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Welder Operation
WELDING LEAD ASSEMBLIES
Welding lead assemblies are not included with all units. Use custom
copper welding cables in the size specified in Table 2 (page 13).
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 a properly
shaded lens (minimum shade 10), flame resistant clothing, leather
welding gloves, and full foot protection.
If heating, welding, or cutting materials that
are galvanized, zinc plated, lead, or cadmium
plated refer to the General Safety Information Section for
instructions. Toxic fumes may be created when these materials are
heated.
2
. Connect the GROUND 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 desired current range with the range selector switch
located at the upper right hand corner of the Alternator control
1
panel. Refer to Figure 6 (page 13). White number 1
2
low range, Black number
3 , for high range.
Compressor Operation
Before starting the compressor, thoroughly
read all component instructions manuals,
especially the engine manual.
1. Start unit per STARTING instructions on page 11.
2. Adjust the regulator knob to vary the outlet pressure according to
the requirements of the tool(s) being used.
3. Connect air hose(s) to outlet connector(s) and connect tool(s) to
hose(s).
4. An ASME safety valve in the manifold will automatically release air
if the tank pressure exceeds the preset maximum.
5. The discharge tube carries compressed air from the pump to the
check valve. This tube becomes very hot during use. To avoid the
risk of severe burns, never touch the discharge tube.
6. The check valve allows air to enter the tank(s), but prevents air in
the tank(s) from flowing back into the compressor pump.
7. There is a drain valve underneath the air tank. Use this valve to
drain moisture from the tank daily to reduce the risk of corrosion.
Reduce tank pressure below 10 psi, then drain the moisture from
the tank daily to avoid tank corrosion.
Drain liquid from tank daily.
14
1
, indicates
2
for medium range, and Red number
2
3
3
5. Set the welding current adjustment knob (see figure 6) to the
proper amperage for the electrode diameter. Refer to the
electrode manufacturer for proper current settings.
Operating the welder above 200 amps exceeds
engine capacity. Do not weld with the welding
current adjustment knob in any of the last four positions while in
the highest toggle switch setting. Doing so may result in damage to
the engine.
The electrode holder and rod are electrically
"live" (current potential) when the engine is
running.
6. Before striking an arc to begin the welding operation, disconnect
ALL loads from the Generator.
7. Position the electrode to begin weld, lower the welding helmet or
position the hand shield, and strike an arc. Adjust weld amperage
as needed.
8. 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 the alternator are protected from overheating
with an automatic thermal switch.
8. All lubricated compressor pumps discharge some condensed
water and oil with the compressed air. Install appropriate water /
oil removal equipment and controls as necessary for the intended
application.
Failure to install appropriate water / oil
removal equipment may result in damage to
machinery or workpiece.
Do not attach air tools to open end of the hose
until startup is complete and the unit checks
okay.
MOISTURE IN COMPRESSED AIR
Moisture in compressed air will form into droplets as it comes
from an air compressor pump. When humidity is high or when a
compressor is in continuous use for an extended period of time,
this moisture will collect in the tank. When using a paint spray or
sandblast gun, this water will be carried from the tank through
the hose, and out of the gun as droplets mixed with the spray
material.
IMPORTANT: This condensation will cause water spots in a paint
job, especially when spraying other than water based paints. If
sandblasting, it will cause the sand to cake and clog the gun,
rendering it ineffective. A filter or air dryer in the air line, located as
near to the gun as possible, will help eliminate moisture.
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