John Deere AC2-CW5220H, AC2-CW5170S User Manual

AC2-CW5170S AC2-CW5220H WELDERATOR

RISK OF INJURY! READ ENTIRE MANUAL

BEFORE OPERATING! THIS MANUAL IS AN IMPORTANT

PART OF THE WELDERATOR AND MUST REMAIN

WITH THIS UNIT WHEN YOU SELL OR RENT IT!

CAUTION

Introduction

THANK YOU for purchasing a John Deere product. READ THIS MANUAL carefully to learn how to operate

and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.

MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch

fasteners may require a specic metric or inch wrench.

RIGHT HAND AND LEFT HAND sides are determined by facing the motor end of the machine.

The SERIAL NUMBER is located in the Specication or Identication Numbers section. Accurately record all the

numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order

parts. File the identication numbers in a secure place

off the machine. WARRANTY is provided from your dealer for customers

who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty

certicate shown in this manual.

This warranty provides you the assurance that your dealer will back products where defects appear within the warranty period. Should the equipment be abused,

or modied to change its performance beyond the original factory specications, the warranty will become void.

PROTECT YOUR INVESTMENT......

Warning: This product contains lead, a chemical known to the State of California to cause birth defects or other reproductive harm.

Wash your hands after handling this product.

2 Operator’s Manual

Use only John Deere Fuel Protect Fuel Stabilizer with Ethanol Protection TY27534 or TY27535. Developed to ensure Optimum Performance and Protection.

IMPORTANT...Use Year Round!

34-1904 012011

Contents

INTRODUCTION ....................................................................................................................................................2

RECOGNIZE SAFETY INFORMATION .................................................................................................................4

CONTROLS ..................................................................................................................................................14-16

INSTALLATION .................................................................................................................................................... 17

OPERATION ....................................................................................................................................................... 22

START-UP ....................................................................................................................................................... 22

WELDING START-UP ..........................................................................................................................................22

SHUTDOWN .......................................................................................................................................................24

OPERATING CONTROLS ....................................................................................................................................24

CABLE SIZE .......................................................................................................................................................25

TROUBLESHOOTING .........................................................................................................................................26

MAINTENANCE ...................................................................................................................................................28

MAINTENANCE CHART: ..................................................................................................................................... 28

CHECKING ENGINE OIL ..................................................................................................................................... 29

CHANGING ENGINE OIL ..................................................................................................................................... 29

WIRING DIAGRAM/ SCHEMATIC ..................................................................................................................33-35

STORAGE........ ....................................................................................................................................................36

SPECIFICATIONS ................................................................................................................................................ 37

WARRANTY ....................................................................................................................................................... 38

All information, illustrations and specications in this manual are based

on the latest information available at the time of publication. The right is

reserved to make changes at any time without notice.

Operator’s Manual 3

CAU

Safety

RECOGNIZE SAFETY INFORMATION

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

A signal word--DANGER, WARNING or CAUTION--is used

with the safety-alert symbol. DANGER identies the most

serious hazards. DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and safety signs on your machine. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your dealer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modications to the machine may impair the

function and/or safety and affect machine life. If you do not understand any part of this manual and need

assistance, contact your dealer.

4 Operator’s Manual

CARBON MONOXIDE - POISONOUS GAS

DANGER DANGER PELIGRO

Use unit outdoors, away from open windows, vents, or doors. Unit exhaust contains carbon monoxide - a poisonous gas that can

kill you. You CAN NOT smell or see this gas. Never use the unit in enclosed or partially-enclosed spaces. The

unit can produce high levels of carbon monoxide very quickly. When you use this unit, remember that you cannot smell or see carbon monoxide. Even if you can’t smell exhaust fumes, you may still be exposed to carbon monoxide.

If you start to feel sick, dizzy, or weak while using the unit, get to fresh air RIGHT AWAY. DO NOT DELAY. The carbon monoxide from the unit can rapidly lead to full incapacitation and death.

If you experience serious symptoms, get medical attention immediately. Inform medical staff that carbon monoxide poisoning is suspected. If you experienced symptoms while indoors, have

someone call the re department to determine when it is safe to

re-enter the building. Never operate the unit in an explosive atmosphere, near combustible

materials or where ventilation is not sufcient to carry away exhaust

fumes. Exhaust fumes can cause serious injury or death. NEVER use the unit indoors, including in homes, garages,

basements, crawl spaces, and other enclosed or partially-enclosed areas, even with ventilation. Opening doors and windows or using fans will not prevent carbon monoxide build-up in the home.

Follow the instructions that come with your unit. Locate the unit outdoors and away from doors, windows, and vents that could allow the carbon monoxide gas to come indoors.

ONLY run unit outdoors and away from air intakes. NEVER run unit inside homes, garages, sheds, or other semi-

enclosed spaces. These spaces can trap poisonous gases EVEN IF you run a fan or open doors and windows.

If you start to feel sick, dizzy, or weak while using the unit, shut if off and get fresh air IMMEDIATELY. See a doctor. You may have carbon monoxide poisoning.

Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up in your home, according to the manufacturer’s installation instructions. The carbon monoxide

alarms should be certied to the requirements of the latest safety

standards for carbon monoxide alarms. (UL 2034, IAS 6-96, or CSA 6.19.01).

Test your carbon monoxide alarm frequently and replace dead batteries.

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a

poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

L'utilisation d'un groupe électrogène à l'intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le gaz d'échappement du groupe électrogène contient de l'oxyde de carbone. C'est un gaz toxique que l'on ne peut pas voir ou sentir. Ne JAMAIS utiliser à l'intérieur d'une maison ou d'un garage, MÊME SI les portes et fenêtres s'ont ouvertes.

N'utiliser qu'à l'EXTÉRIEUR et bien éloigné des fenêtres, portes, et conduits d'aération.

Utilizando un generador adentro PUEDE MATARLE EN MINUTOS. El escape de generador contiene monóxido de carbono. Este es un gas tóxico que usted no puede ver ni puede oler.

Nunca utilice dentro de un hogar ni el garaje, INCLUSO SI puertas y ventanas estén abiertas. Solo utilice AFUERAS y lejos de ventanas abiertas, las puertas, y descargas.

34-1916-092410-E-F-S.

Operator’s Manual 5

SAFETY WARNING WHEN REFUELING

Injury or death may occur as a result of improper fueling. Do not smoke

while lling engine fuel tank.

Always refuel slowly to avoid the possibility of spilled fuel which may

cause a risk of re. Gasoline is extremely ammable and its vapors can explode if ignited.

Observe all safety regulations for the safe handling of fuel. Handle fuel in safety containers. If the container does not have a spout, use a funnel.

Do not overll the fuel tank, leave room for the fuel to expand.

Fill the tank only on an area of bare ground. While fueling the tank, keep

heat, sparks and open ame away. Carefully clean up any spilled fuel

before starting engine.

Always ll fuel tank in an area with plenty of ventilation to avoid inhaling

dangerous fumes. NEVER store fuel for your unit in the home. Gasoline, propane, kerosene,

and other ammable liquids should be stored outside of living areas in

properly-labeled, non-glass safety containers. Do not store them near a fuel-burning appliance, such as a natural gas water heater in a garage. If the fuel is spilled or the container is not sealed properly, invisible vapors from the fuel can travel along the ground and can be ignited by the appliance’s pilot light or by arcs from electric switches in the appliance.

6 Operator’s Manual

ELECTRICAL HAZARDS

This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. Do not touch live electrical parts.

DANGER - IMPROPER CONNECTION OF THE EQUIPMENT-

GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTROCUTION. CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE INDOUBT AS TO WHETHER THE UNIT IS PROPERLY GROUNDED.

This unit is equipped with a grounding terminal for your protection. Always complete the ground path from the unit to an external ground source as instructed in the section labeled “Grounding Instructions” in the Preparation section of this manual.

The unit is a potential source of electrical shock if not kept dry. Keep the unit dry and do not use in rain or wet conditions. To protect from moisture, operate it on a dry surface under an open, canopy-like structure. Dry your hands if wet before touching the unit.

Plug appliances directly into the unit. Or, use a heavy duty, outdoorrated extension cord that is rated (in watts or amps) at least equal to the sum of the connected appliance loads. Check that the entire cord is free of cuts or tears and that the plug has all three prongs, especially a grounding pin.

NEVER try to power the house wiring by plugging the unit into a wall outlet, a practice known as “back feeding”. This is an extremely dangerous practice that presents an electrocution risk to utility workers and neighbors served by the same utility transformer. It also bypasses some of the built-in household circuit protection devices.

If you must connect the unit to the house wiring to power appliances, have a qualified electrician install the appropriate equipment in accordance with local electrical codes. Or, check with your utility company to see if it can install an appropriate power transfer switch.

For power outages, permanently installed stationary units are better suited for providing backup power to the home. Even a properly connected portable unit can become overloaded. This may result in overheating or stressing the unit components, possibly leading to a unit failure.

Do not use worn, damaged, undersized, or poorly spliced welding cables. Do not drape welding cables over your body. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

Operator’s Manual 7

RISK OF FIRE OR EXPLOSION

Serious injury or death may occur from normal sparks in the engine

ignition system or engine exhaust/mufer. Always operate the unit in a well ventilated area free of ammable vapors, combustible dust, gases

or other combustible materials. Do not weld where the atmosphere may

contain ammable dust, gas, or liquid vapors (such as gasoline). DO NOT SMOKE if spraying ammable material. Locate the unit at least

20 feet away from the spray area. (An additional hose may be required.)

Never ll the engine fuel tank while the engine is running or hot. Allow

the engine to cool two minutes before refueling. Do not refuel indoors or in a poorly ventilated area.

Do not operate the unit if gasoline is spilled. Wipe the unit clean and move it away from the spill. Avoid creating any ignition until the gasoline has evaporated.

Do not store the unit near an open ame or any equipment such as a

stove, furnace, water heater, etc. which utilizes a pilot light or sparking device.

A spark arrester must be added to the mufer of this engine if it is to be

used on any forest covered, brush covered or grass covered unimproved land. The arrester must be maintained in effective working order by the operator.

Serious injury may occur if any of the unit's ventilation openings are

restricted, causing the unit to overheat and start a re. Never place

objects against or on top of the unit. Operate the unit at least 12 inches away from any wall or obstruction that would restrict proper ventilation.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode. Accidental contact of electrode to metal objects can

cause sparks, explosion, overheating, or re. Remove all ammables within 35 ft (10.7 m) of the welding arc. Do not

weld where ying sparks can strike ammable material. Watch for re, and keep a re extinguisher nearby.

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and ames. Remove stick electrode from holder when

not in use.

RISK OF BURSTING

Serious injury or death may occur from an air tank explosion if air tanks are not properly maintained. Drain air tank daily or after each use to prevent moisture buildup in the air tank.

If air tank develops a leak, replace the air tank immediately. Never repair,

weld or make modications to the air tank or its attachments. Use only

genuine manufacturer repair parts for your unit. NEVER make adjustments to the factory set pressures.

Serious injury may occur from the unit malfunction or exploding accessories if incorrect system components, attachments or accessories are used. Never exceed manufacturers maximum allowable pressure rating of attachments.

Because of extreme heat, do not use plastic pipe or lead tin soldered joints for a discharge line.

Never use the unit to inate small, low pressure objects such as toys.

8 Operator’s Manual

RISK OF BREATHING

Serious injury or death could occur from inhaling compressed air. The air stream may contain carbon monoxide, toxic vapors or solid particles. Never inhale air from the unit either directly or from a breathing device connected to the unit.

Serious injury or death may occur from inhaling engine exhaust. This unit was designed for outdoor use. Never operate this unit in an enclosed area. Always make certain there is adequate ventilation (fresh outside air) for breathing and combustion. This will prevent the buildup of dangerous carbon monoxide gases. Beware of poorly ventilated areas, or areas with inadequate exhaust fans.

Sprayed materials such as paint, solvents, paint remover, insecticides, weed killers, etc. contain harmful vapors and poisons. Operate the unit only in a well ventilated area. Follow all safety instructions provided with the materials you are spraying. Use of a respirator may be required when working with some materials.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes.

Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel. The coatings and any metals containing these elements can give off toxic fumes if welded.

RISK OF BURNS

Serious injury could occur from touching exposed metal parts. These areas can remain hot for some time after the unit is shutdown. Never allow any part of your body or other materials to make contact with any exposed metal parts on the unit.

Never allow any part of your body to contact the engine mufer, compressor

head or adjacent areas.

Operator’s Manual 9

RISK OF FLYING OBJECTS

Soft tissue damage can occur from the compressed air stream. Always wear

safety glasses to shield the eyes from ying debris.

Never point the air stream at any part of your body, anyone else or animals. Never leave pressurized air in the unit. Shut off the unit and relieve pressure

when storing or attempting maintenance. Serious injury can occur from loose debris being propelled at a high speed

from the compressed air stream. Always maintain a safe distance from people and animals while operating the unit.

Do not move the unit while air tank is under pressure. Do not attempt to move the unit by pulling on the hose.

RISK FROM MOVING PARTS

Risk of bodily injury from moving parts. Before performing maintenance, always turn off the unit. Bleed pressure from the air hose and disconnect spark plug wire to prevent engine from starting unexpectedly. All repairs to the unit should be made by an Authorized Service person.

Do not operate without protective covers/guards. Always turn off the unit before removing any guard. Replace damaged covers/guards before using the unit.

10 Operator’s Manual

IMPORTANT SAFETY INSTRUCTIONS

CAU

WARNING: To reduce the risk of injury, read this operator’s manual completely before using. When using this product, the following basic precautions should always be followed:

1. Risk from Negligence: Risk of injury from negligent use. Never allow children or adolescents to operate this unit! Stay alertwatch what you are doing. Do not operate the unit when fatigued

or under the inuence of alcohol or drugs. Know how to stop the

unit. Be thoroughly familiar with controls.

2. Risk of Unit Damage: Risk of major repair. Do not operate the

unit without an air lter. Do not operate the unit in a corrosive

environment. Always operate the unit in a stable, secure position to prevent the unit from falling. Follow all maintenance

instructions listed in this manual. Overuse can cause overheating; allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or

lter airow to unit.

3. When starting the unit, using recoil starter grip, be sure that nothing is in a position to be hit by the operator’s hand or arm. Be sure the switch on electric power tools is in the “OFF” position before plugging them into the unit.

4. Do not operate the unit or any electrical tool in any area where water or similar materials constitute an electrical hazard to the operator. Do not operate on wet surfaces, in rain or in snow.

5. Always be sure that the unit is on secure footing so that it cannot slide or shift around, endangering workers.

6. Avoid contacting the hot exhaust manifold, mufer or cylinder(s).

7. Keep clear of all rotating parts.

8. Unless the tool or appliance is double insulated, it must be grounded through a properly grounded receptacle. Tools and appliances which have 3 prong plugs must be plugged into extension cords and electrical receptacles with 3 holes. Before operating any electrical item, be sure it is in good repair.

9. Beware of using this equipment in conned spaces. Conned spaces, without sufcient fresh air ventilation, can contain

dangerous gases. Running gasoline engines in such environments can lead to deadly explosions and/or asphyxiation.

10. Use extreme caution when lifting this unit. This unit is heavy so proper lifting techniques should be used.

SAVE THESE INSTRUCTIONS

Operator’s Manual 11

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job. Wear dry, hole-free insulating gloves and body protection.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn

eyes and skin. Sparks y off from the weld. ARC RAYS

can burn eyes and skin. Wear an approved welding helmet

tted with a proper shade of lter lenses to protect your

face and eyes when welding or watching. Wear approved safety glasses with side shields under your helmet.

Use protective screens or barriers to protect others from

ash, glare and sparks; warn others not to watch the arc. Wear protective clothing made from durable, ame-

resistant material and foot protection. Welding, chipping, wire brushing, and grinding cause

sparks and ying metal. As welds cool, they can throw off

slag. Wear approved safety glasses with side shields even under your welding helmet.

PREPARE FOR EMERGENCIES

Keep a rst aid kit and re extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital and re department near your telephone. Be prepared if a re starts.

INSPECT UNIT

Be sure all covers, guards and shields are tight and in place.

Locate all operating controls and safety labels. Inspect power cord for damage before using. There is a

hazard of electrical shock from crushing, cutting or heat damage.

SERVICE UNIT SAFELY

Before servicing the unit, disconnect all equipment and battery (if equipped) and allow unit to cool down.

Service unit in a clean dry at area.

12 Operator’s Manual

SAFETY SIGNS

el producto este en operacion.

CAUTION/PRECAUCION

ARRIBA DE 150°F.

34-0598-010699-E/S-ENG.

WARNING

ADVERTENCIA

34-2666 081711

OPERATING INSTRUCTIONS FOR GENERATOR AND WELDER

WARNING

GENERATOR / WELDER CAN CAUSE SERIOUS INJURY OR DEATH IF OPERATED IMPROPERLY. BEFORE OPERATING

THIS UNIT READ AND UNDERSTAND THE ENTIRE

OPERATOR’S MANUAL AND FOLLOW ALL SAFETY

PRECAUTIONS.

1. Ensure the unit is grounded according to the owner’s manual and national, state, and local codes. Wear proper protective equipment and clear the area of any hazards before operating the unit.

2. To maximize welder output, do not weld while simultaneously filling the air tank or utilizing air tools.

3. Toggle the Full Throttle / Idle Switch to select to Full Throttle.

4. Rotate switch to select weld amperage. Do NOT adjust the control output while welding Use table and electrode packaging to determine the correct size electrode and amperage.

5. For Direct Current Electrode Positive (DCEP), connect work cable to Negative (−) terminal and electrode holder to Positive (+) terminal. (thicker material and more penetration) For Direct Current Electrode negative (DCEN), reverse cable connections.

INSTRUCCIONES DE UTILIZAR PARA GENERADOR Y SOLDADOR

ADVERTENCIA

EL GENERADOR/SOLDADOR PUEDE CAUSAR LA HERIDA SERIA

O LA MUERTE SI UTILIZADO INCORRECTAMENTE. ANTES DE

UTILIZAR ESTA UNIDAD, LEA Y ENTIENDA EL MANUAL DEL

OPERADOR ENTERO Y SIGA TODAS LAS

PRECAUCIONES DE SEGURIDAD.

1. Asegure que la unidad es conectada a la tierra según el manual del propietario y códigos nacionales, estatales, y locales. Lleve el equipo protector apropiado y limpie el área de cualquier riesgo antes de utilizar la unidad.

2. Para maximizar el rendimiento de soldador, no solde mientras simultáneamente llenando el tanque de aire o utilizando instrumentos de aire.

3. Cambie el Interruptor de Toda Velocidad/Ocioso para seleccionar Toda Velocidad.

4. Gire el interruptor para seleccionar el amperaje de soldar. NO ajuste el rendimiento de control mientras soldando. Use la tabla y embalaje de electrodo para determinar el tamaño de electrodo y el amperaje correctos.

5. Para el Electrodo Corriente Directo Positivo (DCEP), una el cable de trabajo al terminal (−) Negativo y el tenedor del electrodo al terminal Positivo (+) . (material más grueso y más penetración) Para el Electrodo Corriente Directo Negativo (DCEN), invierta uniones de cable.

34-1285

34-1615

RISK OF BURNS

MUFFLER AND

ADJACENT AREAS

MAY EXCEED 150°F.

RIESGO DE QUEMAR

EL AMORTIGUADOR Y LAS

AREAS ADYACENTES PUEDEN

TENER TEMPERATURAS POR

34-0598

RISK OF FIRE

Do not add fuel when product is operating. Allow engine to cool for two (2) minutes before refueling.

RIESGO DE FUEGE

No ponga combustible cuando

Permita que el motor se enfrie por 2 minutos antes de reablastecer de combustible.

34-0599

WARNING/ADVERTENCIA

Do not operate unit without beltguard in place.

No opere la unidad sin todas la cubierta correa en su sitio.

34-0826

34-1284

34-0599-E/S-030600-ENG

34-0826-E/S-030600-ENG.

34-1616

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a

poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Operator’s Manual 13

DANGER DANGER PELIGRO

Only use OUTSIDE and far away from windows, doors, and vents.

Ne JAMAIS utiliser à l'intérieur d'une maison ou d'un garage, MÊME SI les portes et fenêtres s'ont ouvertes.

N'utiliser qu'à l'EXTÉRIEUR et bien éloigné des fenêtres, portes, et conduits d'aération.

34-1916

Utilizando un generador adentro PUEDE MATARLE EN MINUTOS.

El escape de generador contiene monóxido de carbono. Este es un gas tóxico que usted no puede ver ni puede oler.

Nunca utilice dentro de un hogar ni el garaje, INCLUSO SI puertas y ventanas estén abiertas.

Solo utilice AFUERAS y lejos de ventanas abiertas, las puertas, y descargas.

34-1916-031607-E-F-S.

34-1286

34-2666

Controls

13 14

1-Pump Air Filter 2-Fuel Cap 3-Engine Air Cleaner 4-Engine Choke 5-Engine Oil Fill 6-Engine Oil Drain 7-Air Tank Drain 8-Pump Oil Fill 9-Pilot Valve

2322

10-Weld Amperage Setting 11-Generator/Welder Selector

Switch 12-Min/Max Weld Amperage

Toggle Switch 13-Positive Welding Terminal 14-Negative Welding Terminal 15-125V Receptacle 16-125/250V 20A Twist Lock

2120

23 25

18-20A Toggle Breaker 19-20A Push Button Breaker 20-Pump Oil Sight Glass 21-Pump Oil Drain 22-Safety Relief Valve 23-Pressure Gauge 24-Regulator 25-Quick Connect

17-Idle Control Switch

14 Operator’s Manual

Controls

12 13

1-Pump Air Filter 2-Fuel Cap 3-Engine Air Cleaner 4-Engine Choke 5-Engine Oil Fill 6-Engine Oil Drain 7-Pump Oil Fill 8-Pilot Valve 9-Weld Amperage Setting

2221

10-Generator/Welder Selector Switch

11-Min/Max Weld Amperage Toggle Switch

12-Positive Welding Terminal 13-Negative Welding Terminal 14-125V Receptacle 15-125/250V 20A Twist Lock 16-Idle Control Switch 17-20A Toggle Breaker

2019

22 24

18-20A Push Button Breaker 19-Pump Oil Sight Glass 20-Pump Oil Drain 21-Safety Relief Valve 22-Pressure Gauge 23-Regulator 24-Quick Connect

Operator’s Manual 15

Controls

1-Engine Air Cleaner 2-Engine Oil Fill 3-Pump Oil Drain 4-Pilot Valve 5-Pump Air Filter 6-Pump Oil Fill 7-Engine Oil Drain 8-Fuel Cap 9-Air Tank Drain 10-Battery

16 Operator’s Manual

11-Weld Amperage Setting 12-Generator/Welder Selector

Switch 13-Min/Max Weld Amperage

Toggle Switch 14-Positive Welding Terminal 15-Negative Welding Terminal 16-Engine Choke 17-125V Receptacle 18-125/250V 20A Twist Lock

19-Idle Control Switch 20-20A Toggle Breaker 21-Engine Keyswitch 22-20A Push Button Breaker 23-Safety Relief Valve 24-Pressure Gauge 25-Regulator 26-Pump Oil Sight Glass 27-Quick Connect

Installation

INSTALLATION

Read safety warnings before setting-up the unit. Ensure the oil level in the unit's pump is adequate. If low, add

SAE-30W non-detergent oil. LOCATION: In order to avoid damaging the unit, do not incline the unit transversely

or longitudinally more than 10°.

WARNING: RISK OF ASPHYXIATION! DO NOT OPERATE

IN AN ENCLOSED AREA. USE THIS PRODUCT ONLY IN WELL VENTILATED AREAS! THE EXHAUST FROM THE ENGINE CONTAINS CARBON MONOXIDE, A POISONOUS, ODORLESS AND INVISIBLE GAS. BREATHING THE GAS CAN CAUSE SERIOUS INJURY, ILLNESS AND POSSIBLE DEATH.

WARNING: RISK OF EXPLOSION OR FIRE CAUSING SERI-

OUS INJURY OR DEATH! DO NOT ALLOW THE ENGINE OR MUFFLER TO COME IN CONTACT WITH FLAMMABLE VAPORS, COMBUSTIBLE DUST, GASES OR OTHER COMBUSTIBLE MATERIALS. A SPARK MAY CAUSE A FIRE.

WHEN USING THE UNIT FOR SPRAY PAINTING, PLACE THE UNIT AS FAR AWAY FROM THE WORK AREA AS POSSIBLE, USING EXTRA AIR HOSES IF NEEDED.

Place unit at least 12 inches away from obstacles that may prevent proper ventilation. Do not place unit in an area:

- where there is evidence of oil or gas leaks.

- where ammable gas vapors or materials may be present.

- where air temperatures fall below 32°F or exceed 104°F.

- where extremely dirty air or water could be drawn into the unit.

SERVICE TRUCK INSTALLATION:

Installations may vary. Mounting should be done to a rigid frame member. Installer is responsible for securing the equipment in a safe manner.

FOR ALL UNITS WITH AIR TANKS:

Optional Hardware: IX-0001 (Isolators)

Operator’s Manual 17

Installation

GROUNDING INSTRUCTIONS

This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock.

DANGER: IMPROPER CONNECTION OF THE EQUIPMENT

GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTROCUTION. CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE UNIT IS PROPERLY GROUNDED.

The screw and ground terminal on the frame must always be used to connect the unit to a suitable ground source. The ground path should be made with #8 size wire. Connect the terminal of the ground wire between the star washers and screw then tighten the screw fully. Connect the other end of the wire securely to a suitable ground source.

The National Electric Code contains several practical ways in which to establish a good ground source. Examples given below illustrate a few of the ways in which a good ground source may be established.

A metal underground water pipe in direct contact with the earth for at least 10 feet can be used as a grounding source. If a pipe is unavailable, an 8 foot length of pipe or rod may be used as the ground source. The pipe should be 3/4 inch trade size or larger and the outer surface must be noncorrosive. If a steel or iron rod is used it should be at least 5/8 inch diameter and if a nonferrous rod is used it should be at least 1/2 inch diameter and be listed as material for grounding. Drive the rod or pipe to a depth of 8 feet. If a rock bottom is encountered less than 4 feet down, bury the rod or pipe in a trench. All electrical tools and appliances operated from this unit, must be properly grounded by use of a third wire or be “Double Insulated”.

It is recommended to:

1. Use electrical devices with 3 prong power cords.

2. Use an extension cord with a 3 hole receptacle and a 3 prong plug at the opposite ends to ensure continuity of the ground protection from the unit to appliance.

John Deere strongly recommends that all applicable federal, state

and local regulations relating to grounding specications be checked

and followed.

LINE TRANSFER SWITCH:

If this unit is used for standby service, it must have a transfer switch between the utility power service and the unit. The transfer switch not only prevents the utility power from feeding into the unit, but also prevents the unit from feeding out into the utility company’s lines. This is intended to protect the serviceman who may be working on a damaged line.

THIS INSTALLATION MUST BE DONE BY A LICENSED ELECTRICIAN AND ALL LOCAL CODES MUST BE FOLLOWED.

18 Operator’s Manual

Installation

GASOLINE ENGINE

Review "Risk of Fire or Explosion" before fueling. Read the engine manual accompanying this unit for correct engine start-up maintenance procedures. Read and understand the safety labels located on the unit.

WARNING: RISK OF EXPLOSION OR FIRE CAUSING

SERIOUS INJURY OR DEATH! DO NOT SMOKE WHILE FUELING!

DO NOT FILL FUEL TANK WHILE THE UNIT IS RUNNING

OR HOT. ALLOW THE UNIT AND ENGINE TO COOL DOWN FOR TWO MINUTES BEFORE REFUELING.

DO NOT FILL FUEL TANK TO POINT OF OVERFLOWING.

ALLOW APPROXIMATELY 1/4" OF TANK SPACE FOR FUEL EXPANSION.

DO NOT PLACE UNIT IN AN AREA WHERE FLAMMABLE

GAS VAPORS MAY BE PRESENT. A SPARK COULD CAUSE AN EXPLOSION OR FIRE.

ALWAYS STORE FUEL AWAY FROM THE UNIT WHILE IT

IS RUNNING OR HOT.

WARNING: RISK OF EXPLOSION OR FIRE CAUSING

SERIOUS INJURY OR DEATH DO NOT ALLOW THE ENGINE OR MUFFLER TO COME IN CONTACT WITH FLAMMABLE VAPORS, COMBUSTIBLE DUST, GASES OR OTHER COMBUSTIBLE MATERIALS. A SPARK MAY CAUSE A FIRE.

WHEN USING THE UNIT FOR SPRAY PAINTING, PLACE

THE UNIT AS FAR AWAY FROM THE WORK AREA AS POSSIBLE, USING EXTRA AIR HOSES IF NEEDED.

A minimum of 87 octane fuel is recommended for use with this air compressor. Do not mix oil with gasoline.

Use of clean, fresh, lead free gasoline is recommended. Leaded gasoline may be used if lead free is not available. Do not use gasoline containing methanol or alcohol.

Refer to the engine manual for all necessary maintenance and adjustments.

ENGINE OIL

Use oil viscosity based on the expected air temperature range during the period between oil changes.

TEMPERATURE CHART

Operator’s Manual 19

Installation

Use a high quality detergent oil with API classications of SJ

or higher. Check oil level before each operation and ensure that it is

maintained.

CAUTION: THIS ENGINE CRANKCASE IS NOT FILLED

WITH OIL AT THE FACTORY, SO BE SURE TO FILL IT BEFORE OPERATING THE ENGINE.

ENGINE OIL CAPACITY

MODEL # Liters Quart Ounces

AC2-CW5170s 1.2 1.27 40.5

AC2-CW5220H 2.0 2.1 67.6

NOTE: These engines are equipped with a “Low Oil” shut-off

system for engine protection. If the engine fails to start, check engine crankcase for oil.

To ll with oil:

1. Level the engine to ensure accurate inspection and

to prevent overlling.

2. Unscrew the oil gauge, wipe the dipstick dry. Reinsert the

oil gauge back into the oil ll gauge opening. Remove the

oil gauge and check the oil level.

3. The oil level should be between the full and low marks on the dipstick.

NOTE: When checking the oil be sure the engine is level.

4. Fill with oil as required through the oil ll gauge opening.

5. Replace the oil gauge and screw in rmly.

6. Wipe up any spilled oil.

FUELING

WARNING: EXPLOSIVE FUEL! GASOLINE IS EX-

TREMELY FLAMMABLE AND ITS VAPORS CAN EXPLODE IF IGNITED.

STORE GASOLINE ONLY IN APPROVED CONTAIN-

ERS, IN WELL VENTILATED, UNOCCUPIED BUILDINGS AND AWAY FROM SPARKS OR FLAMES.

DO NOT FILL THE FUEL TANK WHILE THE ENGINE IS

HOT OR RUNNING, SINCE SPILLED FUEL COULD IGNITE IF IT COMES IN CONTACT WITH HOT PARTS OR SPARKS FROM IGNITION. DO NOT START

THE ENGINE NEAR SPILLED FUEL. NEVER USE GASOLINE AS A CLEANING AGENT. WARNING: DO NOT OVERFILL THE FUEL TANK,

LEAVE ROOM FOR THE FUEL TO EXPAND.

General Recommendations

• Purchase gasoline in small quantities and store in clean,

approved containers.

• To minimize gum deposits in your fuel system and to insure

20 Operator’s Manual

Installation

easy starting, do not use gasoline left over from the previous season.

• Do not add oil to the gasoline.

Fuel Type

• For best results use only clean, fresh, unleaded gasoline with

a pump sticker octane rating of 87 or higher.

• Unleaded gasoline is recommended as it leaves less

combustion chamber deposits. GASOLINE/ALCOHOL BLENDS: Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by

volume) is approved, as a fuel. Other gasoline/alcohol blends are not approved.

GASOLINE/ETHER BLENDS: Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends

(up to a maximum of 15% MTBE by volume) are approved as a fuel. Other gasoline/ether blends are not approved.

BATTERY INSTALLATION

WARNING: SHOULD ONLY BE DONE BY AN AUTHO-

RIZED DEALER.

BATTERY REPLACEMENT #

32-0058

HIGH ALTITUDE

At high altitude, the standard carburetor air/fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from

that at which this engine was certied, for extended periods of

time, may increase emissions. High altitude performance can be improved by specific

modications to the carburetor. If you always operate your unit

at altitudes above 5,000 feet (1,500 meters), have your dealer

perform this carburetor modication. This engine, when operated at high altitude with the carburetor modications for high altitude

use, will meet each emission standard throughout its useful life.

Even with carburetor modication, engine horsepower will

decrease about 3.5% for each 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater

than this if no carburetor modication is made.

NOTE: When the carburetor has been modied for high altitude

operation, the air/fuel mixture will be too lean for low altitude use. Operation at altitudes below 5,000feet (1,500 meters) with

a modied carburetor may cause the engine to overheat and

result in serious engine damage.

For use at low altitudes, have your servicing dealer return the

carburetor to original factory specications.

Operator’s Manual 21

Operation

OPERATION

PRE-OPERATION:

Check the engine oil level before starting. (See engine manual.) Fill the fuel tank according to the engine manual instruction.

Pump oil level should be checked before each use. Check the oil level indicator on the pump crankcase. Make certain the oil is in the center of

the oil sight glass. If the level appears to be low, ll with SAE20 or 30 non-

detergent pump oil.

Remove any moisture in the unit's air tank.

WARNING: NEVER ATTEMPT TO OPEN THE AIR TANK DRAIN

VALVE WHEN MORE THAN 10 PSI OF AIR PRESSURE IS IN THE AIR TANK!

Remove excessive pressure with an air tool, then open the Air Tank Drain Valve in the bottom of the air tank. Close tightly when drained. Make sure the Engine Switch is in the "OFF" position. Make sure the Safety Relief Valve is working correctly. Make sure all guards and covers are in place and securely mounted.

START-UP:

1. Read safety warnings before performing operation.

NOTE: Unplug all equipment from the power receptacles before starting the unit.

2. Make sure the unit is grounded. See Grounding Instructions.

3. Flip the toggle on top of the Pilot Valve to the upright position. This provides a load less start. The unit will unload and allow easier engine start-up.

4. Start the engine. (Refer to the Engine Manual accompanying this unit. On Honda engine units, the choke and key switch is located on the electric box panel.)

5. When the engine has run for 1-2 minutes, ip toggle back to the original

position.

6. Set pressure by adjusting the Pressure Regulator counterclockwise for less pressure and clockwise for more pressure.

7. Ensure breakers are in on position.

8. Test the GFCI receptacle(s) on the unit. Push the test button. The reset button should pop out and there should be no power at the receptacle. Apply a test load or lamp to each receptacle to verify. IF THE RESET BUTTON DOES NOT POP OUT, DO NOT USE THE RECEPTACLES(S). SEE DEALER FOR SERVICE IMMEDIATELY.

9. If GFCI receptacle(s) test correctly, rmly push the reset button to restore

power. A distinctive click should be heard or felt when this is complete. IF THE RECEPTACLE(S) DO NOT RESET PROPERLY, DO NOT USE THE RECEPTACLE(S). SEE DEALER FOR SERVICE IMMEDIATELY.

10.Turn idle control switch to AUTO-IDLE DOWN position. Loads can now be applied to unit.

WELDING START-UP:

1. Remove all AC electrical loads from the unit.

2. Move GEN/WELD switch to WELD position.

3. Position selector switch min/max switch for amperage setting.

22 Operator’s Manual

Operating the Unit

4. Move idle control to full throttle setting.

5. Check grounding.

6. Welding Cable Diagram (Selecting Weld Cable Sizes)*:

Weld Output Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***

Welding

Amperes

100 ft (30 m)

or Less

100% Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 − 100% Duty Cycle

350 ft

(105 m)

400 ft

(120 m)

100 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 2 (35) 1 (50) 1 (50) 2/0 (70) 3/0 (95) 3/0 (95) 200 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use

next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at

least 300 circular mils per ampere ( ) = mm2 for metric use.

***For distances longer than those shown in this guide, call a factory applications

representative at 800-553-9053.

WARNING: DO NOT USE WORN, DAMAGED, UNDERSIZED, OR POORLY SPLICED CA-

BLES. TURN OFF POWER BEFORE CONNECTING TO WELD OUTPUT TERMINALS.

ELECTRODE CHART

AMPERAGE RANGE

ELECTRODE

and

3/32

1/8 5/32 3/16

6010

6011

DIAMETER

100

150

200

250

300

1/16 5/64

6013

3/32

1/8 5/32

3/16 3/32

7014

1/8 5/32 3/16 3/32

7018

1/8 5/32

3/16

34-2670 081711

Operator’s Manual 23

NOTE: This engine is equipped with a “Low Oil” shutdown system for engine protection. The engine stops when the oil level gets too low. The engine will not restart without adding oil.

If you notice any unusual noise or vibration, stop the unit and refer to "Troubleshooting".

SHUTDOWN:

1. Remove all load by turning off electrical appliances and unplugging electric/welding cords.

2. Move the Engine Switch to the "Off" position. (Refer to the Engine Manual accompanying this unit.)

3. Move the GEN/WELD switch to the GEN position.

4. Drain air from the air tanks by releasing air with an attached air tool or by pulling on the Safety Relief Valve.

5. Once the Air Tank Pressure Gauge registers under 10 pounds, open the drain valve under each air tank to drain any moisture.

6. Close fuel valve on unit or engine.

7. Wipe the unit clean and store in a safe, non-freezing, dry area.

NOTE: Failure to allow the engine to cool at idle for two (2) minutes may

result in damage to the generator.

OPERATING CONTROLS

IDLE CONTROL OPERATION:

Note: Idle control is disabled in welding mode. Idle control switch must be at full throttle setting.

The idle control is factory installed. This electrical device is designed to let the engine run at fuel saving low idle speed when the generator or compressor are not loaded, and at full normal governed speed when a load is applied. The idle system overrides the engine governor to provide idle speed. When a load is applied, the electronic circuit reacts to de-energize the idle system so that the engine can resume full governed operating speed.

The idle control system controls the engine speed in the following manner:

1. With the idle control switch in the “FULL THROTTLE” position, start the engine.

2. After one or two minute warm up period, apply load and move the switch to the “IDLE CONTROL” position. The engine will throttle back to idle speed following a 5-8 second delay.

3. When a load is applied to the generator or air compressor tank pressure drops below regulated set point. The idle control system becomes de-energized. The engine then accelerates to normal operating speed, controlled by the governor.

4. When the load is removed or air compressor tank pressure is restored, the idle system becomes re-energized and throttles the engine back to idle speed after a 5-8 second delay.

NOTE: While the engine is idling, the generator voltage is automatically

reduced to reduce generator temperatures. The voltage will return to normal levels immediately upon the application of load.

24 Operator’s Manual

OPERATION

CABLE SIZE:

Equipment damage can result from low voltage. Therefore, to prevent excessive voltage drop between the unit and the equipment, the cable should be of adequate gauge for the length used. The cable selection chart gives the maximum cable lengths for various gauges of wire which can adequately carry the loads shown.

CURRENT LOAD IN WATTS MAXIMUM CABLE LENGTH (FEET)

IN AMPS 120 VOLTS 240 VOLTS #8 WIRE #10 WIRE #12 WIRE #14 WIRE #16 WIRE

2.5 300 600 1000 600 375 250

5 600 1200 500 300 200 125

7.5 900 1800 350 200 125 100

10 1200 2400 250 150 100 50

15 1800 3600 150 100 65

20 2400 4800 175 125 75 50

25 3000 6000 150 100 60

30 3600 7200 125 65

40 4800 9600 90

ELECTRIC MOTOR LOADS:

It is characteristic of common electric motors in normal operation to draw up to six times their running current while starting. This table may be used to estimate the watts required to start “CODE G” electric motors.

CAUTION: IF AN ELECTRIC MOTOR FAILS TO START OR

REACH RUNNING SPEED, TURN OFF THE APPLIANCE OR TOOL IMMEDIATELY TO AVOID EQUIPMENT DAMAGE. ALWAYS CHECK THE REQUIREMENTS OF THE TOOL OR APPLIANCE BEING USED COMPARED TO THE RATED OUTPUT OF THE UNIT.

WATTS REQUIRED TO START MOTOR

MOTOR (H.P.) RUNNING WATTS REPULSION INDUCTION CAPACITOR SPLIT PHASE

1/8 275 600 850 1200

1/6 275 600 850 2050

1/4 400 850 1050 2400

1/3 450 975 1350 2700

1/2 600 1300 1800 3600

3/4 850 1900 2600

1 1100 2500 3300

Operator’s Manual 25

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