Thermal Arc Installation Instructions for Engine Protection Shutdown Kit Installation manual
Installation Instructions for Engine
Protection Shutdown Kit
For the Following Specs:
494690
•
OWNER’S MANUAL Number 430429-213
Revised December 1, 1997
IMPORTANT: Read these instructionsbeforeinstalling, operating, orservicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEPAWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESEINSTRUCTIONS.READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATINGOR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
trainingbefore using this equipment. Anyone not havingextensive training in weldingand cuttingpractices should not attemptto weld.Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled:
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMEDONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touchinglive electricalparts can cause fatal shocks
or severe burns. The electrode and work circuit is
electricallylive whenever the outputison. The input
power circuit and machine internal circuits are also
livewhen powerison. Insemiautomaticorautomatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and bodyprotection.
3. Insulate yourself from work and groundusing dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
SAFETY IN WELDING AND CUTTING. This publication and
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool itor lay it downon theground or the worksurface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do notuseworn,damaged,undersized,orpoorlysplicedcables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Useonlywell-maintainedequipment. Repair or replacedamaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
Eye protection filter shade selector for weldingor cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc welding
(stick) electrodes
Electrode Size
Metal Thickness
or Welding Current
—
—
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in., 4 to 6.4 mm
Over 1/4 in., 6.4 mm
Filter
Shade
No.
2
3or4
3or4
4or5
5or6
4or5
5or6
6or8
10
12
14
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shieldsrecommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gastungsten arc welding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
All
All
All
All
All
All
Under 300 Amp
300 to 400 Amp
Over 400 Amp
May 8, 1996 2-1
Filter
Shade
No.
11
12
12
12
12
12
12
14
9
12
14
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
FUMES AND GASES can be hazardous
to your health.
Weldingproducesfumes andgases.Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-suppliedrespirator.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot workpiece, and hot equipmentcancause fires and burns.
Accidental contact of electrode or welding wire to
metal objects cancause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly coverthem with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks andopenings to adjacent areas.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat andraysof the arc canreact with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxicfumes if welded.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding currentfrom traveling long, possibly
unknown paths and causing electric shock andfire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments suchas leather gloves,heavy
shirt, cuffless trousers, high shoes,and acap.
FLYING SPARKS ANDHOTMETAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gasunder high pressure. If damaged, a cylindercan explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protectcompressed gascylindersfrom excessiveheat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
themtoa stationarysupportorequipment cylinderrackto prevent
falling or tipping.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
3. Keep cylinders away from any welding or other electricalcircuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylindervalve.
7. Keep protectivecap in place over valve except when cylinder is
in use or connected for use.
8. Read and followinstructionson compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
2-2 May 8, 1996
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors,and beltscan cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteriescontain acid andgenerateexplosive gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hotand under
pressure.
WARNING: This product, when used forwelding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5et seq.)
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following isa quotation from the GeneralConclusions Section of the U.S. Congress, Officeof Technology Assessment,
of Power Frequency Electric &Magnetic Fields — BackgroundPaper, OTA-BP-E-63 (Washington, DC: U.S. Government PrintingOffice, May
1989): “... there is now a very large volume of scientificfindings based on experiments at the cellular level and from studies with animalsand
people which clearly establish thatlow frequency magneticfields can interact with,and produce changes in, biological systems. Whilemost of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the followingprocedures:
1. Keep cables close together by twisting ortaping them.
2. Arrange cables to one side and away from the operator.
2. Donotaddfuelwhilesmokingor if unit is near anysparksoropen
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Do not overfilltank — allow room for fuel to expand.
5. Do not spillfuel.If fuel is spilled,cleanup before startingengine.
3. Have only qualified people remove guardsor covers for mainte-
nance and troubleshooting as necessary.
4. To prevent accidentalstartingduringservicing,disconnectnega-
tive (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop enginebefore disconnecting or connecting battery cables.
3. Do not allow toolsto cause sparks when working on a battery.
4. Do not usewelder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. Do not remove radiator cap when engine is hot. Allowengine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removingcap.
Biological Effects
3. Do not coil or drape cables around the body.
4. Keep weldingpower source andcables as far away from body as
practical.
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for completeinformation.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting,ANSIStandard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safetyand Health Standards, OSHA 29 CFR 1910,from Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
CuttingofContainers ThatHaveHeld HazardousSubstances,American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park,Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed GasAssociation, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and WeldingProcesses, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
May 8, 1996 2-3
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