Thermadyne THERMAL ARC MECA-ARC 40300 User manual

МЕСА-АВС? 40300
300 Amp Constant Current Diesel
Engine-Driven Welding Generator
For the Following Specs:
• 6298E-1
IHERMAL С.
А THEHMADYNE. Company
OWNER'S MANUAL Number 430429-427 (Rev - AA)
Revised February 21, 2000
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

430429-427
Table ої Contents
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
INTRODUCTION
How To Use This Manual ................................... 1-1
Equipment Identification ................................... 1-1
Receipt ОГЕаціртепі..................................... 1-1
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2
DESCRIPTION OF EQUIPMENT 3
Generator: «ooo eR Sp аа Q. eens а а wy br а ая А АУЗ 3-1
ENNE: «unterm tede A Reef Ж ЫЛЕ mere die ату eoe Mee ah б ра eut & nen и 3-1
Identification. 1e e а А Ae TS жес wl ee Я а, лк Ge a S 3-1
tabulated: Data «c s er Ко Моя ра оо oU. EES 3-1
Supplementary Materials ................................... 3-2
Engine Controls and Instruments. .............................. 3-2
Generator Controls. о гэл а, ў DAR E ыа 60 RUE bc an RUPEE 3-3
INSTALLATION | 4
General Engine Driven Welder Installation .......................... 4-1
Росано ћи за i ЛАНА УКУ лээр а ee БА S доб 4-1
Safety: à Liu de а ANS Pen dicho, dei de РРО ок бо өн жыр З 4-1
ndoofinstallation:: xu Eus Lana а RA Xon а ELE 4-1
Portable Installation. x = en bea ste op В а аб Ru е EU RES а-а OS 4-1
Initial Preparation For Use .................................. 4-2
Welding: beads; а... 9.9 al qu Race diet аа ua S А аа E Er 4-3
OPERATION 5
Prestarting Instructions .................................... 5-1
Break-in Procedures ..................................... 5-2
Prewelding Instructions . . .................................. 5-2
Welding Z7 eek US аа а оа eh Ass ЕЛЕ ое 5-3
stopping The Engine: г ао ge AER CIDE IRE АН UE 5-3
Storages - злої ns S M suit Steg Tan о пр le i eb ed dpt tte о d ios 5-3
Adverse Weather Precautions ................................ 5-3
MAINTENANCE 6
Engine And Related Components .............................. 6-1
Inspection And Cleaning ................................... 6-1
Lubrication’. «uum а 2 Roy d or a ют Y qe реа pus 6-1
August 24, 1998 Page 1

430429-427
Table of Contents
TROUBLESHOOTING
PARTS LIST
Equipment Identification . . . . . ..
How To Use This Parts List. . . . ..
How To Select Recommended Spares
MATERIAL SAFETY DATA SHEET
DIAGRAMS
ADDENDUM
WARRANTY
Page 2
February 21, 2000 Revised

INTRODUCTION
How To Use This Manual
This Owner's Manual usually applies to just the
underlined specification or part numbers listed on
the cover. If none are underlined, they are ail cov-
ered by this manual.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily rec-
ognized as follows:
WARNING gives information re-
garding possible personal in-
jury. Warnings will be enclosed
in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTE offers helpful information concern-
ing certain operating procedures. Notes
will be shown in italics.
Equipment Identification
The unit's identification number (specification or
part number), model, and serial number usually
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be at-
tached to the rear panel. Equipment which does not
have a control panel such as gun and cable assem-
blies are identified only by the specification or part
number printed on the shipping container. Record
these numbers for future reference.
430429-427
INTRODUCTION
Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
the equipment for possible damage due о shipping.
Ifthere is any damage, notify the carrier immediately
to file a claim. Furnish complete information con-
cerning damage claims or shipping errors to
Thermal Arc, Order Department, 2200 Corporate
Drive, Troy, Ohio 45373-1085. Include all equipment
identification numbers as described above along
with a full description of the parts in error.
Move the equipment to the installation site before
uncrating the unit. A lifting eye extends through the
top of the cabinet on most equipment to facilitate
handling with a hoist or crane. Use care to avoid
damaging the equipment when using bars, ham-
mers, etc., to uncrate the unit.
WARNING: Falling machine due
to lifting eye failure may cause
death or serious injury.
e Lifting device may fail when overloaded.
е This lifting device is designed to lift the
power source ONLY. If the machine is
equipped with a trailer or accessories over
100 pounds, DO NOT LIFT by lifting eyes.
• Avoid sudden jerks, drops, or swinging.
• Check lifting device components visually
for looseness and signs of metal fatigue.
e Before changing any hardware, check
grade and size of bolts, and replace with
bolts of equal or higher size and grade.
Additional copies ofthis manual may be purchased
by contacting Thermal Arc at the address given
above. Include the Owners Manual number and
equipment identification numbers.
August 24, 1998 1-1

430429-427
INTRODUCTION
This page intentionally left blank.
1-2 August 24, 1998

АВС WELDING SAFETY INSTRUCTIONS АМО WARNINGS
instruction 830001
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
дА
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. КЕЕР CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUC-
TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Certain of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and
other guídes to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE. .
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 auto-
matic wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or im-
properly grounded equipment is a hazard.
. Do not touch live electrical parts.
. Wear dry, hole-free insulating gloves and body protection.
. Insulate yourself from work and ground using dry insulating
mats or covers.
. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
. Properly install and ground this equipment according to its
Owner's Manual and national, state, and local codes.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
Electrode Size Filter ||
Welding or Cutting Metal Thickness Shade
Operation or Welding Current No.
Torch soldering — 2
Torch brazing — 3or4
Oxygen cutting
Gas metal-arc welding (MIG)
. Turn off а! equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface. Do
not touch holders connected to two welding machines at the
same time or touch other people with the holder or electrode.
. Do not use worn, damaged, undersized, or poorly spliced ca-
bles.
. Do not wrap cables around your body.
. Ground the workpiece to a good electrical (earth) ground.
. Do not touch electrode while in contact with the work (ground)
circuit.
. Use only well-maintained equipment. Repair or replace dam-
aged parts at once.
. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
. Wear a safety harness to prevent falling if working above floor
level.
. Keep all panels and covers securely in place.
. Wear a welding helmet fitted with a proper shade of filter (see
ANSI 249.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
. Wear approved safety glasses. Side shields recommended.
. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
. Use approved ear plugs or ear muffs if noise level is high.
Electrode Size
Welding or Cutting Metal Thickness
Operation or Welding Current
Non-ferrous base metal АН
Ferrous base metal Al
Light Underiin,25mm | 3or4|
Medium 1t06in.,25-150mm | 40г5||
Неауу Over б іп., 150 тт 5076
Gas welding Plasma arc welding | АЙ
Light Under 1/8 in., З тт 4075| Carbon arc air gouging
Medium 1/8 to 1/2 in., 3-12 mm 5or6 Light
Heavy | Оуег 1/2 іп., 12 тт 6 or 8], Heavy
Shielded metal-arc welding Under 5/32 іп., 4 тт 10 | Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 410 6.4 тт 12 Light Under 300 Amp
| Over 1/4 in., 6.4 mm 14 Medium 300 to 400 Amp
| | Неауу Over 400 Amp
Gas tungsten arc welding (TIG) АІ
Atomic hydrogen welding All
Carbon arc welding Al
May 8, 1996 2-1

АВС WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
. Keep your head out of the fumes. Do not breath the fumes.
. Е inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
. Kf ventilation is poor, use an approved air-supplied respirator.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work-
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
. Protect yourself and others from flying sparks and hot metal.
. Do not weld where flying sparks can strike flammable material.
. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
. Bealertthat welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas underhigh pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
. Protect compressed gas cylinders from excessive heat, me-
chanical shocks, and arcs.
. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
& WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
2-2
. Read the Material Safety Data Sheets (MSDSs) and the manu-
facturer's instruction for metals, consumables, coatings, and
cleaners.
‚ Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
. Do 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.
. Do not weld on coated metals, such as galvanized, lead, or
cadmium 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
containing these elements can give off toxic fumes if welded.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
. Do not weld on closed containers such as tanks or drums.
. 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.
. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
. Wear approved face shield or safety goggles. Side shields
recommended.
. Wear proper body protection to protect skin.
. Keep cylinders away from any welding or other electrical cir-
cuits.
. Never allow a welding electrode to touch any cylinder.
. 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.
. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas. ·
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
May 8, 1996

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
. Do not add fuel while smoking or if unit is near any sparks or open
flames.
. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
. Do not overfill tank — allow room for fuel to expand.
. Do not spill fuel. If fuel is spilled, clean up before starting engine.
. Have only qualified people remove guards or covers for mainte-
nance and troubleshooting as necessary.
. To prevent accidental starting during servicing, disconnect nega-
tive (-) 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.
. Always wear a face shield when working on a battery.
. Stop engine before disconnecting or connecting battery cables.
. 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.
. Do not remove radiator cap when engine is hot. Allow engine to
cool.
. Wear gloves and put a rag over cap area when removing cap.
. Allow pressure to escape before completely removing cap.
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks."
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them. 3. Do not coil or drape cables around the body.
2. Arrange cables to one side and away from the operator. 4. Keep welding power source and cables as far away from body as
practical.
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Code for Safety in Welding and Cutting, CSA Standard W1 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Nationa! Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
September 22, 1999 Revised 2-3

АВС WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
This page intentionally left blank.
2-4 Мау 8, 1996

PRECAUTIONS ОЕ SECURITE ЕМ SOUDAGE А L'ARC
Instruction 830002
PRECAUTIONS DE SECURITE EN SOUDAGE AL ARC
MISE ЕМ GARDE LE SOUDAGE A L'ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OÙ LA MORT. NE LAISSEZ PAS LES
ENFANTS S'APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU'ILS N'AIENT CONSULTE UN
MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D'OPERATION OU LES INSTRUCTIONS AVANT D'INSTALLER,
UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de тёте que des dommages au reste du matériel
et à la propriété, si l'utilisateur n'adhére pas strictement à toutes les régles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l'expérience passée. Ces pratiques doivent étre apprises
par étude ou entrainement avant d'utiliser l'equipement. Toute personne n'ayant pas suivi un entrainement intensif en soudage et coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d'alimentation alors que d'autres
s'adressent aux groupes électrogènes.
La norme 249.1 de l'American National Standard, intitulée "SAFETY IN WELDING AND CUTTING" présente les pratiques sécuritaires а
suivre. Ce document ainsi que d'autres guides que vous devriez connaitre avant d'utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D'INSTALLATION, DE REPARATION, D'ENTRETIEN ET
D'ESSAI.
. Arrétez tout équipement aprés usage. Coupez l'alimentation de
l'équipement s'il est hors d'usage ou inutilisé.
7. N'utilisez que des porte-électrodes bien isolés. Ne jamais plon-
ger les porte-électrodes dans l'eau pour les refroidir. Ne jamais
les laisser trainer par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en méme temps. Ne jamais toucher quelqu'un d'autre avec
l'électrode ou le porte-électrode.
8. N'utilisez pas de câbles électriques usés, endommagés, та!
épissés ou de section trop petite.
N'enroulez pas de câbles électriques autour de votre corps.
N'utilisez qu'une bonne prise de masse pour la mise à la terre
de la piéce à souder.
Ne touchez pas à l'électrode lorsqu'en contact avec le circuit de
soudage (terre).
12. N'utilisez que des équipements en bon état. Réparez ou rem-
L'ELECTROCUTION PEUT ETRE
MORTELLE.
Une décharge électrique peut tuer ou brüler grave-
ment. L'électrode et le circuit de soudage sont sous
tension dés la mise en circuit. Le circuit d'alimenta-
tion et les circuits internes de l'équipement sont
aussi sous tension dés la mise en marche. En
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le
logement des galets d'entrainement et toutes les
pièces métalliques en contact avec le fil de soudage 9.
sont sous tension. Un équipement inadéquatement | 10.
installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des piéces sous tension. 11.
2. Portez des gants et des vétements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et dela mise а la terre au moyen
de tapis isolants ou autres.
placez aussitôt les pièces endommagées.
. Déconnectez la prise d'alimentation de l'équipement ou arrêtez 13. Dans des espaces confinés ou mouillés, n'utilisez pas de source
le moteur avant de l'installer ou d'en faire l'entretien. Bloquez le de courant alternatif, à moins qu'il soit muni d'un réducteur de
commutateur en circuit ouvert ou enlevez les fusibles de tali- tension. Utilisez plutót une source de courant continu.
mentation afin d'éviter une mise en marche accidentelle. 14. Portez un harnais de sécurité si vous travaillez en hauteur.
. Veuillez à installer cet équipement et à le mettre à la terre selon 15. Fermez solidement tous les panneaux et les capots.
le manuel d'utilisation et les codes nationaux, provinciaux et
locaux applicables.
LE RAYONNEMENT DE L'ARC PEUT
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-aprés)
8-V-96
pour vous protéger le visage et les yeux lorsque vous soudez ou
que vous observez l'exécution d'une soudure.
BRÜLER LES YEUX ET LA PE AU; LE 2. це Ене ae 34 sécurité approuvées. Des écrans latéraux
,
BRUIT PEUTENDOMMAGERL'OUIE. 3. Entourez l'aire de soudage de rideaux ou de cloisons pour
L'arc
de
soudage
produit
une
chaleur
et
des
protéger
les
autres
des
coups
d'arc
ou
de
l'éblouissement;
rayons
ultraviolets
intenses,
susceptibles
de
avertissez
les
observateurs
de
ne
pas
regarder
l'arc.
brüler les yeux et la peau. Le bruit causé par 4. Portez des vétements en matériaux ignifuges et durables (laine
certains procédés peut endommager l'ouie. et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d'oreille approuvés
lorsque le niveau de bruit est élevé.
2-1

PRECAUTIONS ОЕ SECURITE ЕМ SOUDAGE А ГАВС
Instruction 830002
SELECTION DES NUANCES РЕ FILTRES OCULAIRES POUR LA PROTECTION DES YEUX ЕМ COUPAGE ЕТ SOUDAGE
(selon AWS А 8.2-73 )
Opération
de
Coupage ou soudage
Brasage tendre au chalumeau
Brasage fort au chalumeau
Oxycoupage
mince
moyen
épais
Soudage aux gaz
mince
moyen
épais
Soudage à Рагс avec
electrode enrobées (SMAW)
Soudage à l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
métaux ferreux
Soudage à l'arc sous gaz
avec électrode de tungstène (GTAW)
Soudage à l'hydrogène
atomique (AHW)
Soudage à Гагс avec
électrode de carbone (CAW)
Soudage à l'arc Plasma (РАМУ)
Gougeage Аіг-Агс avec
électrode de carbone
mince
épais
Coupage à l'arc Plasma (PAC)
mince
moyen
épais
Dimension d'électrode ou
Epaisseur de métal ou
Intensité de courant
toutes conditions
moins de 1 po. (25 mm)
de 1 à 6 po. (25 а 150 mm)
plus de 6 po. (150 mm)
moins de 1/8 po. (3 mm)
de 1/8 à 1/2 po. (За 12 mm)
plus de 1/2 ро. (12 тт)
moins де 5/32 ро. (4 тт)
де 5/32 а 1/4 ро. (4 а 6.4 тт)
plus de 1/4 ро. (6.4 тт)
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes dimensions
moins de 300 ampères
de 300 à 400 ampères
plus de 400 ampères
Nuance de
de filtre
oculaire
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l'intérieur, assurez-vous que l'aire de soudage est bien ven-
tilée ou que les fumées et les vapeurs sont aspirées à l'arc.
3. Si la ventilation est inadequate, portez un respirateur à adduc-
tion d'air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux revéte-
ments et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s'il est bien ventilé;
sinon, portez un respirateur à adduction d'air. Les gaz protec-
teurs de soudage peuvent déplacer Гохудёпе de l'air et ainsi
causer des malaises ou la mort. Assurez-vous que l'air est
propre à la respiration.
6. Ne soudez pas à proximité d'opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l'arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7. Ne soudez des tóles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
51 l'espace est bien ventilé; si nécessaire portez un respirateur
à adduction d'air. Car ces revétements et tout métal qui con-
tient ces éléments peuvent dégager des fumées toxiques au
moment du soudage.
8-V-96

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
LE SOUDAGE PEUT CAUSER UN IN-
CENDIE OU UNE EXPLOSION
L'arc produit des étincellies et des projections. Les
particules volantes, ie métal chaud, les projections
de soudure et l'équipement surchauffé peuvent
causer un incendie et des brülures. Le contact
accidentel de l'électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un échauffement
ou un incendie.
. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
. Ne soudez pas dans un endroit oü des particules volantes ou
des projections peuvent atteindre des matériaux inflammables.
. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l'arc, ou couvrez-les soigneusement avec des
báches approuvées.
LES ETINCELLES ET LES PROJEC-
TIONS BRULANTES PEUVENT
CAUSER DES BLESSURES.
LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font nor-
malement partie du procédé de soudage, traitez-
les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles a un support ou а un
cadre fixe pour les empécher de tomber ou d’étre renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
MISE EN GARDE
LES GAZ D’ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement
nocifs.
LE CARBURANT PEUR CAUSER UN IN-
CENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Instruction 830002
. Méfiez-vous des projections brulantes de soudage suscep-
tibles de pénétrer dans des aires adjacentes par de petites
ouvertures ou fissures.
. Méfiez-vous des incendies et gardez un extincteur a portée de
ја main.
. N'oubliez pas qu'une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l'autre côté.
. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long par-
cours inconnu, et prévenir ainsi les risques d'électrocution et
d'incendie.
. Ne dégelez pas les tuyaux avec un source de courant.
. Otezl'électrode du porte-électrode ou coupez le fil au tube-con-
tact lorsqu'inutilisé apres le soudage.
. Portez des vêtements protecteurs non huileux, tels dès gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.
Le piquage et le meulage produisent des particules métalliques
volantes. En refroidissant, la soudure peut projeter du éclats de
laitier.
. Portez un écran facial ou des lunettes protectrices approuvées.
Des écrans latéraux sont recommandés.
. Portez des vétements appropriés pour protéger la peau.
. Empéchez tout contact entre une bouteille et une électrode de
soudage.
5. N'utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords congus pour chaque application
spécifique; ces équipements et les piéces connexes doivent
étre maintenus en bon état.
6. Ne placez pas le visage face à l'ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publica-
Чоп P-1 de la СВА, identifiée dans la liste de documents
ci-dessous.
LES MOTEURS PEUVENT ETRE DANGEREUX
. Utilisez l'équipement à l'extérieur dans des aires ouvertes et
bien ventilées.
. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d'échappement doivent étre envoyées à l'extérieur, loin
des prises d'air du bátiment.
. Ne faites pas le plein en fumant ou proche d'une source
d'étincelles ou d'une flamme nue.
3. Si c'est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d'en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l'espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
8-V-96

PRECAUTIONS DE SECURITE ЕМ SOUDAGE А РАКС
Instruction 830002
DES PIECES EN MOUVEMENT PEU-
VENT CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et
mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d'installer ou de connecter un système, arrêtez le moteur.
DES ETINCELLES PEUVENT FAIRE EX-
PLOSER UN ACCUMULATEUR;
L'ELECTROLYTE D'UN ACCUMU-
LATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l'électrolyte
acide et dégagent des vapeurs explosives.
LA VAPEUR ET LE LIQUIDE DE RE-
FROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d'un radiateur peut
étre brülant et sous pression.
. Seules des personnes qualifiées doivent démonter des protec-
teurs ou des capots pour faire l'entretien ou le dépannage
nécessaire.
4. Pour empécher un démarrage accidentel pendant l'entretien,
débranchez le cáble d'accumulateur à la borne négative.
5. N'approchez pas les mains ou les cheveux de pièces en mou-
vement; elles peuvent aussi accrocher des vétements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
aprés des travaux d'entretien et avant de faire démarrer le
moteur.
. Portez toujours un écran facial en travaillant sur un accumu-
lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
cábles d'accumulateur.
3. N'utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N'utilisez pas une source de courant de soudag
un accumulateur ou survolter momentanémen
5. Utilisez la polarité correcte (* et —) de l'accumulateur.
e pour charger
un véhicule.
. N'ôtez pas le bouchon de radiateur tant que le moteur n'est pas
refroidi.
. Mettez des gants et posez un torchon sur le bouchon pour Гбіег,
. Laissez la pression s'échapper avant d'ôter complètement le
bouchon.
PRINCIPALES NORMES DE SECURITE
Safety in Welding and Cutting, norme ANSI 749.1, American Weld-
ing Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
24
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, norme ANSI Z87.1, American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
8-V-96

430429-427
DESCRIPTION OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
Generator
The Меда-Агс® diesel engine-driven arc welding
machine is a self-contained unit, mounted on a
welded steel frame. The unit is covered by a sheet
metal canopy, bolted directly to the frame. The
control panel is at the back (generator) end of the
unit.
The generator is an asynchronous brushless self-
excited design. The rotor assembly is supported on
a heavy duty shaft by a single bearing at the rear and
a flexible disc coupling at the engine flywheel.
The generator is a self-excited design utilizing AC
capacitors permanently connected to an excitation
winding on the stator.
The welding circuit 3-phase, wye connected, rec-
tified to DC power by the output rectifier, and stabi-
lized by the stability reactor. The auxiliary power
current provides 115-volt and 230-volt AC power to
the receptacles on the Control Panel for operation
of small tools, lights, etc. See Tabulated Data for
rated auxiliary power of your unit.
Engine
The engine used in this unit is a Perkins Industrial
3-152 diesel engine. It is directly coupled to the
welding generator shaft by a flexible coupling.
Identification
The welding generator unit has an identification
plate attached to the control panel on the left-hand
side. The unit is identified as to SPEC number, by
the dash (—) number which follows it.
The engine identification number is stamped on
right-hand side ofthe cylinder block. When ordering
spare parts, or communicating about this machine,
be sure to specify the engine serial number, engine
type, unit specification and serial numbers. Left- and
right-hand sides of the unit are determined when
facing the control panel. See Supplementary Mate-
rials for address for communicating or ordering
engine parts.
Tabulated Data
Generator:
Output, Auxiliary Power.. ЗКМА, 115/230V AC
Output, Welding Generator ......... 12 kW
Amperes, rated ................ 300 Amps
Voltage, rated ................... 40 Volts
Voltage, open-circuit ....... (max.) 75 Volts
Duty Cycle, rated .................. 100%
Current Range —
И Low Range 1510 200A
НЯ High Range 30 to 400 А
Operating Speed ......... See Engine Data
Engine:
Make and model —
Sie de Detroit Diesel/Perkins 3-152
Type. ге аа Industrial diesel
Displacement ....... 152 cu. in. (2.50 liters)
Brake horsepower .... 38 BHP @ 1800 RPM
Oil sump capacity. ..... 7-1/2 quarts (7 liters)
Cooling system capacity —
За аа лань see cto 9-1/2 quarts (9 liters)
Fuel tank capacity —
За бані 17 gallons (U.S.) (64.4 liters)
Weight (dry) .......... 463 pounds (210 kg)
Normal operating RPM. ......... 1800 RPM
Dimensions and Weight: (See Figure 4-1)
Width (doors closed) ... 28 inches (711 mm)
Width (doors open).... 77 inches (1956 mm)
Length........... 61-1/2 inches (1562 mm)
Height (top of canopy) —
era nS Ne ta РАНО НЛО 41 inches (1041 mm)
Height (over eye in top) —
CT ОКИ 46 inches (1168 mm)
Weight (shipping) —
а das УА approx. 1700 pounds (765 kg)
August 24, 1998
3-1

430429-427
ОЕЗСКІРТІОМ ОР ЕОШРМЕМТ
Range Selector
Switch
Voltrneter
(Optional)
Ammeter
(Optional)
Control Box
Door
Fuel
Gauge
Contactor
Current
Control
Arc Force
Ampere Control 10 Arme
Circuit
Breakers
9 9 5 15 Volt
о, Кесеріасів
2
250 Мон
Receptacle
Current
Control
Switch
Control Remote
Switch Control
Receptacie
Throttle Igniti Hour
gnition Thermostart
Switch
Pushbutton
Ae er
Water
Meter
Ой Pressure 1g Temp.
ig Gauge А-467
Figure 3-1 Control Panel
Supplementary
Materials
NOTE:
Switch
must
be
in
OFF
position
to
Acopy ofthe Perkins Handbook for Diesel Engines
is included with each welding generator unit. Addi-
tional copies may be obtained from the manufac-
turer.
Engine Controls and Instruments
Ignition Switch — The diesel engine starting motor
is actuated by this switch, located in the lower
left-hand corner of the control panel. Do NOT crank
the engine for more than 30 seconds at a time, as
this may cause the starting motor to overheat. Allow
motor to cool before attempting to start the engine
again. Place switch in START position to start, and
return to RUN position after the engine has started.
When engine is shut down, place switch in OFF
position.
avoid lighting the Alternator and Oil Pres-
sure light.
Throttle — This control shuts the diesel fuel sup-
ply off, for normal shutdown of the engine. Pull the
control handle OUT all the way for engine to run at
rated RPM (1800). Push the handle /N against the
panel to shut engine down. Turn contro! handle
counterclockwise to loosen, and clockwise to lock
it in position.
Thermostart Pushbutton — Place the starter
Switch in КИМ position and hold the pushbutton /N
for 15 to 20 seconds, prior to placing the starter
switch in START position. Continue to hold it /N until
engine fires.
3-2
August 24, 1998

CAUTION: Do not hold the pushbutton
ІМ for any longer period of time than the
20 seconds (above). | engine does not
Start first time, place starter switch in
OFF position, then repeat above proce-
dure.
Oil Pressure Light — Glows (red) when oil pressure
drops to 3-5 psi for any reason.
Alternator Light — Glows when engine alternator
circuit is not charging the battery at sufficient level.
Fuel Gauge — Indicates level of fuel in fuel tank.
Hour Meter — Indicates run time on engine.
Water Temp. Gauge — Indicates coolant tempera-
ture.
Generator Controls
Range Selector Switch — This toggle switch is
used to select either the low or high welding range,
as indicated on the Current Control.
Current Control — The welding current control is
located in the center of the control box door panel.
Turning knob clockwise will increase welding cur-
rent, counterclockwise will decrease current.
Voltmeter (Optional) — Indicates open-circuit and
welding arc voltage, when supplied.
Ammeter (Optional) — Indicates welding current
being used to weld, when supplied.
Arc Force Ampere Control — Varies the short-cir-
cuit (welding arc) current and produces an increase
of amperage when arc length is shortened. Turning
430429-427
DESCRIPTION OF EQUIPMENT
this control clockwise increases arc force, counter-
clockwise decreases arc force. See Operation
chapter for details.
Welding Terminals — (See Figure 3-2) — The two
welding terminals are located on the Welding Output
Panel, which is located on the left-hand side of the
unit (facing the control panel). See instructions in
Initial Preparation for Use located in the Installation
chapter.
Auxiliary Power Receptacle — Duplex receptacles
located on the Control Panel (see Figure 3-1) furnish
3-kVA, 115-volt and 230-volt, 60-Hz power.
NOTE: The output voltage will drop below
the rated volts when engine is in the idling
mode. Low voltage may damage electrical
equipment connected to the generator
through this receptacle.
Welding
Terminals
Figure 3-2 Weld Output Panel
August 24, 1998

430429-427
DESCRIPTION OF EQUIPMENT
VOLT-AMP CURVES
MODEL MA-4030D
(TYPICAL)
WELDING VOLTS (DC)
ARC FORCE
SETIINGS
WELDING AMPS (DC)
Volt-Ampere Curve
3-4 August 24, 1998

430429-427
INSTALLATION
INSTALLATION
General Engine Driven Welder
Installation
The frame of an engine driven welder is intended
to be a base to held the welder components to-
gether. This frame is not intended to be the primary
structure of a trailer or wagon. This welder is in-
tended to be installed on a rigid, flat surface. This
surface must allow the weight of the welder to be
distributed емепіу along the length of the welder
frame.
Never install any vibration isolation material (shock
mounts, etc.) beneath the welder frame. This could
defeat the engine/generator shock mounts and
cause abnormal vibration throughout the welder
and produce vibration related problems.
Before choosing an installation location, make
note of where the service items are located on the
welder (oil change/fill, battery, air filter, fuel fill, etc.)
Install the welder for best access to the important
service items. Allow sufficient room for cooling air
intake and exhaust.
if you are unsure about any installation consult the
factory.
Trailer Installation: Do not use the frame assem-
bly of this welder as the frame of a trailer (do not
attach axles or tongues directly to this frame). Wnen
a trailer is required, use only trailers with its own
support frame that has a gross weight rated to carry
the weight of the welder and any other components
mounted on the trailer. Be sure the trailer tires are
for use with trailers. The soft sidewall design used in
radial tires can cause vibration related problems. Be
sure welder frame and trailer frame are electrically
bonded together.
Truck Bed Installation: When installing this
welder on the bed of a truck allow the welder to sit
flat on the bed, or a surface which completely con-
tacts the bottom of the welder frame. Do not modify
the welder frame by cutting or otherwise damaging
it or the warranty may be voided. Bolt the welder
frame directly to the bed to secure it. Do not install
any vibration absorption device (shock mounts, etc)
between the welder and the truck bed. Be sure
welder frame and truck frame are electrically
bonded together.
Ground Installation: The welder will operate per-
fectly fine just sitting on the ground, with or without
August 24, 1998
the shipping skid. No special precautions are re-
quired.
Location
For best operating characteristics and longest unit
life, take care in selecting an installation site. Avoid
locations exposed to high humidity, dust, high am-
bient temperature, or corrosive fumes. Moisture can
condense on electrical components, causing corro-
sion or shorting of circuits. Dirt on components
helps retain this moisture and also increases wear
on moving parts.
Safety
Refer to additional installation instructions under
the Safety Warnings chapter included in this man-
ual.
Indoor Installation
Adequate air circulation is needed at all times in
order to assure proper operation. Provide at least
24 inches (610 mm) of space at radiator end of unit.
Make sure that ventilation openings are not ob-
structed. Allow ample space to open canopy doors
on sides of the unit (see Tabulated Data in Descrip-
tion of Equipment chapter for dimensions) for serv-
icing, and space at the control panel end of unit for
Operation.
If unit is to be operated inside a building, make
certain there is adequate ventilation to carry off
escaping exhaust fumes and to provide an ample
supply of oxygen.
Place unit so that exhaust fumes are carried out of
the building using the shortest exhaust pipe possi-
ble and one with the fewest possible number of
bends. Exhaust back pressure can seriously affect
engine efficiency.
All exhaust connections must be gastight.
Portable Installation
For portable use, the machine may be located
within 12 inches (305 mm) of a truck cab, panel, or
whatever, if it is to be operated in the open air.
The engine ofthe welding machine must be placed
at the tongue end of the portable mounting for
proper balance. If leads, etc., are to be stored on ће
4-1

430429-427
INSTALLATION
unit, they must be forward ої the axle to maintain
proper balance of loading on the tongue end of the
unit.
NOTE: The unit should be operated in as
near a normal horizontal position as possi-
ble and never at a tilt greater than 10? side-
ways and/or 7? maximum, rear down.
Initial Preparation For Use
1. Open canopy doors on sides of engine.
CAUTION: The canopy doors may fall to
a closed position during operation of the
unit if it is resting on an inclined surface,
or for other reasons. Tie the doors to
each other, to lifting eye or fuel filler cap.
Failure to do so may result in injury to
operating personnel.
2. Inspect unit thoroughly to be sure it is in proper
working order. Check all fuel and wire connections
to be certain they are secure. Tighten any loose
screws, nuts, or bolts. Check closely for any dam-
age which may have occurred in transit.
3. Remove all special tags from the machine, read
carefully and follow any special directions they may
carry. Keep tags with manual for future reference.
4. Make certain that all radiator air passages and
cooling fins are free from foreign matter. Use clean,
dry compressed air to blow dirt and dust out of
cooling passages and control cabinet, 25 psi (172
kPa) maximum pressure.
5. Attach battery cables to poles of battery as
indicated on wiring diagram. The negative (—) pole
should be grounded to the frame of the unit in a
secure manner.
WARNING: Connect proper bat-
tery cable clamp to the positive
(* ) battery post first, then the
other cable clamp to the nega-
tive (—) post.
CAUTION: A short circuit to rectifier is
created if a battery is installed with po-
larity reversed. Current can flow from
positive terminal of battery through
negative and positive rectifiers and into
heat sink. From heat sink a completed
circuit exists back to negative battery
terminal. Full battery voltage will be im-
pressed on rectifiers, in the alternator.
The resulting high current will damage
rectifiers and/or wiring harness.
6. Fill fuel tank with grade of fuel recommended by
engine manufacturer. (Consult engine instruction
manual.) Be sure fuel is free of WATER and other
foreign matter. Make sure air vent to fuel tank is
open. See Safety Warnings chapter included in this
manual for precautions necessary when filling the
tank.
7. Check to be sure that radiator is full (about 1"
below neck). If not, add enough coolant (50/50 mix
of water and antifreeze) to fill.
8. Pull the dipstick and check the oil level in crank-
case. If it is necessary to add oil, fill to dipstick mark
with correct seasonal grade of quality detergent oil.
See engine operator's manual for recommended
viscosity and temperature chart (unit is shipped with
SAE 10W30 oil installed).
9. After engine has been properly prepared for use,
start the engine, and allow it to idle for 30 minutes
or so. Carefully check again for any leaks or loose
connections during this period.
10. Determine which welding polarity will be suit-
able for the welding job to be done.
a. For STRAIGHT polarity (DCEN) attach ELEC-
TRODE lead (leading to electrode holder) to the
NEGATIVE (—) terminal on the Terminal and Recep-
tacle Panel. Attach the WORK lead (with clamp on
end) to POSITIVE (* ) terminal.
b. For REVERSE polarity (DCEP) attach ELEC-
TRODE lead (leading to electrode holder) to the
POSITIVE (* ) terminal. Attach the WORK lead (with
clamp on end) to the NEGATIVE (—) terminal.
CAUTION: Do not change welding leads
while generator is running, as open-cir-
cuit voltage (80 volts) is furnished to the
terminals. Shut engine down to change
leads.
11. Make sure that no loose bars, tools, parts, etc.,
are in or on any part of engine as they could cause
4-2
August 24, 1998