GW4500
Welder Operation (Continued)
5.Tighten the set screw, securing the cable in place.
6.Slide the insulated handle onto the electrode holder and tighten the phillips head screw. Do not overtighten the phillips head screw. Overtightening will damage the insulated handle.
DINSE PLUGS (SEE FIGURE 3)
1.Strip 1/2 inch 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.
Set Screw | Boot |
| Welding |
| Cable |
Wire Sleeve |
|
Dinse Plug |
|
Figure 3 |
|
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.
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 protected from overheating with an automatic thermal switch.
Maintenance
INFREQUENT USAGE
If the welder / generator is used infrequently, starting difficulty may occur. To help prevent this, the welder / generators should be run for approximately 30 minutes per week.
STORAGE
If the welder / generators is not to be used for extended periods of time, the following
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
Refer to the engine manual that accompanies this unit for instructions regarding maintenance of engine components.
Never tamper with engine speed
settings or welder / generators frequency settings. Any governor adjustments should be made by qualified personnel only.
WELD CABLES
1.Check condition of weld cables and immediately repair or replace any cables with damaged insulation.
2.Check condition of electrode holder insulating pieces and immediately replace cracked or missing parts.
EVERY 3 MONTHS
Replace any unreadable labels on the welder. Use compressed air to blow all dust and lint from the ventilation openings.
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