Campbell Hausfeld Welder/Generator Manual de usuario

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

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

MANUAL

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Description

Unpacking

General Safety

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

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

General Safety

(Continued)

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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

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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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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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

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

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

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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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.

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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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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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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