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
6
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
!
WARNING
Welder Operations
(Continued)
100 A
6 AWG (15 mm
2
)
6 AWG (15 mm
2
)
4 AWG (20 mm
2
)
150 A
6 AWG (15 mm
2
)
3 AWG (25 mm
2
)
2 AWG (35 mm
2
)
200 A
4 AWG (20 mm
2
)
2 AWG (35 mm
2
)
1 AWG (40 mm
2
)
250 A
3 AWG (25 mm
2
)
2 AWG (35 mm
2
)
1/0 AWG (55 mm
2
)
* 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
