents contaminants in
the air from reacting with the molten
metal. Once the weld cools to the point
that it is no longer glowing red, the
slag can be removed. Removal is done
with a chipping hammer. Lightly tap
the slag with the hammer and break it
loose from the weld bead. The final
clean-up is done with a wire brush.
When making multiple weld passes,
remove the slag before each pass.
WELDING POSITIONS
Four basic welding positions can be used;
flat, horizontal, vertical, and overhead.
Welding in the flat position is easier than
any of the others because welding speed
can be increased, the molten metal has
!
WARNING
Figure 9 - Multiple Weld Passes
Welding Guidelines (Continued)
Welder/Generator
less tendency to run, better penetration
can be achieved, and the work is less
fatiguing.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these welds.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
handbook.
WELD PASSES
Sometimes more then one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and the
cover pass (See Figures 8 & 9). If the
Figure 8 - Weld Passes
Cover
Filler
Root
pieces are thick, it may be necessary to
bevel the edges that are joined at a 60º
angle. Remember to remove the slag
before each pass.
No output voltage
Low output voltage
with no load
High output voltage
with no load
1. Engine speed is too slow
2. Open, shorted, or incorrect wiring
3. Faulty capacitor
4. Open or shorted field windings
5. Open diodes
6. Front panel switch set incorrectly
7. Circuit breaker tripped
1. Engine speed is too slow
2. Open diodes
3. Faulty capacitor
4. Open or shorted field windings
5. Voltage setting on front panel incorrect
1. Faulty capacitor
2. Engine speed is too fast
3. Voltage setting on front panel incorrect
1. Adjust engine speed ✽
2. Referring to the wiring diagram, clean and
reconnect all wiring ✽
3. Replace capacitor ✽
4. Test winding resistance, replace field
winding if necessary ✽
5. Test diodes, replace if necessary ✽
6. Set front panel switch to generator
7. Reset circuit breaker
1. Adjust engine speed ✽
2. Test diodes, replace if necessary ✽
3. Replace capacitor ✽
4. Test winding resistance, replace field
winding if necessary ✽
5. Adjust setting on front panel
1. Replace capacitor ✽
2. Adjust engine speed ✽
3. Adjust setting on front panel
Troubleshooting Chart - Generator
Symptom Possible Cause(s) Corrective Action
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10
Operating Instructions
✽These diagnostic and repair procedures should be performed by an authorized service center.
Troubleshooting Chart - Generator (Continued)
Symptom Possible Cause(s) Corrective Action
Low output voltage
under load
Erratic output voltage
Noisy operation
1. Open diode
2. Engine speed too slow at full load
3. Excessive load applied
4. Voltage setting on front panel incorrect
1. Unbalanced engine
2. Dirty, corroded, or loose wiring
connection
3. Unstable load applied
1. Loose welder/generator or engine bolt
2. Short circuit in welder/generator field or
load
3. Faulty bearing
1. Test diodes, replace if necessary ✽
2. Adjust engine speed ✽
3. Reduce the applied load
4. Adjust setting on front panel
1. Refer to engine manual
2. Referring to the wiring diagram, clean and
reconnect all wiring ✽
3. Remove all loads, then apply each one
individually to determine which one is
causing erratic function
1. Tighten all mountings
2. Test winding resistance, replace field
winding if necessary ✽
Test load devices for shorts. Replace
defective load device.
3. Replace bearing
1. Check work clamp, cable and connection to work
piece. Check electrode cable and clamp
2. Check all welder external connections
3. Set front panel switch to weld
4. Referring to the wiring diagram, clean and
reconnect all wiring ✽
5. Replace capacitor ✽
6. Test winding resistance, replace field winding if
necessary ✽
7. Test diodes, replace if necessary ✽
1.Avoid contact with work piece
2. Make sure clothing and work area are dry
1. Verify that electrode is for alternating current (AC)
2. Use smaller diameter electrode
3. Verify proper grounding. (No paint, varnish or
corrosion)
4. Adjust engine speed
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
1. Inadequate current at electrode
2. Poor connections at welder
3. Front panel switch set incorrectly
4. Open, shorted, or incorrect wiring
5. Faulty capacitor
6. Open or shorted field windings
7. Open diodes
1. Accidental contact with work
piece
2. Current leakage caused by moist
clothing or work area
1. Wrong type of electrode.
2. Electrode diameter too large
3. Work piece not properly
grounded
4. Engine speed is too slow
Welder runs but does not
weld
Welder gives trickle
shocks
Arc difficult to strike
✽These diagnostic and repair procedures should be performed by an authorized service center.
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