Red-D-Arc ZR-10 Operation Manual

IM754

RED-D-ARC
ZR-10

For use with machines having Code Numbers:

August, 2002

10796

OPERATOR’S MANUAL

Red-D-Arc Spec-Built Welding Equipment

This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.

Safety Depends on You

This welder is designed and built with safety in mind.

However, your overall safety can be increased by proper installation

... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

1-800-245-3660

North America’s Largest Fleet of Welding Equipment

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ZR-10

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

to

Mar ‘95

ZR-10

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

ZR-10

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

ZR-10

Mar. ‘93

for selecting a QUALITY product. We want you to take pride in

Thank You

operating this product ••• as much pride as we have in bringing
this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

vv

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi

TABLE OF CONTENTS

vi

Installation.......................................................................................................................Section A

Technical Specifications ................................................................................................A-1,A-2

Installation Instructions.........................................................................................................A-3

Safety Precautions ...............................................................................................................A-3

Machine Grounding.......................................................................................................A-3

Spark Arrester ...............................................................................................................A-3

Trailers....................................................................................................................A-3,A-4

Pre-Operation Engine Service..............................................................................................A-4

Oil..................................................................................................................................A-4

Fuel ...............................................................................................................................A-4

Battery Connections......................................................................................................A-4

Welding Cable Connections..........................................................................................A-4

Angle of Operation ........................................................................................................A-5

High Altitude Operation .................................................................................................A-5

Muffler Relocation .........................................................................................................A-5

Location and Ventilation................................................................................................A-5

Connection of Wire Feeders (Constant Voltage)....................................................A-5,A-6

Connection of Tig Module .............................................................................................A-6

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Output ......................................................................................................................B-1

Engine “ON-OFF” Switch .....................................................................................................B-1

Engine “START” Push Button Switch...................................................................................B-1

Approximate Fuel Consumption ...........................................................................................B-2

Control Switch ...............................................................................................................B-2

Idler Switch....................................................................................................................B-2

Welding ....................................................................................................................B-2

Auxiliary Power ........................................................................................................B-2

Starting / Shutdown Instructions ...................................................................................B-2

Starting the Engine..................................................................................................B-2

Stopping the Engine................................................................................................B-2

Break-In Period .......................................................................................................B-3

Welding Process ..................................................................................................................B-3

Stick (Constant Current) Welding..................................................................................B-3

TIG (Constant Current) Welding ...................................................................................B-3

Wire Feed Welding Processes(CV) .............................................................................B-4

Summary of Welding Processes ..................................................................................B-4

Auxiliary Power ............................................................................................................B-5

Motor Starting ...............................................................................................................B-5

Current Draw from Receptacle-No Welding .................................................................B-6

Electrical Devices used with the ZR-10.........................................................................B-6

Auxiliary Power While Welding .....................................................................................B-7

Standby Power Connections.........................................................................................B-7

Connection of ZR-10 to Premises Wiring .....................................................................B-8

Page

Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ............................................................................................D-1

Engine Adjustments...............................................................................................D-2

Slip Rings ..............................................................................................................D-2

Battery ...................................................................................................................D-2

Honda Engine Maintenace Schedule ....................................................................D-2

Hardware...............................................................................................................D-2

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

Diagrams .........................................................................................................Section F

Wiring Diagram ......................................................................................................F-1

Connection Diagram .............................................................................................F-2

Diminsion Print.......................................................................................................F-3

Parts List..................................................................................................................P380

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS: ZR-10 (K1786-2)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Speed (RPM)

Displacement

cu. in. (cu. cm.)

A-1

Capacities

ZR-10

(Honda 20HP

GX620-K1)

2 Cylinder

4 Cycle

Air-Cooled

Gasoline Engine

Electrical

Ignition

Full Load:

3500 RPM

20 HP

@ 3600 RPM

High Idle:

3700 RPM

Low Idle:

2200 RPM

RATED OUTPUT - WELDER

Welding Output

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

OUTPUT - GENERATOR

Auxiliary Power

9000 Watts, 60 Hz AC

78 Amps @ 115V

39 Amps @ 230V

12.5 Amps @ 460V 3Ø

37.5 cu-in.
(614 cc)

Fuel:

9 Gal (34 L)

Lubricating Oil:

1.9 Qts. (1.8L)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.2 in. 42.3 in. 566 lbs. (257kg.)

770mm 488 mm 1074 mm

ZR-10

A-2

AC STICK / TIG (CC) OUTPUT

A 225 OUTPUT RANGE
B 50 OUTPUT RANGE

A

B

OUTPUT AMPS

OUTPUT VOLTS AC (RMS)

0

50 100 150 200

250

0

10

20

30

40

50

60

70

80

DC STICK / TIG (CC) OUTPUT

OUTPUT AMPS

OUTPUT VOLTS DC (RMS)

A 210 OUTPUT RANGE
B 50 OUTPUT RANGE

A

B

0

50 100 150

200 250 300

350

0

10

20

30

40

50

60

70

80

CV OUTPUT RANGE

0

50

100

150

200

250 300

OUTPUT AMPS

350

0

5

10

15

20

25

30

35

40

DC WIRE FEED (CV) OUTPUT

OUTPUT VOLTS DC (RMS)

SPECIFICATIONS

INSTALLATION

A-2

ZR-10

A-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

•See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case
sides in place as this provides maximum protec­tion from moving parts and assures proper cool­ing air flow.

A-3

When this welder is mounted on a truck or trailer, it’s
frame must be securely connected to the metal frame
of the vehicle.

Where this engine driven welder is connected to
premises wiring such as that in your home or shop, it’s
frame must be connected to the system earth ground.
See further connection instructions in the section enti­tled “Standby Power Connections”, as well as the arti­cle on grounding in the latest U.S. National Electrical
Code and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
front of the welder.

SP ARK ARRESTER

Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, the K894-1 spark arrester must be
installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

Read and understand all Safety Precautions
before operating this machine. Always follow
these and any other safety procedures included in

this manual and in the Engine Owner’s Manual.

MACHINE
GROUNDING

Because this portable engine driven welder or genera­tor creates it’s own power, it is not necessary to con­nect it’s frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).

To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:

• be grounded to the frame of the welder using a

grounded type plug, or

• be double insulated.

TRAILERS

The recommended trailer for use with this equipment
for road, in plant and yard towing by a vehicle

Lincoln’s K957-1. If the user adapts a non-Lincoln trail­er, they must assume responsibility that the method of
attachment and usage does not result in a safety haz­ard nor damage the welding equipment. Some of the
factors to be concidered are as follows:

Design capacity of trailer vs. weight of Lincoln

•

equipment and likely additional attachments.

Proper support of, and attachment to, the base of

•

the welding equipment so there will be no undue
stress to the framework.

Proper placement of the equipment on the trailer to

•

insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

ZR-10

(1)

is

A-4

INSTALLATION

A-4

• Typical conditions of use, i.e., travel speed; rough­ness of surface on which the trailer will be operat­ed; environmental conditions; like maintenance.

• Conformance with federal, state and local laws

(1) Consult applicable federal, stste and lpcal laws

regarding specific requirements for use on public
highways.

(1)

.

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance
instructions supplied with this machine.

WARNING

GASOLINE

explosion.

• Stop engine while fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Keep sparks and flame away from tank.

• Wipe up spilled fuel and allow fumes to clear
before starting engine.

------------------------------------------------------------------------

fuel can cause fire or

-

BATTERY CONNECTIONS

This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the studs provided.These connections
should be checked periodically and tightened if neces­sary. Loose connections will result in overheating of
the output studs.

When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.

OIL

The ZR-10 is shipped with the engine crankcase filled
with SAE 10W-30 oil. Check the oil level before start­ing the engine. If it is not up to the full mark on the dip
stick, add oil as required. Make certain that the oil filler
cap is tightened securely. Refer to the engine Owner’s
Manual for specific oil recommendations.

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Honda GX620 - 1.9 Quarts (1.8 Liters)

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

0-50 Ft.

50-100 Ft.
100-150 Ft.
150-200 Ft.

200-250 Ft.

225 Amps

40% Duty Cycle

3 AWG

3 AWG

2 AWG

1 AWG

1/0 AWG

225 Amps

100% Duty Cycle

1 AWG

1 AWG

1 AWG

1 AWG

1/0 AWG

CAUTION

Connect the work cable directly to the work piece.
Do not allow welding current to return through
electrical conduit, pipes or building structures
that are not suitable to carry welding current. Do
not connect the work cable to the welding frame.
Stray welding currents may also damage auxiliary
power cords or equipment.

ZR-10

A-5

INSTALLATION

ANGLE OF OPERATION

Internal combustion engines are designed to run in a
level condition which is where the optimum perfor­mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain­ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.

When operating at an angle, the effective fuel capaci­ty will be slightly less than the specified 10 gallons.

HIGH AL TITUDE OPERA TION

A-5

LOCATION / VENTILATION

The welder should be located to provide an unrestrict­ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder
so that engine exhaust fumes are properly vented to
an outside area.

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in the ZR-10 base or weld to the

ZR-10 base.

If the ZR-10 will be consistently operated at altitudes
above 5000 ft, a carburetor jet designed for high alti­tudes should be installed. This will result in better
fuel economy, cleaner exhaust, and longer spark plug
life. It will not
decreased at higher altitudes. Engine horsepower is
reduced by 3.5% per 1000 feet for altitudes above
377 feet.

give increased power which is

CAUTION

Do not operate a ZR-10 with a high altitude jet
installed at altitudes below 5000 ft. This will
result in the engine running too lean and result in
higher engine operating temperatures which can
shorten engine life.

High altitude jet kits are available from the engine
manufacturer.

MUFFLER RELOCATION

WARNING

Shut off welder and allow muffler to cool before
touching muffler.

CONNECTION OF WIRE FEEDERS

(Constant voltage)

WARNING

Shut off welder before making any electrical
connections.

CONNECTION OF THE LN-25 TO THE ZR-10

• Shut the welder off.

•

Connect the electrode cable from the LN-25 to the
“ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.

• Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).

• Position the “RANGE” switch to the “WIRE FEED”
position.

• Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.

The ZR-10 is shipped with the exhaust coming out on
the left side. The exhaust can be changed to the
opposite side by removing the two screws that hold
the exhaust port cover in place and installing the
cover on the opposite side. (Operating the ZR-10
without the cover in place will result in a higher noise
level and no increase in machine output.)

• Place the idler switch in the “AUTO” position.

• Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.

NOTE: The welding electrode is energized at all

times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.

ZR-10

A-6

CONNECTION OF THE LN-7 TO THE ZR-10

• Shut the welder off.

• Connect the LN-7 and the K240 contactor kit per
instructions on the connection diagram S17742

(can be found in the back of this manual).

• Place the “RANGE” switch to the “WIRE FEED”
position and the “POLARITY” switch to the
desired polarity.

• Place the “IDLER” switch in the “HIGH” idle
position. The engine idling device may not
function when welding in the “WIRE FEED” mode.

• Adjust wire feed speed at the LN-7 and adjust the
welding voltage with the output “CONTROL” at
the welder.

NOTE: If the output “CONTROL” is set below “3” the

K240 contactor may not pull in.

INSTALLATION

A-6

CONNECTION OF K930-1 TIG MODULE TO THE ZR-10

The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.

NOTE: The TIG Module does not require the use of a

high frequency bypass capacitor. However, if the ZR­10 is used with any other high frequency equipment,
the bypass capacitor must be installed - order kit
T12246.

ZR-10

B-1

OPERATION

SAFETY PRECAUTIONS

Read and understand this entire section before
operating your ZR-10.
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte­nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.

B-1

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.

• Duty Cycle: 100% for both welding and auxiliary
power.

ZR-10

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts
such as output terminals or internal
wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or
vent exhaust outside

•Do not stack anything near the
engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or
guards off.

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

• Only qualified personnel should operate this
equipment.

Constant Voltage 200 Amps DC @ 20 Volts

Welder Controls - Function and Operation

Explanation of Symbols that Appear on this Equipment

ON

OFF

Low Idle

High Idle

ENGINE “ON-OFF” Switch

When placed in the “ON” position, this switch
energizes the engine ignition circuit. When placed in
the “OFF” position, the ignition circuit is de-energized
to shut down the engine.

ENGINE “START” Push-Button Switch

Energizes engine starter motor.

“Polarity” Switch

CAUTION

Never change the “Polarity” switch setting while
welding. This will damage the switch.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door
closed and the side panels in place as these pro­vide maximum protection from moving parts and
insure proper cooling air flow.

GENERAL DESCRIPTION

The ZR-10 is a twin-cylinder, gasoline driven, multi­process arc welder and AC power generator. It is built
in a heavy gauge steel case for durability on the job
site.

“ Range” Switch

Process Maximum Current

STICK/TIG - CC 50, 70, 90
6 Range Settings 125, 175, 210 DC/225 AC

WIRE FEED - CV
1 Range Setting 200

CAUTION

Never change the “RANGE” Switch setting while
welding. This will damage the switch.

ZR-10

B-2

OPERATION

ZR-10 Approximate Fuel Consumption

HONDA 20HP

GX620-K1

Low Idle - No Load
2400 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power
9000 Watts

.3 Gallons/Hour

(1.3 Liters/Hour)

.7 Gallons/Hour

(2.7 Liters/Hour)

1.6 Gallons/Hour
(6.0 Liters/Hour)

1.7 Gallons/Hour
(6.3 Liters/Hour)

1.2 Gallons/Hour
(4.6 Liters/Hour)

1.7 Gallons/Hour
(6.5 Liters/Hour)

B-2

STARTING / SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

WARNING

• Do not touch electrically live parts
of electrode with skin or wet
clothing.

• Keep flammable material away.

• Insulate yourself from work and

ground. Wear eye, ear, and body
protection.

“ CONTROL” SWITCH

Provides a fine welding current adjustment within the
Range Switch settings in the STICK/TIG mode and
welding voltage control with the Range switch set in
the wire feed mode.

“IDLER” SWITCH

The idler switch has two positions, “HIGH” and
“AUTO”.

When in “HIGH” ( ) position, the engine will run
continuously at high idle.
When in “AUTO” ( / ) idle position, the idler
operates as follows:

• WELDING

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 16 seconds.

• AUXILIARY POWER

• Keep your head out of the fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

Be sure all Pre-Operation Maintenance has been per­formed. Also, read the Engine Owner’s Manual.

Remove all loads connected to the AC power recepta­cles. To start the engine, set the “Idler Control” switch
in the Automatic ( / ) position.

Use the choke control as follows:

Honda Engine - Always pull the choke control out

when starting the engine; cold. Place the “Engine”
switch in the “ON” position.

Push the “START” button and crank the engine until it
starts. Release the button as soon as the engine
starts. Do not push the “START” button while the
engine is running because this will cause damage to
the ring gear and/or starter motor. After the engine
has started, slowly return the choke control to the full
“in” position (choke open).

After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.

With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater or 1500W on 460v 3ø)
from the receptacles, the engine will accelerate to
high speed. If no power is being drawn from the
receptacles (and not welding) for 10-16 seconds,
the idler reduces the engine speed to low idle.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.
Stop the engine by placing the “Engine” switch in the
“OFF” position.
A fuel shut off valve is not required on the ZR-10
because the fuel tank is mounted below the engine.

ZR-10

B-3

OPERATION

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi­mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS

BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:

Honda

GX620-K1

First Month

or 20 HRS

Refer to the Engine Owner’s Manual for more informa­tion.

B-3

WELDING PROCESS

STICK (CONSTANT CURRENT) WELDING

Connect welding cables to the "TO WORK” and
"ELECTRODE” studs. Start the engine. Set the
"Polarity” switch to the desired polarity. Set the
“RANGE” switch to a setting that is equal to or slightly
greater than the desired welding current. (The
“RANGE” dial marking indicates the maximum
for that range). Fine adjustment of the welding current
is made by adjusting the output “CONTROL” or

remote control. For best arc stability, use settings 5

through 10.

The ZR-10 can be used with a broad range of AC and
DC stick electrodes. See “Welding Tips 1” included
with the ZR-10 for electrodes within the rating of this
unit and recommended welding currents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-1 TIG Module installed on a ZR-10 provides
high frequency and shielding gas control for AC and
DC GTAW (TIG) welding processes. The TIG Module
allows full range output control. Afterflow time is
adjustable from 0 to 55 seconds.

current

When using the ZR-10 for AC TIG welding of alu­minum, the following settings and electrodes are
recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 70, 90, or 125 80 - 150 Amps
3/32 50, 70, or 90 45 - 130 Amps
1/16 50, or 70 40 - 80 Amps

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 70, 90, 125, or 175 80 - 225 Amps

3/32 50, 70, 90, or 125 50 - 180 Amps
1/16 50, 70, or 90 45 - 120 Amps

The K930-1 TIG Module should be used with the ZR­10 on high idle to maintain satisfactory operation. It
can be used in the AUTO position but the delay going
to flow idle after welding is ceased will be increased if
the AFTERFLOW CONTROL is set above 10 sec­onds.

ZR-10

B-4

OPERATION

WIRE FEED WELDING PROCESSES

(Constant Voltage)

®

The only Innershield
with the ZR-10 is NR®-211-MP. The electrode sizes
and welding ranges that can be used with the ZR-10
are shown in the following table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A

The ZR-10 is recommended for limited “MIG” welding
(GMAW - gas metal arc welding). The recommended
electrodes are .030” and .035” L-50 and L-56. They
must be used with a blended shielding gas such as
C25 (75% Argon - 25% CO

can be used with the ZR-10 are shown in the following
table:

electrode recommended for use

). The welding ranges that

2

B-4

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.030 80 - 110 75A to 120A
.035 70 - 130 120A to 170A

SUMMARY OF WELDING PROCESSES

CONTROL ELECTRODE

CABLE IDLE WHEN NOT TO START

PROCESS USED MODE WELDING WELDING

STICK No AUTO Hot Touch electrode to work.

Welding starts immediately
and engine goes to high
idle.

TIG/K7930-1/K938-1, Yes HIGH Cold Press Amptrol, contactor
K936-( ) /K892-1 closes, welding
(WITH AMPTROL) starts immediately.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding

starts immediately and
engine goes to high idle.

NOTE: Output Control

must be set above “3”.

WIRE FEED, LN-7 WITH Yes HIGH Cold Press gun trigger,
K240 CONTACTOR KIT contactor closes. Welding

starts immediately.

ZR-10

B-5

GND

115 V

115 V

230 V

OPERATION

AUXILIARY POWER

The ZR-10 can provide up to 9,000 watts of 115/230
volts AC, single phase 60Hz power, or 460 Volts,3
phase, 60 Hz for continuous use. The front of the
machine includes four receptacles for connecting the
AC power plugs; one 20 amp 460 volt 3 phase NEMA,
one 50 amp 115/230 volt NEMA 14-50R receptacle
and two 20 amp 115 volt NEMA 5-20R receptacles.
Do not use 3 phase power and single phase power
simultaneously.

B-5

460 Volt 3 Phase Receptacle with Ground

The 460 volt receptacle can supply 12.5 amps of 3
phase power, or up to 15 amps of single phase power.
A NEMA plug L16-20P is required to use this recepta­cle. The ground (GND) connection is connected to the

machine frame, it is NOT the neutral of the three

phase connection, and should under no circum­stances be connected to the neutral of any 3 phase
load. Do not connect 460V 3 phase to premises
wiring.

CAUTION

Do not connect any plugs that connect to the power
receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxil­iary power.

WARNING

A qualified person must make connections to plugs.
Connect each wire of the cord to the proper plug ter­minal, especially ground.

115/230 Volt Dual Voltage Receptacle

The 115/230 volt receptacle can supply up to 39
amps of 230 volt power to a two wire circuit, up to 39
amps of 115 volts power from each side of a three
wire circuit (up to 78 amps total). Do not connect the
115 volt circuits in parallel.

If 460 volt single phase load is to be run, the X lead
must be one of the leads in the circuit in order for the
automatic idle to function. Using a NEMA plug L16­20P, connect either X and Y or X and Z to the recep­tacle, as well as the machine ground.

All auxiliary power is protected by circuit breakers with
the following values:
The 115V has 15 amp circuit breakers for each plug of
the duplex receptacle. The 230V has 50 amp circuit
breakers for each hot lead going the 230V receptacle.
The 460V 3 phase circuit breakers / switch has a 3
phase, 15 amp circuit breaker.

X

(FOR ALL SINGLE AND

THREE PHASE LOADS)

Y

460 V

Z

GND

Ground Wire

Periodically check the ground wire at plugs, power
cords and auxiliary loads to ensure that the grounding
circuit is intact and connected.

115 V Duplex Receptacles

The 115V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.

The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle (Refer to Tables I and II). Do
not attempt to connect power receptacles in parallel.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a

1.5 hp motor is approximately 20 amperes (10
amperes for 230 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 230V operation
only.

The 460 volt 3 phase output of the ZR-10 is capable
of running most 460VAC 3 phase motors up to 10HP.
A 10HP motor must be started with no load on the
motor and no other load connected to the machine,
since the full load current of a 10HP 460VAC 3 phase
motor is approximately 12.5 amps. Refer to the recon­nect phase output to any load, the ground at the 3

phase receptacle is NOT the neutral of 3 phase con-

nection, and should under no circumstance be con­nected to the neutral of any 3 phase load.

ZR-10

B-6

TABLE I Maximum Current Draw from 115V Duplex Receptacles - No Welding

Load From
115V/230V
Dual Voltage Total From Total From
Receptacle Each 115V Both 115V

Duplex Duplexes

0 20* 40

2.2 KW 20* 40

4.5 KW 20* 40

6.7 KW 20* 20

9.0 KW 0 0

*NEMA 5-20P Plug required for 20Amp Draw

ELECTRICAL DEVICES USE WITH THE ZR-10

Type Common Electrical Devices Possible Concerns

OPERATION

TABLE II Maximum Current Draw from 115V GFCI
Duplex Receptacles - No Welding

Load From

115V/230V

Dual Voltage Total From Total From

Receptacle Each 115V Both 115V

Duplex Duplexes

0 20 40*

2.2 KW 20 40*

4.5 KW 20 40*

6.7 KW 20 20*

9.0 KW 0 0

*Maximum current draw from each 115V
GFCI Duplex is 20 amps

TABLE lll

B-6

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capac-

itative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe
operation. DO NOT RUN

THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect­ed to the ZR-10

complicated electrical equipment. er along with transient and

surge protection is required,
and liabilities still exist. DO

NOT USE THESE DEVICES
WITH A ZR-10.

ZR-10

B-7

OPERATION

B-7

AUXILLIARY POWER WHILE WELDING

It must be noted that the above auxiliary power ratings
are with no welding load. Simultaneous welding and
power loads are permitted by following Table III. The
permissible currents shown assume that current is
being drawn from either the 115V or 230V supply (not
both at the same time). Also, the “Output Control” is
set at “10” for maximum auxiliary power.

TABLE III

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) @ 115V -or- @ 230V

Max. Stick or Wire

Feed Setting None 0 0
175 Stick Setting 2100 18 9
125 Stick Setting 3800 32 16

90 Stick Setting 5000 42 21
70 Stick Setting 5600 48 24
50 Stick Setting 6300 54 27

NO WELDING 8000 70 35

• Take necessary steps to assure load is limited to
the capacity of the ZR-10 by installing a 35 amp
230V double pole circuit breaker. Maximum rated
load for the 230V auxiliary is 35 amperes. Loading
above 35 amperes will reduce output voltage below
the allowable-10% of rated voltage which may dam­age appliances or other motor-driven equipment.

• Install a 50 amp 115/230V plug (NEMA type 14-

50)to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. (The50 amp
115/230V plug is available in the optional plug kit.)

• Plug this cable into the 50 amp 115/230V receptacle
on the ZR-10 case front.

STANDBY POWER CONNECTIONS

The ZR-10 is suitable for temporary, standby, or emer­gency power using the engine manufacturer’s recom­mended maintenance schedule.

The ZR-10 can be permanently installed as a standby
power unit for 230V-3 wire, single phase 35 ampere
service.

WARNING

(Connections must be made by a licensed electri­cian who can determine how the 115/230V power
can be adapted to the particular installation and
comply with all applicable electrical codes.)
The following information can be used as a guide
by the electrician for most applications (refer also
to the connection diagram shown in Figure 1.)

• Install a double pole, double throw switch between
the power company meter and the premises discon­nect.

• Switch rating must be the same or greater than the
customer’s premises disconnect and service over­current protection.

ZR-10

B-8

230 Volt

60 Hz.
3-Wire

Service

POWER

COMPANY

METER

230 VOLT

115 VOLT

115 VOLT

LOAD

N

NEUTRAL
BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

N

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

230 VOLT

GROUNDED CONDUCTOR

35AMP

230 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT

PROTECTION.

50 AMP, 115/230

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 115/230 VOLT

RECEPTACLE

OPERATION

Figure 1

CONNECTION OF ZR-10 TO PREMISES WIRING

B-8

WARNING

Connection of ZR-10 to premises wiring must be
done by a licensed electrician and must comply
with the National Electrical Code and all other
applicable electrical codes.

ZR-10

C-1

ACCESSORIES

OPTIONAL EQUIPMENT (Field Installed)

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS

For road, off-road and in-plant and yard towing.
(For highway use, consult applicable federal, state
and local laws regarding requirements for brakes,
lights, fenders, etc.).

C-1

GFCI Receptacle Kit (K1690-1) - Includes one UL

approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc­tions. Replaces the factory installed 115V duplex
receptacle. Each receptacle of each GFCI Duplex is
rated at 20 Amps, but the maximum total current from
each GFCI Duplex is limited to 20 Amps.

Two kits are required.

Two-Wheel Undercarriage (K889-2) - For moving by
hand. Overall Width 29 in (.74m)

Caster for Undercarriage (K893-1) - Mounts to the
front of the K889-2 to allow easy movement on
smooth surfaces. Includes 6” diameter hard rubber
wheel and convenient toe-on, toe-off locking brake.

Canvas Cover (K886-1) - To protect the ZR-10 when
not in use. Made from attractive red canvas material
which is flame retardant, mildew resistant, and water
repellent.

Power Plug Kit (K802-N) - Provides four 115V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 115/230V, 50 amps. (For K1418-2 or
K1419-2 CSA machines and machines with GFCI
receptacles, use K802-R).

Power Plug Kit (K802-R) - Provides four 115V plugs
rated at 15 amps each and one dual voltage, full KVA
plug rated at 115/230V, 50 amps.

Accessory Kit (K710) - Includes 30 ft (9.1m) 3 AWG
electrode cable, 25 ft. (7.6m) 3 AWG work cable,
headshield with No. 12 filter, GC300 work clamp and
Cooltong® 300 electrode holder. Cables are rated at
225 amps, 40% duty cycle.

Remote Control Receptacle Kit (K892-1) - Includes
a 6-pin MS-type (Amphenol) receptacle and a local­remote toggle switch that mounts in the case front.
Requires a Remote Control Option.

Remote Control (K857) - Consists of a control box
with 25 ft. (7.5m) of four conductor cable. Permits
remote adjustment of output voltage. (Requires
Remote Control Receptacle Kit to be mounted in
machine.)

TIG Module (K930-2) - Provides high frequency and
shielding gas control for AC and DC GTAW (TIG)
welding applications. Its compact case is designed for
easy carrying, complete with a handle. High frequen­cy bypass is built in.The K938-1 Contactor Kit must
be field installed in the TIG Module when used with a
ZR-10. Additionally, the K936-3 control cable is
required if remote control is used. If remote control is
not used the K936-4 control cable is required.

Foot Amptrol (K870)
Remote Control Cable (K936-3) - Control cable for

connecting the K930-2 TIG Module to a ZR-10
equipped with a K892-1 Remote Kit. 9-Socket to a
grounded 115 V plug and a 6 pin MS-connector.
(Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground)

Remote Control Cable (K936-4) - Control cable for
connecting the K930-2 TIG Module to a ZR-10 not
equipped with a K892-1 Remote Kit. 9-Socket to a
grounded 115 V plug and a 6 pin MS-connector.
(Contains circuits 31, 32, and ground)

Docking Kit (K939-1) - For mounting the K930-1 TIG
Module unit on top of the ZR-10.

Remote Control Receptacle Kit (K892-1) - Required
when using a K930-1 TIG Module with and optional
amptrol.

Wire Feed:
LN-25 (K449) - Includes internal contactor for across

the arc operation (no control cable). Provides “cold”
electrode until gun trigger is pressed. Includes gas
solenoid. Remote control Receptacle Kit (K892-1) and
Remote voltage Control Kit (K444-1) are required for
voltage control at the feeder.

Spark Arrester Kit (K894-1) - Includes a heavy
gauge steel, approved spark arrester and clamp for
easy mounting to muffler exhaust pipe.

LN-7 - Contactor Kit (K240) is required.
Magnum Gun is required for gas-shielded welding.

Innershield Gun is required for gasless welding.

ZR-10

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do the maintenance

work. Turn the engine off before working inside
the machine. In some cases, it may be
necessary to remove safety guards to perform
required maintenance. Remove guards only
when necessary and replace them when the
maintenance requiring their removal is
complete. Always use the greatest care when
working near moving parts.

• Do not put your hands near the engine cooling

blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

D-1

ROUTINE MAINTENANCE

• At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and add
oil if indicated.

CAUTION

Make certain that the oil filler cap is securely tight­ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.

• OIL - Maintenance schedule for changing the oil and
oil filter after break-in:

Honda GX620-K1

Oil 6 months or 100 hours
Oil Filter Every year or 200 hours

The above schedule is for normal operating condi­tions. More frequent oil changes are required with
dusty, high temperature and other severe operating
conditions. Refer to the maintenance section of the
Engine Owner's Manual for more information.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

•See additional warning information

throughout this operator’s manual and
the Engine manual as well.

-----------------------------------------------------------

• Read the Safety Precautions in the front of this
manual and the engine instruction manual before
working on this machine.

• Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep
hands, hair, clothing, and tools away from gears,
fans, and all other moving parts when starting,
operating, or repairing the equipment.

• If guards are missing from a machine, obtain
replacements from a Lincoln Distributor. (See
Operating Manual Parts List.)

: Engine life will be reduced if the oil and oil fil-

NOTE

ter are not changed according to the manufacturer’s
recommendation.

• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replace­ment of the air cleaner filter every 100 hours.
More frequent servicing is required with dusty
operating conditions. Refer to the maintenance
section of the Engine Owner’s Manual for more
information.

• Refer to the maintenance section of the Engine
Owner’s Manual for the maintenance schedule,
spark plug servicing, cooling system servicing, and
fuel filter replacement.

• Blow out the machine with low pressure air period­ically. In particularly dirty locations, this may be
required once a week.

• Output Range Selector and Polarity Switches:

Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the han­dle from maximum to minimum setting twice each
morning before starting to weld.

ZR-10

D-2

(3)

ENGINE ADJUSTMENTS

MAINTENANCE

BATTERY

D-2

OVERSPEED IS HAZARDOUS

WARNING

The maximum allowable high idle speed for this
machine is 3750 RPM, no load. Do NOT tamper
with governor components or setting or make any
other adjustments to increase the maximum
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary. If brushes are
to be replaced, clean slip rings with a fine emery
paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

HONDA ENGINE MAINTENANCE SCHEDULE

Regular Service Period (3)

ITEM Perform at every indicated month or operating hour
interval, whichever comes first.

Engine Oil Check Level

Change

Engine Oil Filter Replace

Air Cleaner Check

Each

Use

First

Month or

20 Hrs.

•

• •

•

Every
3 Months
or 50 Hrs.

WARNING

• GASES FROM BATTERY can explode.- Keep sparks,
flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect negative

cable from old battery first and connect to new battery
last.

• CONNECTING A BATTERY CHARGER - Remove bat­tery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
ventilated.

• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.

• BATTERY ACID CAN BURN EYES AND SKIN.- Wear
gloves and eye protection and be careful when work­ing near battery. Follow instructions printed on bat­tery.

When replacing, jumping, or otherwise connectingthe bat­tery to the battery cables, the properpolarity must be
observed. Failure to observethe proper polarity could result
in damage to thecharging circuit. The positive (+) battery
cablehas a red terminal cover.

If the battery requires charging from an external charger,
disconnect the negative battery cable first and then the posi­tive battery cable beforeattaching the charger leads. Failure
to do so can result in damage to the internal chargercompo­nents. When reconnecting the cables, connect the positive
cable first and the negative cable last.

HARDWARE

Both English and Metric fasteners are used in this welder.

Every

6 Months or

100 Hrs.

Every

Year or

300 Hours

• or 200
Hours

Clean

Replace

Spark Plug Clean adjust

Replace

Spark Arrestor
(Optional Part)

Engine Speed Check-Adjust

Valve Clearance Check-Readjust

Fuel Filter Check

Fuel Line Check

(1) Service more frequently when used in dusty areas.
(2) Replace the paper element only.

These items should be services by an authorized engine dealer.

Clean

Replace

(Replace if necessary)

• (1)

• (2)

•

•

•

• (3)

• (3)

•

• (3)

Every 2 Years (3)

ZR-10

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will
invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all
safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

ZR-10

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-2

RECOMMENDED

COURSE OF ACTION

No welder or output power.

Engine will not idle down to low
speed.

1. Open in miscellaneous leads.

2. Open lead in flashing or field
circuit.

3. Faulty rotor.

4. Faulty Potentiometer (R1).

5. Faulty stator Field winding.

6. Faulty Field rectifier (D2).

7. Faulty P.C. Board.

1. Idler switch on High Idle.

2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).

3. External load on welder or
auxiliary power.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Authorized Field
Service Facility.

Engine will not go to high idle when
attempting to weld.

4. Faulty wiring in solenoid circuit.

5. Faulty idler solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to
work.

2. No voltage signal from the
current sensor.

3. No open circuit voltage on
output studs.

4. Faulty P.C. Board.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

CAUTION

ZR-10

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-3

RECOMMENDED

COURSE OF ACTION

Engine will not go to high idle when
using auxiliary power.

Engine will not crank or is hard to
crank.

Engine shuts down.

1. No voltage signal from the
current sensor.

2. Auxiliary power load less than
100 to 150 watts.

3. Faulty P.C. Board.

1. Battery will not hold a charge.
Faulty Battery.

2. No or insufficient charging
current.

3. Loose battery cable
connection(s).

1. Out of fuel.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Authorized Field
Service Facility.

Engine does not develop full power.

Engine is hard to start.

2. Low oil level.

1. Fuel filter clogged.

2. Air filter clogged.

1. Spark plugs do not have
specified gap.

2. Spark plugs are fouled.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

CAUTION

ZR-10

F-1

G4375

DIAGRAMS

F-1

D1

S2

PCB1

12

8

254

-

3 TURNS

CCW

1 TURN

75A

R1

76A

77A

OUTPUT

CONTROL

261

260

3

10

254

+

L1

CHOKE

ZR-10 HONDA

START

221

5D

211

208C

BUTTON

208B

5H

GROUND SCREW

AT BLOWER BAFFLE

209A

-

AM1

+

S5

208A

IN "RUN"

POSITION

"S3" SHOWN

S3

CB7

P5

J5

1

J1

7

77
75
5E
76

215
224

12

E

WORK

5F

6

8

10

S2

C1

R6

R5

R4

R3

R2

R1

ELECTRODE

GND-E

S1

GND-G

201A

219

200B

REACTOR

REACTOR

2
W2

4

3

S1

C1

GND-C

7

9

3

STATOR

STATOR

6

W1

GND-D

4

3

2

1

GND-E

77A

76A

75A

200B

7

3

5

9

GND-D

3

+

12 VOLT

BATTERY

209

209A

211B

5D

5E

211

208

5H

221

224C

224

224A

210

211B

D9

DIODE

IN LINE

4 AMP

25A

IDLER

SOLENOID

215

213

METER

HOUR

+

224A

213

224B

210

S4

POSITION

IN "AUTO"

"S4" SHOWN

J2

-

120V

3E

211

NO

CONNECTION

224E

225A

+

GND-G

CB1
6

ENGINE

STARTER

224C

221

208

35A

200

FIELD

C1

CAPACITOR

200A

219

D2

-

5

5K

5L

12

FOOT

GND-H

CR1

SOLENOID

B/Y

B/R

N.A.

IGNITION

210A

OIL

SWITCH

PRESSURE

+

+

ROTOR

1

2

3

6

21

J1

J5

SLIP RING NEAREST LAMINATION

201

201A

CB4

20A

3A

5

5L

J3

120V

3B

20A

CB3

11

5K

J4

CB2

35A

11

115V/230V

ENGINE

CROSS

SUPPORT

212

FUEL

SOLENOID

SHUTOFF

MODULE

W

W/U

GY

GND-C

GY

3B

3A

3E

TERMINALS

(WHITE WIRES)

SILVER COLORED

STARTER

B

6

5

4

3

MODULE

2
1

RECTIFIER/REGULATOR

CONNECTOR PIN NUMBERS:

7

12

43

HONDA ENGINE COMPONENTS

20 AMP

CHARGE COIL

GY = GRAY

U = BLUE

R = RED OR PINK

B = BLACK OR GRAY

W = WHITE

LEAD COLOR CODE:

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

2002
08-

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR

ZR-10

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

F-2

M17486

ELECTRODE CABLE

LN-25

WIRE FEEDER

REMOTE CONTROL

TO WORK

ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

TO WORK

WORK CLIP LEAD

TO WORK

6 PIN
AMPHENOL

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH
IN "OUTPUT CONTROL REMOTE" POSITION.

ZR-10 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM

CRM 21883

OPTIONAL K444-1

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR
SWITCH TO THE WIRE FEED (CV) POSITION.

WARNING

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.
Do not touch electrically live parts.

Keep guards in place.
Keep away from moving parts.
Only qualified personnel should install,use
or service this equipment.

F-2

CONNECTION OF ZR-10 TO LN-7 & K240 CONTACTOR KIT

CONNECTION OF LN-7 & K240 CONTACTOR KIT WITH 115 VOLT AC AUXILIARY POWER AND CV OUTPUT

CONTROL CABLE

N.D.

CONNECT THE CONTROL CABLE
GROUND LEAD TO THE FRAME
TERMINAL MARKED NEAR
THE TERMINAL STRIP OR TO
AN UNPAINTED FRAME SCREW.

N.F. & N.G.

WELDER STANDARD OUTPUT TERMINALS

WARNING: Turn the power off when making connections.
N.A. Use power source polarity switch to set for desired electrode

N.J.

polarity. Position the output selector switch on the power
source to the CV position.

N.B. 3 conductor #16 power cord physically suitable for the

installation and plug rated at 115 volts 15 amperes AC.

N.C. Plug into 115 volt AC receptacle on welder control panel or

other 115 volt AC supply rated at a minimum of 500 volt­amperes.

N.D. Leads #21 and GND. do not appear on LN-7’s with codes

below 7026.

N.E. Welding cables must be of proper capacity for the current

and duty cycle of immediate and future applications.

N.F. If LN-7 is equipped with a meter kit, extend lead #21 using

#14 or larger insulated wire physically suitable for the instal­lation. An S16586-”length” remote voltage sensing work

21

N.C.

77

WORK

N.B.

POWER
SOURCE

75

76

ELECTRODE

ZR-10

GND. 32 2 4 31

2

32

AUTO.
EQUIP.

lead may be ordered for this purpose. Connect it directly to
the work piece independent of the welding work cable. For
convenience, this extended #21 lead should be taped to the

4

POWER
SOURCE

welding work lead.
N.G. Tape up bolted connection where lead #21 is extended.
N.H. Idler switch on power source must be in high idle position.
N.J. If an optional remote output control is used, connect it to this

terminal strip or 6 pin Amphenol receptacle. NOTE: Terminal

strip or 6 pin Amphenol receptacle not available on all power

sources.
CAUTION: Any speed up of the engine RPM by changing the gov-

ernor setting or over-riding the throttle linkage will cause an

increase in the AC auxiliary voltage. If this voltage goes

above 140 volts, the LN-7 control circuit will be damaged.

The engine governor setting is pre-set at the factory - do not

adjust above RPM specifications listed in engine welder

operating manual.

31

TO LN-7

K240 CONTACTOR KIT
115V (50/60HZ.)
(NOTE : 600 AMP CAPACITY)

ELECTRODE CABLE TO LN-7

TO WORK

S17742
10-2-92

F-3

CENTER

OF

GRAVITY

WITH

OIL

IN

DIAGRAMS

F-3

ENGINE AND FUEL TANK EMPTY.

21.25

21.21

13.25

42.00

30.00

UNDERCARRIAGE MOUNTING HOLES

8.80

3-15-00A

M19725

DIMENSION PRINT - ZR-10 (Honda)

9.29

OF SHAFT

L

C

9.31

2.00

FOR OIL FILTER

REMOVAL

9.09

18.17

9.09

9.09

17.00

26.59

30.28

ZR-10

NOTES

ZR-10

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

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