Table of Contents
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Installation.......................................................................................................................Section A
Technical Specifications ................................................................................................A-1,A-2
Installation Instructions. ........................................................................................................A-3
Safety Precautions ...............................................................................................................A-3
Machine Grounding .......................................................................................................A-3
Spark Arrester ...............................................................................................................A-3
Trailers....................................................................................................................A-3,A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil ..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Battery Connections ......................................................................................................A-4
Welding Cable Connections ..........................................................................................A-4
Angle of Operation ........................................................................................................A-5
High Altitude Operation .................................................................................................A-5
Muffler Relocation .........................................................................................................A-5
Location and Ventilation ................................................................................................A-5
Connection of Wire Feeders (Constant Voltage)....................................................A-5,A-6
Connection of Tig Module .............................................................................................A-6
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
General Description..............................................................................................................B-1
Welder Output ......................................................................................................................B-1
Approximate Fuel Consumption ...........................................................................................B-2
Control Switch ...............................................................................................................B-2
Idler Switch....................................................................................................................B-2
Welding ....................................................................................................................B-2
Auxiliary Power ........................................................................................................B-2
Starting / Shutdown Instructions ...................................................................................B-2
Starting the Engine..................................................................................................B-2
Stopping the Engine ................................................................................................B-2
Break-In Period .......................................................................................................B-3
Welding Process ..................................................................................................................B-3
Stick (Constant Current) Welding..................................................................................B-3
TIG (Constant Current) Welding ...................................................................................B-3
Wire Feed Welding Processes(CV) .............................................................................B-4
Summary of Welding Processes ..................................................................................B-4
Auxiliary Power ............................................................................................................B-5
Motor Starting ...............................................................................................................B-5
Current Draw from Receptacle-No Welding .................................................................B-6
Electrical Devices used with the ZR-10.........................................................................B-6
Auxiliary Power While Welding .....................................................................................B-7
Standby Power Connections .........................................................................................B-7
Connection of ZR-10 to Premises Wiring .....................................................................B-8
Accessories .....................................................................................................Section C
Optional Equipment ...............................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Adjustments...............................................................................................D-2
Slip Rings ..............................................................................................................D-2
Battery ...................................................................................................................D-2
Honda Engine Maintenace Schedule ....................................................................D-2
Hardware ...............................................................................................................D-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
Diagrams .........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Connection Diagram .............................................................................................F-2
Diminsion Print.......................................................................................................F-3
Parts List ..................................................................................................................P380
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