IM754
RED-D-ARC August, 2002
ZR-10
10796
For use with machines having Code Numbers:
RETURN TO MAIN MENU
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 i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ZR-10
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
5.a. Welding may produce fumes and gases
accidental contact with the workpiece or ground) use
hazardous to health. Avoid breathing these
the following equipment:
fumes and gases.When welding, keep
� Semiautomatic DC Constant Voltage (Wire) Welder.
your head out of the fume. Use enough
� DC Manual (Stick) Welder.
ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
ZR-10
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
ZR-10
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
ZR-10
v v
for selecting a QUALITY product. We want you to take pride in
Thank You operating this product •â?¢â?? 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.
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
Page
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
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 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS: ZR-10 (K1786-2)
INPUT - GASOLINE ENGINE
Capacities
Make/Model Description Speed (RPM) Displacement
Horsepower
cu. in. (cu. cm.)
Full Load:
2 Cylinder Fuel:
ZR-10 3500 RPM
4 Cycle 9 Gal (34 L)
(Honda 20HP 37.5 cu-in.
Air-Cooled
GX620-K1) 20 HP High Idle: (614 cc)
Gasoline Engine Lubricating Oil:
@ 3600 RPM 3700 RPM
Electrical 1.9 Qts. (1.8L)
Ignition 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
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 A-2
INSTALLATION
SPECIFICATIONS
AC STICK / TIG (CC) OUTPUT
80
A 225 OUTPUT RANGE
70 B 50 OUTPUT RANGE
OUTPUT VOLTS AC (RMS)
60
50
40
30
20 B
A
10
0
0 50 100 150 200 250
OUTPUT AMPS
DC STICK / TIG (CC) OUTPUT
80
A 210 OUTPUT RANGE
70
OUTPUT VOLTS DC (RMS)
B 50 OUTPUT RANGE
60
50
40
30
20
A
B
10
0
0 100 150 200 250 300
50 350
OUTPUT AMPS
DC WIRE FEED (CV) OUTPUT
40
35
OUTPUT VOLTS DC (RMS)
30
25
20
15
10 CV OUTPUT RANGE
5
0
0 200
100 250 300 350
50 150
OUTPUT AMPS
ZR-10
A-3 A-3
INSTALLATION
SAFETY PRECAUTIONS When this welder is mounted on a truck or trailer, it’s
frame must be securely connected to the metal frame
WARNING of the vehicle.
Do not attempt to use this equipment until you
Where this engine driven welder is connected to
have thoroughly read the engine manufacturer’s
premises wiring such as that in your home or shop, it’s
manual supplied with your welder. It includes
frame must be connected to the system earth ground.
important safety precautions, detailed engine
See further connection instructions in the section enti-
starting, operating and maintenance instructions,
and parts lists. tled “Standby Power Connections�, as well as the arti-
------------------------------------------------------------------------ cle on grounding in the latest U.S. National Electrical
ELECTRIC SHOCK can kill. Code and the local code.
� Do not touch electrically live parts or
electrode with skin or wet clothing. In general, if the machine is to be grounded, it should
� Insulate yourself from work and be connected with a #8 or larger copper wire to a solid
ground earth ground such as a metal water pipe going into the
� Always wear dry insulating gloves.
ground for at least ten feet and having no insulated
------------------------------------------------------------------------
joints, or to the metal framework of a building which
ENGINE EXHAUST can kill.
has been effectively grounded. The U.S. National
� Use in open, well ventilated areas or
vent exhaust outside. 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.
MOVING PARTS can injure.
� Do not operate with doors open or
guards off.
SPARK ARRESTER
� Stop engine before servicing.
Some federal, state, or local laws may require that
� Keep away from moving parts.
gasoline engines be equipped with exhaust spark
------------------------------------------------------------------------
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
•See additional warning information at
The standard muffler included with this welder does
front of this operator’s manual.
not qualify as a spark arrester. When required by local
----------------------------------------------------------- regulations, the K894-1 spark arrester must be
installed and properly maintained.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case
CAUTION
sides in place as this provides maximum protec-
tion from moving parts and assures proper cool-
An incorrect arrester may lead to damage to the
ing air flow.
engine or adversely affect performance.
Read and understand all Safety Precautions
TRAILERS
before operating this machine. Always follow
The recommended trailer for use with this equipment
these and any other safety procedures included in
for road, in plant and yard towing by a vehicle(1) is
this manual and in the Engine Owner’s Manual.
Lincoln’s K957-1. If the user adapts a non-Lincoln trail-
er, they must assume responsibility that the method of
MACHINE
attachment and usage does not result in a safety haz-
GROUNDING
ard nor damage the welding equipment. Some of the
factors to be concidered are as follows:
Because this portable engine driven welder or genera-
tor creates it’s own power, it is not necessary to con-
� Design capacity of trailer vs. weight of Lincoln
nect it’s frame to an earth ground, unless the machine equipment and likely additional attachments.
is connected to premises wiring (your home, shop,
etc.). � Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
� Proper placement of the equipment on the trailer to
must:
insure stability side to side and front to back when
� be grounded to the frame of the welder using a
being moved and when standing by itself while
grounded type plug, or
being operated or serviced.
� be double insulated.
ZR-10
A-4 A-4
INSTALLATION
BATTERY CONNECTIONS
� Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions; like maintenance.
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
� Conformance with federal, state and local laws.(1) the “STOP� position and attach the disconnected
cable securely to the negative battery terminal before
(1) Consult applicable federal, stste and lpcal laws attempting to operate the machine. If the battery is
regarding specific requirements for use on public discharged and does not have enough power to start
highways. the engine, see the battery charging instructions in the
Battery section.
PRE-OPERATION SERVICE
WELDING OUTPUT CABLES
CAUTION
With the engine off, connect the electrode and work
READ the engine operating and maintenance cables to the studs provided.These connections
instructions supplied with this machine. should be checked periodically and tightened if neces-
sary. Loose connections will result in overheating of
WARNING the output studs.
GASOLINE fuel can cause fire or
When welding at a considerable distance from the
explosion.-
welder, be sure you use ample size welding cables.
� Stop engine while fueling.
Listed below are copper cable sizes recommended for
� Do not smoke when fueling.
the rated current and duty cycle. Lengths stipulated
� Do not overfill tank.
are the distance from the welder to work and back to
� Keep sparks and flame away from tank.
the welder again. Cable sizes are increased for
� Wipe up spilled fuel and allow fumes to clear
greater lengths primarily for the purpose of minimizing
before starting engine. cable voltage drop.
------------------------------------------------------------------------
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
OIL 225 Amps 225 Amps
40% Duty Cycle 100% Duty Cycle
The ZR-10 is shipped with the engine crankcase filled
3 AWG 1 AWG
0-50 Ft.
with SAE 10W-30 oil. Check the oil level before start-
ing the engine. If it is not up to the full mark on the dip
3 AWG 1 AWG
50-100 Ft.
stick, add oil as required. Make certain that the oil filler
cap is tightened securely. Refer to the engine Owner’s
2 AWG 1 AWG
100-150 Ft.
Manual for specific oil recommendations.
150-200 Ft. 1 AWG 1 AWG
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER) 200-250 Ft. 1/0 AWG 1/0 AWG
Honda GX620 - 1.9 Quarts (1.8 Liters)
CAUTION
FUEL Connect the work cable directly to the work piece.
Do not allow welding current to return through
electrical conduit, pipes or building structures
Fill the fuel tank with clean, fresh, lead-free gasoline.
that are not suitable to carry welding current. Do
Observe fuel gauge while filling to prevent overfilling.
not connect the work cable to the welding frame.
Stray welding currents may also damage auxiliary
power cords or equipment.
ZR-10
A-5 A-5
INSTALLATION
LOCATION / VENTILATION
ANGLE OF OPERATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
Internal combustion engines are designed to run in a
avoid heated air coming out of the welder recirculating
level condition which is where the optimum perfor-
back to the cooling air inlet. Also, locate the welder
mance is achieved. The maximum angle of operation
so that engine exhaust fumes are properly vented to
for the engine is 15 degrees from horizontal in any
an outside area.
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain-
ing the oil at the normal (FULL) oil capacity in the
WARNING
crankcase in a level condition.
� Damage to the fuel tank may cause
When operating at an angle, the effective fuel capaci-
fire or explosion. Do not drill holes
ty will be slightly less than the specified 10 gallons.
in the ZR-10 base or weld to the
ZR-10 base.
HIGH ALTITUDE OPERATION
CONNECTION OF WIRE FEEDERS
If the ZR-10 will be consistently operated at altitudes
above 5000 ft, a carburetor jet designed for high alti- (Constant voltage)
tudes should be installed. This will result in better
fuel economy, cleaner exhaust, and longer spark plug
WARNING
life. It will not give increased power which is
decreased at higher altitudes. Engine horsepower is Shut off welder before making any electrical
reduced by 3.5% per 1000 feet for altitudes above connections.
377 feet.
CAUTION CONNECTION OF THE LN-25 TO THE ZR-10
Do not operate a ZR-10 with a high altitude jet
� Shut the welder off.
installed at altitudes below 5000 ft. This will
result in the engine running too lean and result in
� Connect the electrode cable from the LN-25 to the
higher engine operating temperatures which can
“ELECTRODE� terminal of the welder. Connect
shorten engine life.
the work cable to the “TO WORK� terminal of the
welder.
High altitude jet kits are available from the engine
manufacturer.
� Position the welder “Polarity� switch to the desired
polarity, either DC (-) or DC (+).
MUFFLER RELOCATION
� Position the “RANGE� switch to the “WIRE FEED�
position.
WARNING
� Attach the single lead from the LN-25 control box
Shut off welder and allow muffler to cool before
to the work using the spring clip on the end of the
touching muffler.
lead - it carries no welding current.
The ZR-10 is shipped with the exhaust coming out on
� Place the idler switch in the “AUTO� position.
the left side. The exhaust can be changed to the
opposite side by removing the two screws that hold
� Adjust wire feed speed at the LN-25 and adjust
the exhaust port cover in place and installing the
the welding voltage with the output “CONTROL�
cover on the opposite side. (Operating the ZR-10
at the welder.
without the cover in place will result in a higher noise
level and no increase in machine output.)
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 A-6
INSTALLATION
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.
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 ZR-
10 is used with any other high frequency equipment,
the bypass capacitor must be installed - order kit
T12246.
ZR-10
B-1 B-1
OPERATION
WELDER OUTPUT
SAFETY PRECAUTIONS
� Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
Read and understand this entire section before
operating your ZR-10.
� Duty Cycle: 100% for both welding and auxiliary
Do not attempt to use this equipment until you
power.
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
ZR-10
include important safety precautions, detailed
engine starting, operating and maintenance Constant Current 225 Amps AC @ 25 Volts
instructions and parts lists. 210 Amps DC @ 25 Volts
ELECTRIC SHOCK can kill. Constant Voltage 200 Amps DC @ 20 Volts
•Do not touch electrically live parts
such as output terminals or internal
Welder Controls - Function and Operation
wiring.
Explanation of Symbols that Appear on this Equipment
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
Low Idle
OFF
ON High Idle
------------------------------------------------------------------------
ENGINE “ON-OFF� Switch
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or When placed in the “ON� position, this switch
vent exhaust outside
energizes the engine ignition circuit. When placed in
the “OFF� position, the ignition circuit is de-energized
•Do not stack anything near the
to shut down the engine.
engine.
------------------------------------------------------------------------
ENGINE “START� Push-Button Switch
MOVING PARTS can injure.
•Do not operate with doors open or Energizes engine starter motor.
guards off.
“Polarity� Switch
•Stop engine before servicing.
CAUTION
•Keep away from moving parts
Never change the “Polarity� switch setting while
------------------------------------------------------------------------
� Only qualified personnel should operate this welding. This will damage the switch.
equipment.
� Range� Switch
ADDITIONAL SAFETY PRECAUTIONS
Process Maximum Current
Always operate the welder with the hinged door
STICK/TIG - CC 50, 70, 90
closed and the side panels in place as these pro-
6 Range Settings 125, 175, 210 DC/225 AC
vide maximum protection from moving parts and
insure proper cooling air flow.
WIRE FEED - CV
1 Range Setting 200
GENERAL DESCRIPTION
The ZR-10 is a twin-cylinder, gasoline driven, multi-
process arc welder and AC power generator. It is built
CAUTION
in a heavy gauge steel case for durability on the job
site.
Never change the “RANGE� Switch setting while
welding. This will damage the switch.
ZR-10
B-2 B-2
OPERATION
ZR-10 Approximate Fuel Consumption
STARTING / SHUTDOWN INSTRUCTIONS
HONDA 20HP STARTING THE ENGINE
GX620-K1
WARNING
Low Idle - No Load .3 Gallons/Hour
2400 RPM (1.3 Liters/Hour)
� Do not touch electrically live parts
High Idle - No Load .7 Gallons/Hour
of electrode with skin or wet
3700 RPM (2.7 Liters/Hour) clothing.
AC CC Weld Output 1.6 Gallons/Hour
225 Amps @ 25 Volts (6.0 Liters/Hour)
DC CC Weld Output 1.7 Gallons/Hour
210 Amps @ 25 Volts (6.3 Liters/Hour) � Keep flammable material away.
DC CV Weld Output 1.2 Gallons/Hour
200 Amps @ 20 Volts (4.6 Liters/Hour)
� Insulate yourself from work and
Auxiliary Power 1.7 Gallons/Hour
ground. Wear eye, ear, and body
9000 Watts (6.5 Liters/Hour)
protection.
� CONTROL� SWITCH
� Keep your head out of the fumes.
Provides a fine welding current adjustment within the
� Use ventilation or exhaust to
Range Switch settings in the STICK/TIG mode and
remove fumes from breathing zone.
welding voltage control with the Range switch set in
the wire feed mode. Be sure all Pre-Operation Maintenance has been per-
formed. Also, read the Engine Owner’s Manual.
“IDLER� SWITCH Remove all loads connected to the AC power recepta-
cles. To start the engine, set the “Idler Control� switch
The idler switch has two positions, “HIGH� and in the Automatic ( / ) position.
“AUTO�.
Use the choke control as follows:
When in “HIGH� ( ) position, the engine will run Honda Engine - Always pull the choke control out
continuously at high idle. when starting the engine; cold. Place the “Engine�
When in “AUTO� ( / ) idle position, the idler switch in the “ON� position.
operates as follows:
Push the “START� button and crank the engine until it
� WELDING starts. Release the button as soon as the engine
starts. Do not push the “START� button while the
When the electrode touches the work, the welding engine is running because this will cause damage to
arc is initiated and the engine accelerates to full the ring gear and/or starter motor. After the engine
speed. has started, slowly return the choke control to the full
“in� position (choke open).
After welding ceases (and no auxiliary power is
After running at high engine speed for 10-14 seconds,
being drawn), the engine will return to low idle
the engine will go to low idle.
after approximately 10 to 16 seconds.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
� AUXILIARY POWER
STOPPING THE ENGINE
With the engine running at low idle and auxiliary
Remove all welding and auxiliary power loads and
power for lights or tools is drawn (approximately
allow engine to run at low idle speed for a few minutes
100-150 watts or greater or 1500W on 460v 3ø)
to cool the engine.
from the receptacles, the engine will accelerate to
Stop the engine by placing the “Engine� switch in the
high speed. If no power is being drawn from the
“OFF� position.
receptacles (and not welding) for 10-16 seconds,
A fuel shut off valve is not required on the ZR-10
the idler reduces the engine speed to low idle.
because the fuel tank is mounted below the engine.
ZR-10
B-3 B-3
OPERATION
BREAK-IN PERIOD
WELDING PROCESS
STICK (CONSTANT CURRENT) WELDING
It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
Connect welding cables to the "TO WORK� and
level twice a day during the break-in period (approxi-
"ELECTRODE� studs. Start the engine. Set the
mately 50 running hours).
"Polarity� switch to the desired polarity. Set the
“RANGE� switch to a setting that is equal to or slightly
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
greater than the desired welding current. (The
BREAK-IN, THE UNIT SHOULD BE
“RANGE� dial marking indicates the maximum current
SUBJECTED TO MODERATE
for that range). Fine adjustment of the welding current
LOADS, WITHIN THE RATING OF
is made by adjusting the output “CONTROL� or
THE MACHINE. AVOID LONG IDLE
remote control. For best arc stability, use settings 5
RUNNING PERIODS. REMOVE
through 10.
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
The ZR-10 can be used with a broad range of AC and
DC stick electrodes. See “Welding Tips 1� included
The engine manufacturer’s recommendation for the
with the ZR-10 for electrodes within the rating of this
running time until the first oil change is as follows:
unit and recommended welding currents of each.
Honda
GX620-K1
TIG (CONSTANT CURRENT) WELDING
First Month
The K930-1 TIG Module installed on a ZR-10 provides
or 20 HRS
high frequency and shielding gas control for AC and
DC GTAW (TIG) welding processes. The TIG Module
Refer to the Engine Owner’s Manual for more informa- allows full range output control. Afterflow time is
tion. adjustable from 0 to 55 seconds.
When using the ZR-10 for AC TIG welding of alu-
minum, 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 ZR-
10 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 sec-
onds.
ZR-10
B-4 B-4
OPERATION
WIRE FEED WELDING PROCESSES
(Constant Voltage)
The only Innershield® electrode recommended for use
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% CO2). The 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
.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 B-5
OPERATION
AUXILIARY POWER 460 Volt 3 Phase Receptacle with Ground
The 460 volt receptacle can supply 12.5 amps of 3
The ZR-10 can provide up to 9,000 watts of 115/230
phase power, or up to 15 amps of single phase power.
volts AC, single phase 60Hz power, or 460 Volts,3
A NEMA plug L16-20P is required to use this recepta-
phase, 60 Hz for continuous use. The front of the
cle. The ground (GND) connection is connected to the
machine includes four receptacles for connecting the
machine frame, it is NOT the neutral of the three
AC power plugs; one 20 amp 460 volt 3 phase NEMA,
phase connection, and should under no circum-
one 50 amp 115/230 volt NEMA 14-50R receptacle
stances be connected to the neutral of any 3 phase
and two 20 amp 115 volt NEMA 5-20R receptacles.
load. Do not connect 460V 3 phase to premises
Do not use 3 phase power and single phase power
wiring.
simultaneously.
CAUTION 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
Do not connect any plugs that connect to the power
automatic idle to function. Using a NEMA plug L16-
receptacles in parallel.
20P, connect either X and Y or X and Z to the recep-
------------------------------------------------------------------------
tacle, as well as the machine ground.
Start the engine and set the “IDLER� control switch to
the desired operating mode. Set the “CONTROL� to
All auxiliary power is protected by circuit breakers with
10. Voltage is now correct at the receptacles for auxil-
the following values:
iary power.
The 115V has 15 amp circuit breakers for each plug of
the duplex receptacle. The 230V has 50 amp circuit
WARNING
breakers for each hot lead going the 230V receptacle.
The 460V 3 phase circuit breakers / switch has a 3
A qualified person must make connections to plugs.
phase, 15 amp circuit breaker.
Connect each wire of the cord to the proper plug ter-
Y
minal, especially ground.
460 V
115/230 Volt Dual Voltage Receptacle
Z
X
The 115/230 volt receptacle can supply up to 39
amps of 230 volt power to a two wire circuit, up to 39 GND
(FOR ALL SINGLE AND
amps of 115 volts power from each side of a three THREE PHASE LOADS)
Ground Wire
wire circuit (up to 78 amps total). Do not connect the
Periodically check the ground wire at plugs, power
115 volt circuits in parallel.
cords and auxiliary loads to ensure that the grounding
circuit is intact and connected.
GND
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
115 V
to the machine, since the full load current rating of a
230 V
1.5 hp motor is approximately 20 amperes (10
115 V
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
115 V Duplex Receptacles run provided the receptacle rating as previously stated
The 115V auxiliary power receptacles should only be is not exceeded. This may necessitate 230V operation
used with three wire grounded type plugs or approved only.
double insulated tools with two wire plugs.
The 460 volt 3 phase output of the ZR-10 is capable
The current rating of any plug used with the system of running most 460VAC 3 phase motors up to 10HP.
must be at least equal to the current load through the A 10HP motor must be started with no load on the
associated receptacle (Refer to Tables I and II). Do motor and no other load connected to the machine,
not attempt to connect power receptacles in parallel. since the full load current of a 10HP 460VAC 3 phase
motor is approximately 12.5 amps. Refer to the recon-
nect 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 con-
nected to the neutral of any 3 phase load.
ZR-10
B-6 B-6
OPERATION
TABLE II Maximum Current Draw from 115V GFCI
Duplex Receptacles - No Welding
TABLE I Maximum Current Draw from 115V Duplex Receptacles - No Welding
Load From
Load From
115V/230V
115V/230V
Dual Voltage Total From Total From
Dual Voltage Total From Total From
Receptacle Each 115V Both 115V
Receptacle Each 115V Both 115V
Duplex Duplexes
Duplex Duplexes
0 20 40*
0 20* 40
2.2 KW 20 40*
2.2 KW 20* 40
4.5 KW 20 40*
4.5 KW 20* 40
6.7 KW 20 20*
6.7 KW 20* 20
9.0 KW 0 0
9.0 KW 0 0
*Maximum current draw from each 115V
*NEMA 5-20P Plug required for 20Amp Draw
GFCI Duplex is 20 amps
TABLE lll
ELECTRICAL DEVICES USE WITH THE ZR-10
Type Common Electrical Devices Possible Concerns
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 recom-
mended 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-
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.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-
ed to the ZR-10
ZR-10
B-7 B-7
OPERATION
� Take necessary steps to assure load is limited to
AUXILLIARY POWER WHILE WELDING
the capacity of the ZR-10 by installing a 35 amp
230V double pole circuit breaker. Maximum rated
It must be noted that the above auxiliary power ratings
load for the 230V auxiliary is 35 amperes. Loading
are with no welding load. Simultaneous welding and
above 35 amperes will reduce output voltage below
power loads are permitted by following Table III. The
the allowable-10% of rated voltage which may dam-
permissible currents shown assume that current is
age appliances or other motor-driven equipment.
being drawn from either the 115V or 230V supply (not
both at the same time). Also, the “Output Control� is
� Install a 50 amp 115/230V plug (NEMA type 14-
set at �10� for maximum auxiliary power.
50)to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. (The50 amp
TABLE III
115/230V plug is available in the optional plug kit.)
SIMULTANEOUS WELDING AND POWER
� Plug this cable into the 50 amp 115/230V receptacle
Output Selector Permissible Power Permissible Auxiliary
on the ZR-10 case front.
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
STANDBY POWER CONNECTIONS
The ZR-10 is suitable for temporary, standby, or emer-
gency power using the engine manufacturer’s recom-
mended 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 electri-
cian 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 discon-
nect.
� Switch rating must be the same or greater than the
customer’s premises disconnect and service over-
current protection.
ZR-10
B-8 B-8
OPERATION
Figure 1
CONNECTION OF ZR-10 TO PREMISES WIRING
230 VOLT
GROUNDED CONDUCTOR
POWER
230 Volt 115 VOLT
60 Hz.
COMPANY
3-Wire
115 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
35AMP
PROTECTION
230 VOLT
DOUBLE
POLE
50 AMP, 115/230 CIRCUIT
VOLT PLUG 230 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 115/230 VOLT
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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 C-1
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed) GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc-
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
tions. Replaces the factory installed 115V duplex
SMALL WELDERS
receptacle. Each receptacle of each GFCI Duplex is
rated at 20 Amps, but the maximum total current from
For road, off-road and in-plant and yard towing.
each GFCI Duplex is limited to 20 Amps.
(For highway use, consult applicable federal, state
and local laws regarding requirements for brakes,
Two kits are required.
lights, fenders, etc.).
TIG Module (K930-2) - Provides high frequency and
Two-Wheel Undercarriage (K889-2) - For moving by
shielding gas control for AC and DC GTAW (TIG)
hand. Overall Width 29 in (.74m)
welding applications. Its compact case is designed for
easy carrying, complete with a handle. High frequen-
Caster for Undercarriage (K893-1) - Mounts to the
cy bypass is built in.The K938-1 Contactor Kit must
front of the K889-2 to allow easy movement on
be field installed in the TIG Module when used with a
smooth surfaces. Includes 6� diameter hard rubber
ZR-10. Additionally, the K936-3 control cable is
wheel and convenient toe-on, toe-off locking brake.
required if remote control is used. If remote control is
not used the K936-4 control cable is required.
Canvas Cover (K886-1) - To protect the ZR-10 when
not in use. Made from attractive red canvas material
Foot Amptrol (K870)
which is flame retardant, mildew resistant, and water
repellent.
Remote Control Cable (K936-3) - Control cable for
connecting the K930-2 TIG Module to a ZR-10
Power Plug Kit (K802-N) - Provides four 115V plugs
equipped with a K892-1 Remote Kit. 9-Socket to a
rated at 20 amps each and one dual voltage, full KVA
grounded 115 V plug and a 6 pin MS-connector.
plug rated at 115/230V, 50 amps. (For K1418-2 or
(Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground)
K1419-2 CSA machines and machines with GFCI
receptacles, use K802-R).
Remote Control Cable (K936-4) - Control cable for
connecting the K930-2 TIG Module to a ZR-10 not
Power Plug Kit (K802-R) - Provides four 115V plugs
equipped with a K892-1 Remote Kit. 9-Socket to a
rated at 15 amps each and one dual voltage, full KVA
grounded 115 V plug and a 6 pin MS-connector.
plug rated at 115/230V, 50 amps.
(Contains circuits 31, 32, and ground)
Accessory Kit (K710) - Includes 30 ft (9.1m) 3 AWG
electrode cable, 25 ft. (7.6m) 3 AWG work cable,
Docking Kit (K939-1) - For mounting the K930-1 TIG
headshield with No. 12 filter, GC300 work clamp and
Module unit on top of the ZR-10.
Cooltong® 300 electrode holder. Cables are rated at
225 amps, 40% duty cycle.
Remote Control Receptacle Kit (K892-1) - Required
when using a K930-1 TIG Module with and optional
Remote Control Receptacle Kit (K892-1) - Includes
amptrol.
a 6-pin MS-type (Amphenol) receptacle and a local-
remote toggle switch that mounts in the case front.
Wire Feed:
Requires a Remote Control Option.
LN-25 (K449) - Includes internal contactor for across
the arc operation (no control cable). Provides “cold�
Remote Control (K857) - Consists of a control box
electrode until gun trigger is pressed. Includes gas
with 25 ft. (7.5m) of four conductor cable. Permits
solenoid. Remote control Receptacle Kit (K892-1) and
remote adjustment of output voltage. (Requires
Remote voltage Control Kit (K444-1) are required for
Remote Control Receptacle Kit to be mounted in
voltage control at the feeder.
machine.)
LN-7 - Contactor Kit (K240) is required.
Spark Arrester Kit (K894-1) - Includes a heavy
gauge steel, approved spark arrester and clamp for
Magnum Gun is required for gas-shielded welding.
easy mounting to muffler exhaust pipe.
Innershield Gun is required for gasless welding.
ZR-10
D-1 D-1
MAINTENANCE
ROUTINE MAINTENANCE
SAFETY PRECAUTIONS
� At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank.
WARNING Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and add
� Have qualified personnel do the maintenance
oil if indicated.
work. Turn the engine off before working inside
the machine. In some cases, it may be
necessary to remove safety guards to perform
CAUTION
required maintenance. Remove guards only
when necessary and replace them when the Make certain that the oil filler cap is securely tight-
maintenance requiring their removal is ened after checking or adding oil. If the cap is not
complete. Always use the greatest care when tight, oil consumption can increase significantly
working near moving parts. which may be evidenced by white smoke coming
from the exhaust.
� Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by � OIL - Maintenance schedule for changing the oil and
following the instructions, take the machine to oil filter after break-in:
the nearest Lincoln Field Service Shop.
Honda GX620-K1
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
Oil 6 months or 100 hours
� Do not touch electrically live parts or
electrode with skin or wet clothing.
Oil Filter Every year or 200 hours
� Insulate yourself from work and
ground
� Always wear dry insulating gloves. The above schedule is for normal operating condi-
------------------------------------------------------------------------ tions. More frequent oil changes are required with
ENGINE EXHAUST can kill. dusty, high temperature and other severe operating
� Use in open, well ventilated areas or conditions. Refer to the maintenance section of the
vent exhaust outside.
Engine Owner's Manual for more information.
NOTE: Engine life will be reduced if the oil and oil fil-
------------------------------------------------------------------------
MOVING PARTS can injure. ter are not changed according to the manufacturer’s
� Do not operate with doors open or recommendation.
guards off.
� Stop engine before servicing. � Air Cleaner - With normal operating conditions, the
� Keep away from moving parts.
maintenance schedule for cleaning and re-oiling
------------------------------------------------------------------------
the foam pre-filter is every 25 hours and replace-
ment of the air cleaner filter every 100 hours.
•See additional warning information
More frequent servicing is required with dusty
throughout this operator’s manual and operating conditions. Refer to the maintenance
the Engine manual as well. section of the Engine Owner’s Manual for more
----------------------------------------------------------- information.
� Read the Safety Precautions in the front of this � Refer to the maintenance section of the Engine
manual and the engine instruction manual before Owner’s Manual for the maintenance schedule,
working on this machine. spark plug servicing, cooling system servicing, and
fuel filter replacement.
� Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep � Blow out the machine with low pressure air period-
hands, hair, clothing, and tools away from gears, ically. In particularly dirty locations, this may be
fans, and all other moving parts when starting, required once a week.
operating, or repairing the equipment.
� Output Range Selector and Polarity Switches:
� If guards are missing from a machine, obtain Switch contacts should not be greased. To keep
replacements from a Lincoln Distributor. (See contacts clean, rotate the switch through its entire
Operating Manual Parts List.) range frequently. Good practice is to turn the han-
dle from maximum to minimum setting twice each
morning before starting to weld.
ZR-10
D-2 D-2
MAINTENANCE
BATTERY
ENGINE ADJUSTMENTS
WARNING
OVERSPEED IS HAZARDOUS
� GASES FROM BATTERY can explode.- Keep sparks,
flame and cigarettes away from battery.
To prevent EXPLOSION when:
WARNING � INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
The maximum allowable high idle speed for this last.
machine is 3750 RPM, no load. Do NOT tamper � CONNECTING A BATTERY CHARGER - Remove bat-
with governor components or setting or make any tery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
other adjustments to increase the maximum
reinstalling, connect negative cable last. Keep well
speed. Severe personal injury and damage to the ventilated.
machine can result if operated at speeds above
� USING A BOOSTER - connect positive lead to battery
maximum. first then connect negative lead to engine foot.
� BATTERY ACID CAN BURN EYES AND SKIN.- Wear
Adjustments to the engine are to be made only by a gloves and eye protection and be careful when work-
Lincoln Service Center or an authorized Field Service ing near battery. Follow instructions printed on bat-
tery.
Shop.
When replacing, jumping, or otherwise connectingthe bat-
SLIP RINGS tery to the battery cables, the properpolarity must be
observed. Failure to observethe proper polarity could result
A slight amount of darkening and wear of the slip rings in damage to thecharging circuit. The positive (+) battery
and brushes is normal. Brushes should be inspected cablehas a red terminal cover.
when a general overhaul is necessary. If brushes are
to be replaced, clean slip rings with a fine emery If the battery requires charging from an external charger,
paper. disconnect the negative battery cable first and then the posi-
tive battery cable beforeattaching the charger leads. Failure
CAUTION to do so can result in damage to the internal chargercompo-
nents. When reconnecting the cables, connect the positive
Do not attempt to polish slip rings while engine is cable first and the negative cable last.
running.
HARDWARE
HONDA ENGINE MAINTENANCE SCHEDULE Both English and Metric fasteners are used in this welder.
Regular Service Period (3) Each First Every Every Every
Use Month or 3 Months 6 Months or Year or
20 Hrs. or 50 Hrs. 100 Hrs. 300 Hours
ITEM Perform at every indicated month or operating hour
interval, whichever comes first.
Engine Oil Check Level �
Change � �
Engine Oil Filter Replace � or 200
Hours
Air Cleaner Check �
Clean � (1)
Replace � (2)
Spark Plug Clean adjust �
Replace �
Spark Arrestor Clean �
(Optional Part)
Engine Speed Check-Adjust � (3)
Valve Clearance Check-Readjust � (3)
Fuel Filter Check �
Replace � (3)
Fuel Line Check Every 2 Years (3)
(Replace if necessary)
(1) Service more frequently when used in dusty areas.
(2) Replace the paper element only.
(3) These items should be services by an authorized engine dealer.
ZR-10
E-1 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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Authorized Field Service Facility.
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.
CAUTION
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.
ZR-10
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
No welder or output power. 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).
If all recommended possible areas of
7. Faulty P.C. Board. misadjustment have been checked
and the problem persists, Contact
Engine will not idle down to low 1. Idler switch on High Idle. your local Authorized Field
speed. Service Facility.
2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).
3. External load on welder or
auxiliary power.
4. Faulty wiring in solenoid circuit.
5. Faulty idler solenoid.
6. Faulty P.C. Board.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work.
2. No voltage signal from the
current sensor.
3. No open circuit voltage on
output studs.
4. Faulty P.C. Board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
ZR-10
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Engine will not go to high idle when 1. No voltage signal from the
using auxiliary power. current sensor.
2. Auxiliary power load less than
100 to 150 watts.
3. Faulty P.C. Board.
Engine will not crank or is hard to 1. Battery will not hold a charge.
crank. Faulty Battery. If all recommended possible areas of
misadjustment have been checked
2. No or insufficient charging and the problem persists, Contact
current. your local Authorized Field
Service Facility.
3. Loose battery cable
connection(s).
Engine shuts down. 1. Out of fuel.
2. Low oil level.
Engine does not develop full power. 1. Fuel filter clogged.
2. Air filter clogged.
Engine is hard to start. 1. Spark plugs do not have
specified gap.
2. Spark plugs are fouled.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
ZR-10
F-1
ZR-10 HONDA
3 TURNS
1 TURN CCW
3
OUTPUT
"S3" SHOWN 261 R1
GROUND SCREW 254
IN "RUN" CONTROL
L1 260
AT BLOWER BAFFLE CHOKE
POSITION
+-
208A 209A + 10 76A 75A
77A
S3 S2
AM1
S5
START
221 D1
BUTTON
208C 8
-
208B
1 2 PCB1
5H 211 5D 254
CB7 3 4
25A S1
210 WORK
5F E 12 7
213 R1
213
S4 8
S2
R6
R2 J1
10
GND-E C1
R3 R5
ELECTRODE
"S4" SHOWN 1
6
R4
IDLER S1
IN "AUTO"
77
75
5E
GND-G
76
SOLENOID
215
224
224B
219
2
W2
201A
200B
POSITION REACTOR
224A +
HOUR METER C1
GND-C
215 GND-D STATOR
224 W1
5H 5D
3 9
6 7
5E
GND-E P5
12 34
5 3
12 VOLT
224A J5
BATTERY
208 211 3
75A 77A
211B
209A
224C + 76A
221
D9
GND-D
209
4 AMP
7
IN LINE 211B
9 200B
210
DIODE
J2
-
NO 3E
224E 211
CONNECTION
225A 120V +
6 CB1 GND-G
221
208 224C STARTER
ENGINE 35A
SOLENOID FOOT
210A D2 C1 FIELD
N.A.
OIL CAPACITOR
CR1 200
B/R
PRESSURE 200A
ZR-10
-
GND-H 12 5
B/Y 219
5L
SWITCH 5K
IGNITION
MODULE FUEL ENGINE +
CROSS 201
W/U SHUTOFF SUPPORT J4 11
SOLENOID
W 115V/230V
212 201A
GY CB4
GY
DIAGRAMS
GND-C 20A ROTOR
11 J3
CB2 120V
20 AMP
5K CB3
12 3 4 35A
3E
56 STARTER
CHARGE COIL 3B 5
20A SLIP RING NEAREST LAMINATION
3B 5L
SILVER COLORED 3A 3A
RECTIFIER/REGULATOR TERMINALS
(WHITE WIRES)
MODULE B
HONDA ENGINE COMPONENTS
CONNECTOR PIN NUMBERS:
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. 4 3 12 7
LEAD COLOR CODE:
2 1 2 1
3
6
B = BLACK OR GRAY
J5 J1
R = RED OR PINK
W = WHITE
U = BLUE
GY = GRAY
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR
ELECTRICAL SYMBOLS PER E1537 08-2002
G4375
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-1
F-2
F-2
ZR-10 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
6 PIN
OPTIONAL K444-1
AMPHENOL
REMOTE CONTROL
LN-25
WIRE FEEDER
ELECTRODE
TO WORK
WORK CLIP LEAD
TO WORK
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR
SWITCH TO THE WIRE FEED (CV) POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH
IN "OUTPUT CONTROL REMOTE" POSITION.
CRM 21883
M17486
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 TO LN-7
21 GND. 32 2 4 31
N.D.
CONNECT THE CONTROL CABLE
K240 CONTACTOR KIT
N.B.
N.C.
GROUND LEAD TO THE FRAME
115V (50/60HZ.)
TERMINAL MARKED NEAR
(NOTE : 600 AMP CAPACITY)
POWER
THE TERMINAL STRIP OR TO
31
32
2
4
SOURCE
AN UNPAINTED FRAME SCREW.
77 76 75
AUTO. POWER
SOURCE
N.F. & N.G. EQUIP.
ELECTRODE CABLE TO LN-7
WORK ELECTRODE
N.J.
S17742
TO WORK
10-2-92
WELDER STANDARD OUTPUT TERMINALS
lead may be ordered for this purpose. Connect it directly to
WARNING: Turn the power off when making connections.
the work piece independent of the welding work cable. For
convenience, this extended #21 lead should be taped to the
N.A. Use power source polarity switch to set for desired electrode
welding work lead.
polarity. Position the output selector switch on the power
source to the CV position.
N.G. Tape up bolted connection where lead #21 is extended.
N.B. 3 conductor #16 power cord physically suitable for the
N.H. Idler switch on power source must be in high idle position.
installation and plug rated at 115 volts 15 amperes AC.
N.J. If an optional remote output control is used, connect it to this
N.C. Plug into 115 volt AC receptacle on welder control panel or
terminal strip or 6 pin Amphenol receptacle. NOTE: Terminal
other 115 volt AC supply rated at a minimum of 500 volt-
strip or 6 pin Amphenol receptacle not available on all power
amperes.
sources.
N.D. Leads #21 and GND. do not appear on LN-7’s with codes
CAUTION: Any speed up of the engine RPM by changing the gov-
below 7026.
ernor setting or over-riding the throttle linkage will cause an
increase in the AC auxiliary voltage. If this voltage goes
N.E. Welding cables must be of proper capacity for the current
above 140 volts, the LN-7 control circuit will be damaged.
and duty cycle of immediate and future applications.
The engine governor setting is pre-set at the factory - do not
adjust above RPM specifications listed in engine welder
N.F. If LN-7 is equipped with a meter kit, extend lead #21 using
operating manual.
#14 or larger insulated wire physically suitable for the instal-
lation. An S16586-â€lengthâ€? remote voltage sensing work ZR-10
CENTER OF GRAVITY WITH OIL IN
C OF SHAFT ENGINE AND FUEL TANK EMPTY.
L DIMENSION PRINT - ZR-10 (Honda)
F-3
9.31 9.29
21.25
21.21
30.28
26.59
2.00
FOR OIL FILTER
REMOVAL
13.25
17.00
ZR-10
9.09 9.09
8.80 30.00
DIAGRAMS
42.00
UNDERCARRIAGE MOUNTING HOLES
9.09
18.17
3-15-00A
F-3
M19725
NOTES
ZR-10
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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