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manual abstract
Unit is shipped with 10W30 engine oil. Engine stops if oil pressure gets too low. ET Follow run-in procedure in engine manual. 1 Fuel Add fresh fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13mm)from top to allow room for expansion (see fuel tank window on base). 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). 03 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. Engine Prestart Checks (Kohler-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure gets too low. ET Follow run-in procedure in engine manual. 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 (see fuel tank window on base). 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). 03 To improve cold weatherstarting: Keep battery in good condition. Store battery in warm area off concrete surface. Use correct grade oil weather. for cold OM-945 Page 13 4-4. Activating The Dry Charge Battery (If Applicable) £ °o^ 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 elec-trolytelevel. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger A 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. U3 When electrolyte is low, add only distilled water to cells to maintain proper level. Tools Needed: glasses drybatt! 1/98 - S-0886 OM-945 Page 14 3-4. Fuel Consumption (All Models) ai i \ to cc LU 7.57 6.62 5.67 4.73 3.78 2.84 1.89 0.95 DC < O 1.67 1.46 1.25 1.04 0.84 0.63 0.42 0.21 Q£ I < o <ñ d> WELD AMPERES AT 100% DUTY CYCLE ■ ■_i_i_i_i_i_i_i_i_i_i 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 POWER KVA AT 100% DUTY CYCLE 3-5. Duty Cycle £k Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. A Exceeding duty cycle can damage unit and void warranty. % DUTY CYCLE Continuous Welding 100% Duty Cycle at 170 Amperes CC/DC 6 Minutes Welding 4 Minutes Resting 60% Duty Cycle at 210 Amperes CC/DC 3 Minutes Welding 7 Minutes Resting 30% Duty Cycle at 230 Amperes CC/DC 197 148 OM-945 Page 11 3-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. DC AMPERES 197 253 SECTION 4 - INSTALLATION 4-1. Installing Welding Generator A Movement A Do not lift unit from end. OR Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Location Grounding \ \J \ \ / ) / Tt^ OR Electrically bond generator frame to vehicle frame by metal-to-metal contact. A Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use #10 AWG or larger insulated copper wire. A If unit does not have GFCI receptacles, use GFCI-protected extension cord. install! 8/99 - Ref. 800 652 / Ref. 800 477-A/ 158 936-A/ S-0854 OM-945 Page 12 4-5. Connecting the Battery ik Tools Needed: S ■ £ 1/2 in Ref. 194 024 / Ref. 802 341 / Ref. S-0756-D 4-6. Installing Exhaust Pipe A ET Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: ~-~T 1/2 in 801 681 / Ref. 194 024 OM-945 Page 15 4-7. Connecting to Weld Output Terminals A 1 Negative (-) Weld Output Terminal 2 Positive (+) Weld Output Terminal For Direct Current Electrode Positive (DCEP), connect work cable to Negative (-) terminal and elec-trode holder cable to Positive (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections. Tools Needed: ■5~ 4? 3/4 in Ref. 194 024 4-8. Selecting Weld Cable Sizes Welding Amperes 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%...