PowR-Quip Contractor Series, W240MG1400KP Assembly And Operating Instructions Manual

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

IMPORTANT

To help us serve you better do not hesitate to contact us if you have any problems or suggestions.

This manual has important information for installation, operation and maintenance of your equipment. It is very

important to read this manual carefully before starting your equipment. Always keep this owner´s manual in a safe place for further reference.

INDICATIONS

IMPORTANT SAFETY INFORMATION INDICATES HOW TO PREVENT

DAMAGE TO EQUIPMENT AND PERSONAL SAFETY INSTRUCTIONS

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

DESCRIPTION

These units are provided with four strokes air cooled

engines designed to run at 3750 RPM max. and continuously deliver a current corresponding to its rated power. In these models a device is provided for automatic engine turning off when the engine has low oil level, so protecting it. This characteristic is generally associated with long running models.

The alternator is thermally protected. To operate this unit

as a generator or a welder, place the front panel switch according to what you want.

UNPACKING

When you unpack, inspect carefully for any damage

that may had occurred during shipment. Make sure that

any xture, screws, etc., are tightened before operating

the unit.

SAFETY MEASURES

Report any missing item by contacting the place of

purchase.

Before starting or servicing the welder/generator, read

and understand all instructions. Failure on complying with safety precautions or instructions can cause damage to the equipment and/or personal injury or death.

NEVER OPERATE THIS WELDER/GENERATOR IN AN EXPLOSIVE OR FLAMMABLE ENVIROMENT OR IN AREAS WITH INSUFFICIENT VENTILATION.

Be sure that all tools and accessories are well prepared for use and are properly grounded. Use one phase tools or apparatus provided with three-prong plug power cord. If an extension cord is used, be sure this has three- prong plugs with a suitable ground connection..

DO NOT OPERATE YOUR EQUIPMENT ON WET SURFACES OR UNDER THE RAIN.

TURN OFF AND DISCONNECT THE SPARKPLUG WIRE BEFORE PERFORMING ANY SERVICE OR MAINTENANCE TO THE UNIT.

Use only unleaded fuel. Do not ll the fuel tank with the

engine running. Take precautions to avoid spilling of

fuel while lling the tank. Make sure that fuel tank cap is

securely in place before starting the engine. Clean any spilled fuel before starting the engine. Allow engine to

cool for at least two minutes before lling the tank.

This welder/generator can be used for auxiliary

emergency electrical service, in these cases, a double throw switch shall be installed between the entrance main switch and the electrical distribution box. This switch must be installed by a licensed electrician

The instructions about the engine for these units are included in a separate manual. Keep all the manuals for future references.

Never use this welder/generator for any application

other than that specied by the manufacturer. Never

operate this welder/generator under conditions not approved by the manufacturer. Never attempt to modify the equipment to operate in a way other than that for which it was designed.

For maintenance and repairs use only products and

original components.

Before operation, make sure your equipment is properly

connected to ground. For proper grounding procedures refer to “grounding instructions” section in this manual.

Make sure that your equipment is used only by persons who have read and understood these instructions.

If your welder/generator is going to be in a xed place, hold it rmly to the oor (use anchors, expansive dowels

or similar) if not, make always sure that it will not move with the vibrations.

Keep all persons away from the equipment during its operation. Do not allow people wearing jewelry or loose clothing manage the equipment, since these can be caught by moving parts, causing damage to equipment and/or personal injury. Keep the people away from movable pieces or that which can become hot during functioning.

Be sure that all electrical appliances are switched off

before connecting them to your equipment.

NEVER MIX OIL WITH GASOLINE. THIS FOURSTROKE ENGINE IS DESIGNED TO BE FUELED WITH PURE GASOLINE. OIL IS ONLY USED FOR ENGINE LUBRICATION

KEEP ALWAYS ACCESSIBLE A FIRE EXTINGUISHER WHILE YOU ACCOMPLISHE ARC WELDING WORKS.

All installation, maintenance, repair and operation of this

equipment shall be carried out by persons qualied in

accordance with national, state and local codes.

THE INAPPROPRIATE USE OF ELECTRIC ARC WELDING WELDERS CAN CAUSE INJURY, ELECTRIC SHOCK AND EVEN DEATH. TAKE ALL PRECAUTIONS DESCRIBED IN THIS MANUAL TO REDUCE THE POSSIBILITY OF ELECTRIC SHOCK

Check that all components of the arc welder are clean

and in good condition prior to operating the welder. Make sure that the insulation of all cables, electrode holders and power cords are not damaged. Always repair or replace damaged components before operating the welder. Always keep panels, guards, etc. of the welding machine in place when you operate.

Wear always dry protection clothing, welder gloves and insulated footwear.

Always operate the welding machine in a clean, dry and

well-ventilated area. Do not operate the welding machine

in humid, wet, rainy areas or with insufcient ventilation.

Make sure that the work piece is properly supported and grounded prior to begin any electric arc welding operation.

Keep always the welder/generator clean and well

maintained.

You must stretch the welding cable before use to avoid overheating and damage to the cable insulation.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

NEVER IMMERSE THE ELECTRODE OR ELECTRODE HOLDER IN WATER. IF THE WELDING MACHINE IS WET FOR ANY REASON, BE SURE THAT IT IS COMPLETELY CLEAN AND DRY BEFORE ATTEMPTING TO USE IT.

Always shut down your equipment before moving the unit.

Always attach rst the work conductor.

Check that the work piece is positively grounded.

Always shut the electric welder off and remove the electrode from the holder when welder is not in use.

Never allow any part of the human body to touch the work electrode and ground or the grounded work piece at the same time.

The human body conditions and inconvenient body positions while welding can cause electrical shock hazard. When crouching, kneeling or at elevations, be sure to insulate all conductive parts, wear appropriate protective clothing and take precautions to prevent injuries caused by falls.

Never attempt to use this equipment with current

settings or duty cycles higher than those specied on

the equipment labels.

Never use an electric arc welder to thaw frozen pipes.

THE DETACHED SPARKS AND HOT METAL CAN CAUSE INJURIES.

AS THE WELDS TURNS COLDER IT IS POSSIBLE THAT DETACHMENT OF SLAGS OCCUR. TAKE ALL PRECAUTIONS DESCRIBED IN THIS MANUAL TO REDUCE THE POSSIBILITY OF INJURIES CAUSED BY SPARKS AND HOT METAL DETACHMENTS.

When chipping or grinding metal parts wear approved by ANSI protective helmet or safety glasses with side protection. Use ear plugs when welding above your head to prevent spatter or slag falling into your ears.

ELECTRIC ARC WELDING OPERATIONS PRODUCE A BRIGHT LIGHT AND HEAT, AND ULTRAVIOLET (UV) RAYS. THIS MAY CAUSE INJURIES TO THE EYES AND SKIN. TAKE ALL PRECAUTIONS DESCRIBED IN THIS MANUAL TO REDUCE THE POSSIBILITY OF INJURY.

All persons using this equipment or who are in the area while the equipment is being used shall use protective equipment that includes: helmet or protective welding

glass shade 10, wear resistant to ames, leather welding

gloves and full foot protection.

NEVER SEE THE OPERATIONS OF ARC WELDING WITHOUT EYE PROTECTION DESCRIBED ABOVE. NEVER USE DARK FILTER LENSES THAT ARE CRACKED, BROKEN OR UNDER 10 SHADOW CLASSIFICATION. WARN OTHERS IN THE AREA THAT THEY DO NOT SEE THE ARC.

ELECTRIC ARC WELDING OPERATIONS CAUSE SPARKS AND HOT METAL AT TEMPERATURES THAT CAN CAUSE SERIOUS BURNS. WEAR GLOVES AND PROTECTIVE CLOTHING WHEN PERFORMING ANY METAL WORK.

TAKE ALL PRECAUTIONS DESCRIBED IN THIS MANUAL TO REDUCE THE POSSIBILITY OF BURNS ON THE SKIN AND CLOTHING.

Make sure that all persons in the area of doing welding are protected from heat, sparks, and ultraviolet rays. Use

additional protection for face and ame resistant barriers

as needed.

Never touch work pieces until they have completely cooled down.

HEAT AND SPARKS PRODUCED DURING SOME WELDING WORKS AND OTHER METAL WORKING OPERATIONS CAN IGNITE FLAMMABLE AND EXPLOSIVE MATERIALS. TAKE ALL PRECAUTIONS DESCRIBED IN THIS MANUAL TO REDUCE THE POSSIBILITY OF FLAMES AND EXPLOSIONS.

Remove all ammable materials within a radius of 35 feet

(11 meters) away from the place where the welding work

is being performed. If it is not possible to remove them

tightly cover ammable materials with reproof covers.

Take precautions to make sure that sparks ying and the heat do not cause ames in hidden areas, behind

screens, etc.

FIRE HAZARD. DO NOT WELD ON CONTAINERS OR PIPES THAT CONTAIN OR HAVE CONTAINED FLAMMABLE OR COMBUSTIBLE LIQUIDS MATERIALS.

SOLDERING OF CYLINDERS OR CLOSED TANKS OR DRUMS CAN CAUSE EXPLOSION IF APPROPRIATE HOLES HAVE NOT DONE ON THEM.

VERIFY THAT ANY CYLINDER OR CLOSED CONTAINER TO BE SOLDERED HAS A SUITABLE VENTILATION HOLE, SO THAT EXPANDING GASES CAN BE RELEASED.

DO NOT BREATHE FUMES PRODUCED BY THE ARC WELDING PROCESS. THESE GASES ARE DANGEROUS.

IF THE AREA OF WELDING CAN NOT BE VENTILATED PROPERLY, BE SURE TO WEAR A RESPIRATOR WITH A TANK OF OXYGEN.

Keep head and face away from the welding gases.

Do not perform electric arc welding operations on metals that are galvanized or cadmium plated, or contain zinc, mercury, or beryllium, without completing the following precautions: a. remove the coating from the base metal. b. make sure that the area of soldering it is well ventilated. c. use a respirator with oxygen. Extremely toxic gases are created when these metals are heated.

THE ELECTROMAGNETIC FIELD THAT IS GENERATED DURING ARC WELDING CAN INTERFER THE OPERATION OF VARIOUS ELECTRICAL AND ELECTRONIC DEVICES, FOR EXAMPLE CARDIAC PACEMAKERS. PEOPLE WHO USE SUCH DEVICES SHOULD CONSULT WITH A DOCTOR BEFORE MAKING ANY ELECTRIC ARC WELDING OPERATION

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Route the electrode and work cables together and secure

with tape when possible.

Never wrap the welder cables around the body.

Always place the electrode and work connectors so that they are on the same side of the body.

Exposure to electromagnetic elds during welding may

have other health effects which are unknown.

MAKE ALWAYS SURE THE AREA OF SOLDERING IS SAFE AND FREE OF HAZARDS (SPARKS, FLAMES, THE RED METAL OR SLAG) BEFORE IT IS ABANDONED. MAKE SURE THE MACHINE IS SHUTDOWN AND THE ELECTRODE HAS BEEN REMOVED. MAKE SURE THAT THE WELDING CABLES ARE LOOSE WOUND AND OUT OF THE WAY. MAKE SURE THAT ALL METAL AND SLAG HAS BEEN COOLED.

ADDITIONAL SAFETY MEASURES

Those who live and work in the United States must realize that according to the laws of this country the following codes apply for work with welders: ANSI Standard Z49.1, OSHA 29 CFR 1910, NFPA Standard 70, CGA Pamphlet P-1, CSA Standard W117.2, NFPA Standard 51B ANSI Standard Z87.1. Those people who are resident in Latin American countries should consult local codes and regulations that apply in their respective countries. Also all users should consult the safety measures provided by the manufacturers of the products to be used.

PRECAUTIONS FOR NOISE

The welder/generator can produce high levels of sound, a prolonged exposition to above 85 dB sound level is harmful to the ear. Wear ear protection when operating around the generator while it is running

LOCATION GENERAL

LOCATION

The selection of the appropriate location to store the

welder/generator after use can increase signicantly the

performance, reliability and life of the equipment.

For best results store the welder/generator in an environment that is clean and dry. Dust and dirt in the unit maintain moisture and increase wear of moving parts.

Store electrodes in a clean, dry location with low humidity

to preserve the ux coating.

GENERAL OPERATION

Check engine oil level. Oil shall not be mixed with

gasoline, however, adequate oil supply is necessary for the lubrication of the engine. Refer to the engine manual

for the oil type and quantity specications.

THE UNIT IS SHIPPED WITHOUT OIL IN THE ENGINE.

OPERATION OF THE EARTH INTERRUPTER WILL NOT BE EFFECTIVE IF THE WELDER/GENERATOR IS NOT PROPERLY CONNECTED TO EARTH. REFER TO THE SECTION TITLED GROUNDING FOR APPROPRIATE STEPS TO GROUND YOUR WELDER/ GENERATOR

When installing a GFI, be sure to comply with all national and local regulations. If you are not sure about the regulations or procedures, obtain assistance from a

qualied electrician.

LUBRICATION

Do not attempt to start this engine without lling the crankcase with the amount and type of suitable oil. (Use

SAE 10W-30). Your unit has been shipped from the factory without oil in the crankcase. Operating the unit without oil can ruin the engine.

Fill the engine with oil according to the engine manual. In this engine, the plastic cap on the casing contains a bayonet with marks of full and empty.

THE LOW OIL LEVEL SENSOR

This unit is equipped with an oil low level sensor. Initially, if the oil level is lower than the required, sensor will activate

a protective device to stop the engine. (See the attached

engine manual for more information). If unit shuts off and the oil level is within specifications, check that the unit is not positioned at an angle that forces oil to vary its level. Place it on an even surface to correct this problem. If the engine does not start, oil level could be not sufficient to deactivate low oil level switch. Make sure that the oil plug mark is at correct level.

FUEL

Fill the tank with unleaded gasoline for cars, clean, fresh. You can use regular grade gasoline provided than it is

high octane rating (at least 90 octane). We recommend

that you always use a gasoline additive. A gasoline additive will minimize the formation of fuel gum deposits during storage. Gasoline additive can be added to the gasoline in the tank or added to the fuel or gasoline in a storage container. Fuel and engine smoke are flammable, and potentially explosive. Use an appropriate procedure to store and handle fuel. Always maintain ABC fire extinguishers on hand.

It is strongly recommended the use of a ground fault

interrupter (GFI). Ground fault circuit breakers can signicantly reduce the possibility of injury if a short circuit

occurs. To install a GFI, the neutral wire of the welder/ generator must be internally grounded to the frame of the welder/generator, and the frame must be properly grounded.

CAUTION

Do not overfill the tank. Maintain a maximum level of fuel to 1/4 inch below the top of the fuel tank. This will allow expansion in hot weather, thus avoiding spillage.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

GROUNDING

SETTLEMENT OF THE ENGINE

Be sure that the welder/generator is grounded to prevent

accidental electric shock. It has an earth terminal provided for this purpose.

The ground wire size must be 8 AWG and you can

connect to the terminal using at tip screwdriver to lift

the terminal screws that tighten the cable.

The other end of the ground wire must be fastened securely to an approved grounding source.

Following this is described ground sources approved by the national electric code.

Other ground sources may be acceptable.

Refer to the national electric code and local regulations for more information on sources of ground. If you are not sure about the regulations or procedures, obtain

assistance from a qualified electrician (licensed or certied)

a. an underground water pipe of at least 10 feet (3 m)

length.

b. a non-corrosive underground pipe at least 8 feet (2.4

meters) long and ¾ inches in diameter.

c. underground bar of copper of at least 8 feet (2.4 m)

length and 5/8 inches in diameter.

d. a Nonferrous rod of at least 8 feet (2.4 m) in length and

½ inch in diameter and approved for grounding purposes. Any bar or pipe used to make a ground connection must

be carried to eight feet (2.4 m) deep or buried in the

deepest possible trench.

START PROCEDURE

Remove all electrical loads from the welder / generator.

After initial start-up, the engine must pass a settlement run according to the manufacturer’s instructions. Refer to the engine manual for instructions on proper settlement run procedure.

TURN OFF

Turn off and remove all devices of electric charge from

the welder/generator.

Allow the engine to run for 2-3 minutes without electrical loads.

Turn the engine switch to the (OFF) position.

Check that the welder/generator has completely stopped.

Close the fuel supply valve.

Allow the unit to cool before installing any cover

LOW OIL LEVEL SHUT DOWN

These models are of long run, an automatic low oil level shutdown switch is provided to protect the engine and the welder/generator.

When the engine oil level drops below the level needed for a proper functioning of the engine, low oil level shutdown switch makes the engine turns off. If the oil level is low when trying to start the engine of the equipment, the low oil level shutdown switch prevents the engine from starting. If the engine does not start, check the oil level.

Note: It is important to keep the unit on an even surface. The oil level shutdown switch can prevent the engine from

starting even if oil level is sufcient, when the welder/

generator is placed on an inclined surface.

OPERATION AS A GENERATOR

Turn fuel shut-off valve in counterclockwise direction to

allow the fuel to ow.

Turn the engine switch to the (ON) position.

Adjust lever choke in the following way: a. for a cold engine, move the choke lever as much as

possible to the left, ooded completely in ON (open)

position. b. for a warm/hot engine move the choke lever to an intermediate position between the positions of drowned and run.

Pull the starter rope with a rm and smooth motion.

Note: Some models may be equipped with an electric starter. For models equipped with an electric starter, turn the key.

After each start-up, allow the engine to run for 2-3 minutes without load.

As the engine heats up and stabilizes, setting drowning right lever, until it is positioned on the RUN label.

THE ENGINE SPEED IS DEFAULT TO PROVIDE ADEQUATE VOLTAGE OUTPUT. NEVER ATTEMPT TO MODIFY OR ADJUST THE MOTOR SPEED OR OUTPUT VOLTAGE.

THE FRONT PANEL SWITCH MUST BE PLACED IN GENERATOR.

PREPARATION AND INSTALLATION OF

THE GENERATOR

Place generator outdoors where it will be used. This

should be on a at surface, and away from ammable

materials. Do not allow the generator to get wet.

Fill the tank of fuel (outdoors) up to 21 litres of gasoline, do not ll the tank up to the top.

Add 1.1 liters of oil to the engine by removing the bayonet that is located on the side of the engine. Use SAE 10W-30 oil. Use a funnel to avoid spillage of oil. Check the oil level with the bayonet; this should be marked “full”. Carefully replace the oil plug, so avoiding damaging of the threads.

Before connecting the equipment to the generator,

check they are in off position. Go to the section HOW TO DETERMINE POWER in this manual. Do not overload the generator. Calculate the total power of the equipment. The maximum power of the generator is indicated in the

specication sheet.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

GENERATOR CONNECTIONS

WARNING

If the generator will be used to replace energy during electrical utility lack of services, power input must be insulated . Refer to the

electrical safety measures of the generator in the INSTALLATION section in this manual. These connections must be made only by a qualified electrician.

GENERATOR START

CAUTION

WARNING

Gasoline is very dangerous. If gasoline makes contact with hot surfaces can cause serious injury or death.

1. Do not fill the fuel tank with the engine running.

2. Turn off engine and wait 2 minutes before filling fuel

3. Do not spill fuel when filling the tank.

4. Do not mix oil with gasoline.

5. Follow the instructions and warnings contained in the engine manual.

HOW TO DETERMINE THE POWER

In order to prevent overloading and possible damage to your generator, it is necessary to know the total power of the connected load. To determine which tools and/or appliances your generator will run, follow the steps below:

Determine if you want to operate a device or multiple devices simultaneously.

Verify start and function power of the apparatuses to be connected to the generator by checking the power required in the product label or have help using the values

of table 1 or by calculations (multiply amps x volts).

Summarize all the start and function powers. If label gives only the voltage and amperage, multiply volts x amp = watts. 1kW = 1,000 watts.

This product contains or produces chemicals when it is used, considered by the State of California to cause cancer, birth defects and other serious damage. (California Code of Health and Safety

25249.5 et seq.)

All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headache, dizziness, nausea, confusion

and eventually death. Carbon monoxide is deadly, odorless and invisible gas, and it can be present even though you cannot see or smell it. Deadly levels of carbon monoxide can be accumulated quickly, and you may lose ability to save yourself. Also, deadly levels of carbon monoxide can be stored for hours or days in closed or poorly ventilated areas. If you experience any symptoms of poisoning, get fresh air and seek for medical help. To prevent serious injury or death by carbon monoxide:

NEVER operate engine indoors. Although the case of having ventilating fans, windows or open doors, carbon monoxide can quickly reach dangerous levels.

NEVER turn on engines in areas poorly ventilated or partially closed. Areas such as warehouses, garages, basements, homes, rooms, etc.

NEVER turn on engines when the engine exhaust gases may go into buildings through openings such as windows or doors.

During starting the motor-driven appliances or tools

require more power than what is specified on its nameplate. Note: Consider 2 ½ - 4 times the power marked on the nameplate for start.

The welder/generator’s rated watts shall match or exceed the number of watts required by all the apparatuses you want to be supplied by the generator.

The continuous generator power decreases according to the temperature and altitude of the place where you are using the equipment. Use the power correction table and

multiply the rated power indicated in the specicatrion

shhet by the correction factor.

Always connect the bigger load rst, and then add the

other apparatuses one by one.

VOLTAGE REQUIREMENT

You must use a conditioner (regulator) line when one

or more of the following solid state equipment will be connected to the generator:

• Control for garage door openers.

• Kitchen appliances with digital displays.

• Televisions.

• Stereo.

• Personal computers.

• Quartz watches.

• Photocopy machines.

• Telephone equipment

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

CAUTION

The requirements of operating voltage and frequency of all electronic equipment shall be checked prior to plugging them into this

generator. Damage may occur if the equipment is not designed to operate within a voltage variation of +/-10% and frequency variation of +/-3 Hz of the rating appearing on the nameplate of the generator. In order to avoid damage, always have an additional burden other than solid state load plugged into the generator in case of using only solid state (such as a television set) loads. A line conditioner may be necessary for some applications of solid state equipment.

INSTALLATION

WARNING

To avoid possible personal injury or property damage, it is necessary that the installation and all service be performed by a qualified electrician or authorized service representative. Under no

circumstances shall be permitted that a non qualified person make cable or wiring works into the electrical utility circuits.

In order to avoid the feedback to the electrical utility systems, isolation of the location or facility electrical system is required.

Before make the temporary connection of the generator to the location or facility electrical system, turn off or disconnect the main service.

If the generator is to be used as a source of backup power in the event of a power failure, it must be installed by a licensed electrician in accordance with all applicable local electrical codes.

Proper use requires the installation of a transfer switch double throw by a qualified electrician trained and qualified to ensure that the building’s electrical circuits may be switched safely between utility power and the generator’s output, avoiding the feedback to the power supply system.

WARNING

To avoid feedback towards the power supply systems, isolation of the location or facility electrical system is required. Before temporary

connection of the generator to the location or facility electrical system, turn off the main switch. Before making permanent connections, you must install a double-throw transfer switch. To avoid electrocution or property damage, only qualified electricians can connect the generator to the location or facility electrical system. California laws require the isolation of the residence electrical system before connecting a generator to the residential electrical systems.

Always follow the codes and ordinances that apply

to the installation of any equipment related to this product. NFPA 70 - National Electrical Code. NFPA 30 - Standard for installation and use of stationary engines of fuel. Agricultural facilities wiring manual for auxiliary electric power for farms.

ELECTRICAL EXTENSIONS

All loads supplied from the generator will be connected

to the panel using extensions or cables and it must be done by means of 3-prong grounded 125 volts 15A and 20 A plugs, 4-prong grounded 125/250 volts 30 A twist lock plugs, or 4-prong grounded 125/250 V 50 A. The receptacles must not be loaded above the amperage rating.

5-15P

5-20P

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

L14-30P

14-50P

Refer to the nameplate on the welder/generator for the power and amperage ratings. Note: The required power can be calculated by multiplying the volts and the amperes. The resulting number is the power in watts.

Always switch off and remove the electric load before turn on or

off the welder/generator engine.

Refer to the table for minimum sizes of extension cord in accordance with the needs of loads.

When the load increases you must use an extension cord of bigger size. Use of inappropriate AWG size extensions can cause serious problems with voltage, resulting in a loss of energy and damage of the tools.

The smaller the AWG number is, the higher the conductor

amperage. A 14 AWG conductor, for example, can carry out a current higher than that corresponding to a 16 AWG one.

When there are connected multiple extensions it must checked that each extension is of the minimum recommended cable size.

If an extension is used with outputs for more than one apparatus sum the amperes of the nameplate of each one of the devices to determine the minimum extension cord size.

The extensions for 120 V outputs shall be 3-wire ones, where the green wire is the ground wire, the white or gray lead is connected to the neutral of generator, and the black wire is the hot wire.

If not load real watts are known, table 1 can be used as a general guide. Remember that apparatuses which generate heat during operation such as heaters, incandescent lamps, motors and hair dryers, require a power higher than devices that

generate little heat during operation such as uorescent

lamps, radios and clocks.

Power cords and extension cords may require additional power depending of the cord length . Keep cords of the smaller possible length. See tables 3 and 4 for the recommended extension cords size and length depending on the amperage or wattage.

The circuit protection is provided by two OPS (thermal

breaker) that opens when the welder/generator load exceeds its maximum capacity or a short circuit occurs. If the OPS is activated, use the following procedure to correct the problem: a. turn off and unplug all electrical load. b. try to determine the cause of the electrical problem overload or short circuit. c. do not use any device that has a short circuit. Avoid overloading the welder/generator d. press the OPS button to reset it.

A REPEATED OPERATION OF THE OVERLOAD PROTECTOR INDICATES A PROBLEM AND CAN CAUSE DAMAGE TO THE PRODUCT OR ELECTRICAL DEVICES. DO NOT OPERATE THE WELDER/GENERATOR IF THE OPS IS REPETEADLY ACTIVATED.

Extensions for 125/250 outputs shall be 4-wire ones, where the

green wire is the ground wire, the white or gray lead is connected to the neutral of generator, and black and red wires are the hot wires.

INSTRUCTIONS FOR USE AS

EMERGENCY GENERATOR

Caution to avoid feedback to public services systems. This requires an isolation of the electrical system. To isolate the electrical system, perform the following procedures.

Turn off the main electrical system switch prior to connecting the equipment.

In accordance with national and local standards, two-

throw transfer switch must be installed in the system.

ALWAYS DISCONNECT THE MAIN SUPPLY BEFORE TEMPORARILY CONNECTING THE WELDER/ GENERATOR TO A BUILDING ELECTRICAL SYSTEM.

THE INSTALLATION OF YOUR WELDER/GENERATOR AS A BACKUP POWER SOURCE MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN.

CAUTION BEFORE STARTING

Before starting the unit, check for loose or missing parts and any kind of damage that may have occurred during the sent.

STARTING THE ENGINE

Check the oil level.

Disconnect all electrical loads from the unit. Open the fuel shut-off valve.

If the engine is cold move the choke to the right lever.

Move the start switch to the “ON” position.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Pull the retractable motor cord (with a fast steady pull), if

manual start, or turn the ignition switch key, if it is electric

start (turn the ignition key to the “START” position, and

then release the key after the engine starts).

After starting back choke lever to its original position (to

the left)

OPERATION WELDER

THE SWITCH ON THE FRONT PANEL MUST BE PLACED IN ANY WELDING POSITION AS REQUIRED.

Welding cables and clamps are not included with the

units. Use welding cable of the size specied in table 5.

CAUTION

Allow the welder/generator to run with no load for five minutes after each initial start-up to allow the engine and the alternator to stabilize.

DANGER

• It must be provided adequate ventilation for

toxic gases and air flow for engine cooling (the engine is cooled by air that is injected by its own fan)

• Do not start or start the welder/generator in

an enclosed area, even if doors or windows are open.

• The motor has carbon monoxide, a poisonous, odorless

and invisible gas.

• Vacuum carbon monoxide can cause nausea, fainting

or even death.

HOW TO APPLY A LOAD

This unit has been pretested and adjusted to handle its full capacity. To start the generator, disconnect all loads. Apply load only after the welder/generator is running. Voltage is regulated via the engine speed adjusted at the factory for correct output. Move the motor speed will make you lose the warranty.

GENERATOR’S TURN OFF

Remove all electrical loads.

Let the engine run for a few minutes without load.

Move the motor key to the “OFF” position. (Turn the key

to “OFF” on the electric start models)

Do not leave the welder/generator until operation is

stopped completely.

Close the fuel valve if the motor must be placed in storage

or transport.

If you are going to place a cover over the equipment for protection, wait until the unit has became cool.

INITIAL START UP

CLIP FOR GROUNDING (FIG.1)

Remove ½” (1.3 cm) of

insulation from the end of one wire welding.

Loosen the hex nuts on work clamp.

Insert the end of the welding cable through clamp handle and slide the wire bare under the clamp block.

Tighten hex nuts securing the cable in place.

ELECTRODE HOLDER (FIG.2)

Remove 1” (2.5 cm) of

insulation from the end of the other wire welding.

Remove handle insulated electrode holder and slide it over the welding cable.

Loosen the two set screws which are located in the lower part of the electrode holder making sure that the

blade is between cable and xing screws.

Slide the wire without insulation within the back of the

electrode holder making sure that the blade is between

cable and xing screws.

Tighten the two fastening screws securing the cable in place.

Slide the handle into place in the electrode holder.

PLUGGING DINSE

Remove ½” (1.27 cm)

of insulation from the end of one wire welding.

Insert this end of the welding cable through the transition from the “dinse” plug and slide the bare into the sleeve of the cable wire.

CAUTION

Do not apply a strong electrical charge during the initial period of operation (the first 2 or 3 hours of operation).

A controlled initial startup procedure helps to ensure correct operation of the engine and generator. Follow the procedure described in the engine manual engine.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Insert assembly sleeve cable soldering wire into the back

of the plug “dinse”.

Tighten the fastening screws securing the cable in place.

Slide the attachment of transition over the hex portion of the plug “dinse”.

Repeat the same steps for the other side.

WELDING STORAGE

Check that the surfaces of metals to be welded are free from dirt, rust, paint, oil and other contaminants. These

pollutants make difcult the welding operation and cause

poor welds.

ALL THOSE PERSONNEL WHO USE THIS EQUIPMENT OR WHO ARE IN THE AREA WHILE EQUIPMENT IS BEING USED SHALL WEAR PROTECTION FOR WELDING THAT INCLUDE: EYE PROTECTION WITH PROPER SHADE (10 SHADE MIN), CLOTHING RESISTANT TO FLAMES, WELDING LEATHER GLOVES AND FEET TOTAL PROTECTION.

IF WELDING OR CUTTING MATERIALS ARE GALVANIZED, OR ZINC, LEAD OR CADMIUM PLATED REFER TO THE SECTION OF SAFETY INFORMATION FOR INSTRUCTIONS. WHEN THESE METALS ARE HEATED EMIT EXTREMELY TOXIC GAS.

Connect work clamp to the work piece. Make sure that the contact made on bare metal and are not clogged with paint, varnish, rust or non-metallic materials.

Insert the exposed part of the electrode (the end without ux) within the jaws of the electrode holder.

Place the adjustment knob amperage in the rating suitable for the diameter of the electrode. Refer to the table on the front panel for proper electrode current values.

THE ELECTRODE HOLDER AND ROD ARE ELECTRICALLY ENERGIZED WHEN THE ENGINE IS RUNNING.

Position the electrode to begin weld, lower welding helmet or position the hand shield and set the arc. Adjust the amperage welding as required.

When nished welding, turn the engine off and store the

unit properly.

DUTY CYCLE / THERMAL 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 can occur during one minute, and then the welder must be left to cool for nine minutes.

If the equipment is not used for long periods of time, the

following prior to storage procedures must be performed:

Check the oil level and add oil if necessary.

Run the equipment until fuel is exhausted.

Remove the spark plug and pour about a teaspoon of oil into the spark plug hole.

Pull the starter rope several times to distribute the oil throughout the cylinder and combustion chamber.

Slowly pull the starter rope until you feel resistance. This indicates that the piston is moving upward in the compression cycle and that the intake and exhaust valves

are closed. (The piston pushes a small amount of air

from the spark plug in the compression hole) The use of fuel stabilizers helps prevent gum and varnish buildup in fuel system.

Whenever the equipment is stored, make sure that the fuel shut-off valve is in closed position.

Refer to the engine manual accompanying this unit for instructions regarding maintenance of engine components.

NEVER MODIFY THE SPEED AND FREQUENCY SETTINGS THE WELDER/GENERATOR HAS AS DONE AT THE FACTORY. ANY ADJUSTMENT MUST BE PERFORMED BY QUALIFIED PERSONNEL.

WELDING CABLES

Check condition of weld cables and repair or replace immediately any cables with damaged insulation.

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 the dirt and lint from the ventilation openings.

The internal components of this welder are protected against overheating with an automatic thermal switch.

TABLE 5

CABLE TOTAL LENGHT

MAXIMUM WELDING

CURENT

The cable lenght is the total of the ground cables and electrode

COOPER WIRE SUGGESTED SIZES FOR WELDING MACHINES

WELDING CABLES

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

INSTRUCTIONS FOR WELDING

This type of welding machine use a process known as

shielded arc (SMAW) welding. This process is used to

join metals by heating them with an electric arc created between the electrode and the work piece.

Used electrodes in protected arc welding have two parts, the inner core is a metal rod which shall be similar in composition to the base metal and an outer coating layer which is called flux. There are several types

of ux. Different ux or coatings are used depending on

a situation of welding in particular.

While the metal is melted, it can be contaminated by elements in the air. This contamination could weaken the

weld. The ux coating creates a protective barrier called

slag that protects the molten metal from contaminants.

When current (amperage) ows through the circuit to

the electrode, an arc between the end of the electrode and the work piece is formed. The melted metal of the

electrode ows into the molten crater and forms a bond with the work piece as shown in gure above

Note: Discontinue using and discard electrodes that burn

up to 1 to 2 inches (2.5 to 5 cm) from the electrode holder.

ESTABLISHMENT OF AN ARC

Place the bare end of the electrode in the electrode holder. Take the electrode holder gently to reduce the fatigue of the hand and arm.

Note: Always keep the jaws of the electrode holder clean to insure good electrical contact with the electrode.

BE CAREFUL OF NOT TO TOUCH WITH THE ELECTRODE THE WORKPIECE OR WORK BENCH SINCE THIS WOULD CAUSE AN ARC.

The best method to establish and maintain an arc is the method of scratching. Scratch the electrode at an angle along the surface like you will do to light a match. Once it makes contact with the plate, lift the electrode

approximately 1/16” (1.5

mm) from the surface and the arc will be

established (see Figure aside).

Note: If the electrode stick to the work piece, peel it off by turning it quickly or bending in the electrode holder while pulling up.

If the electrode does not take off, release the electrode by releasing it from the electrode holder.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

TYPE AND SIZE OF ELECTRODES

Four types of electrodes are recommended for this welder. The electrodes are commonly known by the designation of

the AWS (American Welding Society) as detailed below.

E-6011 DEEP PENETRATION

• Flat bead with deep penetrating arc.

• For rusty or dirty mild steel general repair .

E-6013 GENERAL PURPOSE

• All positions, bar of soft deposit with little spatter

• For mild steel general work.

E-7014 FAST FILL

• Smooth bead and fast replacement

• Ideal for joints with poor t up and general repair work.

E-7018 - AC HIGH STRENGTH

• Ideal for pipes and structural applications.

• Low hydrogen reduces porosity for a resistant welding.

Note: Only E-6013 and E-7018 electrodes are recommended for use with this welder. Other electrodes are designed to be used with open circuit voltages greater than these welders are capable of producing. Recommended electrode diameter is

3/32 “(2. 4 mm) to 5/32” (3.9 mm) for E-6013; and 3/32 “(2. 4 mm) to 1/8” (3.2 mm) for E-7018.

Basic instructions for arc welding

Four basic techniques affect the quality of the welding. These are: amperage value, angle of welding electrode, arc length and speed of movement. The proper use of these techniques is necessary for obtaining a good quality weld.

THE AMPERAGE VALUE

The correct amperage involves the adjustment of the welding machine to the required amperage value. This is regulated by a knob on the welder. The amperage required depends on

the size (diameter) of the electrode used and the thickness

of the work piece.

Consult specications listed on the welder. Excessive amps burn through light metals and the bead is at and porous. The ange appears high and irregular if the amperage is too low.

WELDING ELECTRODE ANGLE

Weld electrode angle is the angle in which the electrode is held during the welding process. The use of the correct angle

ensures adequate penetration and a formation of ange.

Electrode angle involves two positions: the angle of

displacement and working angle (see gure below).

Travel angle is the angle in the line of welding and may vary from 5 to 45 degrees from the vertical, depending on the conditions of soldering.

Work angle is the angle from horizontal, measured at right angles to the line of welding.

For most applications, a displacement of 45 degree angle and an angle of 45

degree work is sufcient. For specic

applications, refer to the manual of arc welding.

Note: Right handed welders should weld from left to right. Left handed welders should weld from right to left. Electrode must always point towards the sediment of welding as shown.

ARC LENGHT

The arc length is the distance from the work piece to the tip of the electrode, the distance which must traverse the arc. A proper arc length is essential to generate the heat

required for welding (see gure below).

An arc that is too long produces an unstable arc, reduces

penetration, increases the spatter and causes at and wide

beads. A too short arc does not create enough heat to melt the work piece, the electrode tends to stick, penetration is

inadequate and uneven anges with irregularities will be.

A proper arc should not be greater than the diameter of the bar. The sound of a proper arc is steady, clear sparking similar to bacon fry.

After completing welding, wait to cool the welded sections.

A layer of protection, called slag now covers the ange

and this avoids that air pollutants react with molten metal. Once the weld cools to the point that is not red hot, slag can be removed.

The removal is carried out with a hammer chisel. Gently

hit the slag with the hammer and peel of the ange. The nal cleaning is done with a wire brush. When they do

several steps of welding, remove slag before each pass.

WELDING POSITIONS

It can use four

basic positions; flat, horizontal, vertical and over head. Welding in the flat position is the easiest of any of the others because welding speed can be increased, the molten metal has less tendency to corrode, penetration can be achieved and the work is less fatiguing.

TRAVEL SPEED

The travel speed is the speed at which the welding

electrode is moving moves along the area (see g. 7).

When the speed is very high, the bead is narrow and the curl of the lip are pointed as shown. When the speed is

very low weld metal accumulates and the ange is high

and wide. To control the speed of the displacement, note

the ange (not the arc) when welding.

The ange is melted, orange metal behind the arc. The

width should be approximately twice the diameter of the welding rod. Check the travel speed to obtain an even

ange width.

REMOVAL OF SLAG

USE ANSI (ANSI Z87.1) APPROVED SAFETY GOGGLES AND PROTECTIVE CLOTHING WHEN REMOVING SLAG. FIRED HOT REMANENTS CAN CAUSE PERSONAL INJURY IN ANY AREA.

Other positions require different welding techniques as dithering, circular step and short length soldering. A high level of skill is required to perform these welds.

The work must be done in the at position if possible. For

specic applications, refer to the manual of arc welding.

STEPS OF WELDING

Occasionally more than one pass

is necessary to ll the joint. The root pass is rst, followed by the steps of lling and the cover pass (see above and aside gures).

If the pieces are thick, it might be

necessary to bevel the edges that are attached to an angle of 60 degrees. Remember to remove the slag after each step.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

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PowR-Quip Contractor Series, W240MG1400KP Assembly And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual