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Fuel Consumption 226 022-A 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 25 50 75 100 140 U.S. Gal./Hr. Power In KW Weld Amps At Rated Duty Cycle Weld Aux Power OM-4418 Page 14 4-4. Duty Cycle 212 950 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. 1 100% Duty Cycle This unit is rated for continuous welding at 90 amperes CC/AC. 2 30% Duty Cycle This unit is rated at 30% duty cycle (3 minutes welding, 7 minutes resting) at 140 amperes CC/AC. NOTICE . Exceeding duty cycle can damage unit and void warranty. 1 2 4-5. Generator Power Curve 226 077 The ac generator power curves show the generator power available in amperes at the receptacles. 300 250 200 150 100 50 0 0 10 20 30 40 50 60 AC Power Volts AC Power Amperes 4-6. Volt-Ampere Curves 226 078 The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. 90 80 70 60 50 40 30 20 10 0 0 50 100 150 200 AC Volts AC Amps Max Amp Min Amp Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-4418 Page 15 OM-4418 Page 16 SECTION 5 . INSTALLATION 5-1. Installing Welding Generator Ref install1 8/06 . Ref. 151 556 / 158 936-A / 803 467-C / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Movement Airflow Clearance Location ! Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. ! Do not install unit where air flow is restricted or engine may overheat. 3 Rating Label . Typical Locate rating label on unit. Label provides information such as weld output ratings, generator ratings, and engine information. Evidence of label tampering voids warranty. Ref: rot_label 2008-01 . 803 467 1 5-2. Rating Label Location OM-4418 Page 17 ! Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ! Bed liners, shipping skids, and some running gear insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. ! If unit does not have GFCI receptacles, use GFCI-protected extension cord. 1 Equipment Grounding Terminal (On Front Panel) 2 Grounding Cable (Not Supplied) 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. Electrically bond generator frame to vehicle frame by metal- to-metal contact. 5-3. Grounding Generator To Truck Or Trailer Frame rot_grnd 2008-01 . 800 652-D 1 3 2 GND/PE 5-4. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Use ground device as stated in electrical codes. OM-4418 Page 18 Open/On 1 Closed/Off 5-5. Engine Prestart Checks 803 468-D Full Gasoline 1/2 in (13 mm) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low. 1 Fuel Valve Open valve. Close fuel valve before moving unit or carburetor may flood and make starting difficult. Fuel Add fresh fuel before starting engine the first time . Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day. Oil After fueling, check oil with unit on level surface. If oil reservoir is not full, add oil until oil nearly overflows at oil fill. This unit has a low oil level shutdown switch to prevent starting an engine that is low on oil. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the low oil level shutdown system to monitor oil level. To improve cold weather starting, use correct grade oil for cold weather (see engine owner’s manual). Always close fuel valve after stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult. OM-4418 Page 19 5-6. Connecting To Weld Output Terminals 803 469-D / 226 005 / 803 778-A 1 AC Weld Output Terminals Connect work and electrode cables to weld terminals. (Polarity does not matter for AC welding.) ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 2 Weld Output Terminal 3 Supplied Weld Output Terminal Nut 4 Weld Cable Terminal 5 Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. ...