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Engine Cooling System
WARNING
Air to cool the engine is drawn in the base sides and
exhaust through radiator & case back. It is important
that the intake and exhaust air is not restricted. Allow a
minimum clearance of 0.6m from the case back and
40cm from either side of the base to a vertical surface.
Battery Connection
WARNING
Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.
The machine is shipped with the negative battery cable
disconnected. Make certain that the RUN-STOP switch
is in the STOP position. Attach the negative battery
cable to the negative battery terminal and tighten using a
13mm socket or wrench. It may be helpful to remove the
coolant over-fill bottle. Pull up on bottle to remove from
bracket.
Note: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the
battery with the correct polarity.
Muffler Outlet / Spark Arrestor
In addition to operating as a Spark Arrestor. The Spark
Arrestor serves as an outlet cover for the muffler as well
as providing additional sound reduction. Remove from
the box and install using the clamp and instructions
provided. An incorrect spark arrestor may lead to
damage to the engine or adversely affect performance.
WARNING
An incorrect spark arrestor may lead to damage to the
engine or adversely affect performance.
Remote Control
The machine is equipped with a 6-pin and a 14-pin
connector. The 6-pin connector is for connecting the
K857 or K857-1 Remote Control or for TIG welding, the
K870 foot Amptrol or the K963-3 hand Amptrol. When in
the CC-STICK, DOWNHILL PIPE, or CVWIRE modes
and when a remote control is connected to the 6-pin
Connector, the auto-sensing circuit automatically
switches the OUTPUT control from control at the welder
to remote control.
When in TOUCH START TIG mode and when an
Amptrol is connected to the 6-Pin Connector, the
OUTPUT dial is used to set the maximum current range
of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect a wire
feeder control cable. In the CV-WIRE mode, when the
control cable is connected to the 14-pin connector, the
auto-sensing circuit automatically makes the Output
Control inactive and the wire feeder voltage control
active.
WARNING
NOTE:
When a wire feeder with a built in welding
voltage control is connected to the 14-pin connector, do
not connect anything to the 6-pin connector.
Electrical Connections
English
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 to
which this engine driven welder supplies power must:
Be grounded to the frame of the welder using a
grounded type plug.
Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame of
the vehicle. Use a #8 or larger copper wire connected
between the machine grounding stud and the frame of
the vehicle. When this engine driven welder is
connected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the
section entitled "Standby Power Connections".
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.
A machine grounding stud marked with the symbol
provided on the front of the welder.
Welding Terminals
The machine is equipped with a toggle switch for
selecting "hot" welding terminal when in the "WELD
TERMINALS ON" position or "cold" welding terminal
when in the "REMOTE" position.
Welding Output Cables
With the engine off connect the electrode and work
cables to the output studs. The welding process dictates
the polarity of the electrode cable. These connections
should be checked periodically and tightened with a
19mm wrench.
Table below lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Total Combined Length of Electrode and Work
Cable Length
0-30 meters
30-46 meters
46-61 meters
6
WARNING
Cables
Cable Size for 305 A @
35%Duty Cycle
1/0 AWG
2/0 AWG
3/0 AWG
English
is
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