●
USING A BOOSTER — connect
positive lead to battery first then
connect negative lead to negative
battery lead at the lower control
panel support.
BATTERY ACID can burn eyes and skin.
●
Wear gloves and eye protection and be careful
when working near battery.
●
Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
• Spark Arrester and Muffler may be
hot!
• Allow engine to cool before servicing
spark arrester!
• Do not operate engine while servicing
spark arrester!
------------------------------------------------------------------------
SPARK ARRESTER
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca-
tions where unarrested sparks may present a fire haz-
ard. The muffler included with this welder has been
modified and now qualifies as a spark arrester. Spark
arresting mufflers will have a clean out service plug
and will have “US FOREST SERVICE APPROVED”
stamped on the muffler shell. Any spark arrester must
be serviced and properly maintained.
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
A-5
INSTALLATION
SAE-500™
A-5
WELDING OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary.
Listed in Table A.1 are copper cable sizes recom-
mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased
for greater lengths primarily for the purpose of mini-
mizing cable voltage drop.
Table A.1 Combined Length of Electrode and
Work Cables.
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug, or
b) be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See the article on grounding in the latest U.S.
National Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
welding generator frame foot.
Up to 100FT.
Up to 31m
2/0 AWG
100-200FT.
31-61m
3/0 AWG
200-250FT.
61-76m
4/0 AWG
AMPS
@60%
Duty Cycle
400
TOTAL COMBINED LENGTH OF ELEC-
TRODE AND WORK CABLES
WARNING
CAUTION
Summary of Contents for SAE -500
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