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manual abstract
Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low. 1 Fuel Valve Open valve. Close fuel valve before moving unit or carburetor may flood and make starting difficult. Fuel Add fresh fuel before starting engine the first time . 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. Oil After fueling, check oil with unit on level surface. If oil reservoir is not full, add oil until oil nearly overflows at oil fill. This unit has a low oil level shutdown switch to prevent starting an engine that is low on oil. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the low oil level shutdown system to monitor oil level. To improve cold weather starting, use correct grade oil for cold weather (see engine owner’s manual). Always close fuel valve after stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult. OM-4418 Page 18 5-4. Connecting To Weld Output Terminals 803 469-D / 226 005 / 803 778-A 1 AC Weld Output Terminals Connect work and electrode cables to weld terminals. (Polarity does not matter for AC welding.) ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 2 Weld Output Terminal 3 Supplied Weld Output Terminal Nut 4 Weld Cable Terminal 5 Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean. Tools Needed: 3/4 in 1 5 3 4 Do not place anything between Correct Installation Incorrect Installation 2 weld cable terminal and copper bar. 5-5. Selecting Weld Cable Sizes* Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or poorly spliced cables. Welding Amperes Weld Cable Size** and 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 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) * This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **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. ( ) = mm2 for metric use S-0007-F ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-4418 Page 19 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MATERIAL THICKNESS REFERENCE CHART OM-4418 Page 20 OM-4418 Page 21 SECTION 6 . OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) 803 468-D / 803 469-D / 226 005 2 3 1 4 6-2. Description Of Controls (See Section 6-1) 1EngineSwitchUseswitch to control ignition circuit, and tostopengine. 2Choke ControlUsecontrol to change engine air/fuel mix. Movecontrol to right (Choke) if starting a coldengine.Move control to left (Run) if starting awarm engine. 3Starter HandleTo Start: Open fuel valve (see Section 5-3). Turn Engine switch to On. Set Choke control. Pull starter handle until engine starts. Move Choke control to the left (Run) asthe engine warms. This unit has a low oil level shutdown to prevent starting an engine that is too low on oil. The low oil level shutdown may not stop a running engine. Check oil level if the engine does not start, or has stopped and cannot be restarted. To Stop: turn engine switch to Off. Always close fuel valve after stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult. 4Amperage ControlUse control to select weld amperage. Controlmaybe adjusted while welding. Set Amper- age control at max. for full generator poweroutputat ac receptacles. To Set Amperage control: Use electrodechart(see Section 6-3) to determine correctsize electrode. Select electrode type and setAmperagecontrol to corresponding amper- age range on nameplate. Adjust control withinselectedrang...
Other models in this manual:Welding Systems - CHAMPION 4500 210 597J (4.01 mb)