OPERATING INSTRUCTIONS (CONTINUED)
Welder Operation
Welding leads assemblies are not included with all units. See pages 34 and 35 for available welding cable sets or
use custom copper welding cables in the size specified in Table 3 (page 8).
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.
(minimum shade 10), flame resistant clothing, leather welding gloves, and full foot protection.
Toxic fumes may be created when these materials 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 desired current range with the range selector switch located at the upper right hand corner of the
Alternator control panel. White indicates low range, Yellow for medium range, and Red for high range.
5. Set the welding current adjustment knob to the proper amperage for the electrode diameter. Refer to the
electrode manufacturer for proper current settings.
the highest toggle switch setting. Doing so may result in damage to the engine.
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.
Compressor Operation
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 tanks, but prevents air in the tanks from flowing back into the
compressor pump.
7. There is a drain valve underneath the front air tank. Use this valve to drain moisture from the tanks daily to
reduce the risk of corrosion. Reduce tanks pressure below 10 psi, then drain the moisture from the tanks
daily to avoid tank corrosion.
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.
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
If heating, welding, or cutting materials that are galvanized, zinc plated, lead, or
cadmium plated refer to the General Safety Information Section for instructions.
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 electrode holder and rod are electrically "live" (current potential) when the
engine is running.
Before starting the compressor, thoroughly read all component instructions
manuals, especially the engine manual.
Drain liquid from tank after each use.
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.
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