Assessments - 3, GPA: 3
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1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 3 4 2 OR OR 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location Grounding Do not lift unit from end. 4-1. Installing Welding Generator 4-2. Engine Prestart Checks Ref. 151 983 / 801 942-C / Ref. 800 395 1/2 in (13 mm) Full Gasoline Full Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in engine manual. This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. 1 Fuel Add fresh fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day. 2 Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). To improve cold weather starting: Keep battery in good condition. Store battery in warm area off concrete surface. Use correct grade oil for cold weather. 4-3. Activating The Dry Charge Battery (If Applicable) 3 1 2 4 5 Remove battery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well Fill each cell with electrolyte to bottom of well (maximum). . Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger . Read and follow all instructions supplied with battery charger. Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery. . When electrolyte is low, add only distilled water to cells to maintain proper level. 6 + – 5 A For 30 Minutes Tools Needed: rubbergloves OR 30 A For 12 Minutes glasses drybatt1 1/98 – S-0886 OM-4402 Page 14 OM-4402 Page 15 4-4. Connecting The Battery Ref. 800 394-C / Ref. 198 912 / Ref. S-0756-D + – 3/8, 1/2 in Connect negative (–) cable last. Tools Needed: 4-5. Installing Exhaust Pipe 801 681 / Ref. 198 912 Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: 1/2 in 4-6. Connecting To Weld Output Terminals Do not connect to CC and CV terminals at the same time. 1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld Output Terminal 3 Wire (CV) Weld Output Terminal For MIG welding, connect work cable to Work terminal and wire feeder cable to Wire (CV) terminal. For Stick/TIG welding, connect work cable to Work terminal and electrode holder cable to Stick/TIG (CC) terminal. 801 943-B / Ref. 198 912 1 2 3 4-7. Selecting Weld Cable Sizes Welding Amperes AmperesAmperes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E 4-8. Remote 14 Receptacle Information Engine runs at weld/power speed whenever a device connected to the remote 14 receptacle is running. NOTE AJ K I B L NH D DDM MM G GG E C F Socket* Socket Information 24 VOL 24 VOL24 VOLTS TSTS AC ACAC 1 1115 VOL 15 VOL15 VOLTS TSTS AC ACAC A/V A/V AMPERAGE AMPERAGEAMPERAGEVOLTAGE GND GND 801 943-B *The remaining sockets are not used. A 24 volts ac. B Contact closure to A completes 24 volt ac contactor control circuit. Protected by circuit breaker CB5. I 115 volts ac. J Contact closure to I completes 115 volt ac contactor control circuit. Protected by circuit breaker CB6. C 0 to +10 volts dc output to remote control. D Remote control circuit common. E 0 to +10 volts dc input command signal from remote control. G Circuit common for 24 and 115 volt ac circuits. K Chassis common. OM-4402 Page 16 OM-4402 Page 17 4-9. Adjusting MIG Weld Puddle Consistency 801 944-C / Ref. 198 912 Stop engine. Stabilizer DC-Z is factory connected to suit most MIG (Wire Welding) applications. To change MIG weld puddle consistency, proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three leads 79 will be referred to as inner, middle, and outer. 1 Stabilizer DC-Z 2 Inner Lead 79 3 Middle Lead 79 4 Outer Lead 79 5 Wire (CV) Weld Output Terminal Middle lead 79 is connected to Wire (CV) weld termin...