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Champion 10,000

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1. SECTION 11 ELECTRICAL DIAGRAM NOILdO QNnONO NIML A NVNO 3SV8 lo ja LL FER 10 ff e YxY Y gt GION310S E 331HOX 430 1nHS e 1304 24 154 Lu ug Lu LH L 1 SOd wa 2 161 1938 LHS ao z a 5 3 GION310S 2 340 1nHS MOIVIS 4L SS Tana YOLWNYAL home z oa ai 154 S lt o Q N gt ia aL NY ve FANSS Ad ia N3INVIS g 3 V V vga PET 21 T p VE 5 9 2 55 25 vou Y YOU vou vou f oz 9 7777 m NYI 34nss3Md TA Wo 4 K e e a Y 02 d gt v9 5 9 z 27 7 lt lt OF oZ lt g lt wa 9 2 o S A E 2 X M lt 15 VV 4 n Y 891d 2S aes 198 V T 49 M OO ole eZ 15 09 09 G 182 14 07134 ff 12 o Q p Q
2. ELECTRODE POSITION PENETRATION DEEP ALL DEEP MIN PREP ROUGH HIGH SPATTER ALL LOW GENERAL ALL MED SMOOTH EASY FAST ALL LOW LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER y y A V y ALL LOW CAST IRON 308L ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it S 0049 13 4 Striking an Arc Tapping Technique SSS 3 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it 5 0050 945 45 13 5 Positioning Electrode Holder 907 90 Y 2 5 End View of Work Angle lt 5 Side View of Ele
3. 1 pud f duet sev aues Figure 13 2 Panel Front wComponents 1 3248 soie tement 208 149 Bracket Mtg Rectifier 1 POET 193 067 Kit Accy 20 Ft 2 W Elec Hldr 15 Ft Grd consisting of 1 ET 600 319 Cable Weld Cop Strd No 2 Epdm Jkt order by ft 35 du Le ue 040 234 Af 2 Holder Electrode 200a 1 TERT 130 750 Clamp Work 300 Amp 1 ERR 600 720 Term Ring Tng 500stud Solistrand 2 2 sick Graig Dit deg eoe 034 377 Term Ring Tng 312stud Solistrand 2ga 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 802 344 E 4 Figure 13 2 Panel Front w Components OM 945 Page 54 Item Dia Part No Mkgs No Description Quantity Figure 13 2 Panel Front w Components Figure 13 1 Item 47 ded ated 198 122 Stand off Support Pc Card 250w Post amp lock 500 6 Ex aii epi dne Nameplate
4. 20 7 2 Optional Generator Power Receptacles 21 7 3 Wiring Optional 240 Volt Plug 21 SECTION 8 MAINTENANCE ONAN POWERED UNITS 22 8 1 Maintenance Label Onan Powered Units 22 8 2 Routine Maintenance Onan Powered Units 23 8 3 Servicing Air Cleaner Onan Powered Units 24 8 4 Overload Protection Onan Powered Units 25 8 5 Servicing Optional Spark Arrestor Onan Powered 25 8 6 Changing Engine Oil Filter and Fuel Filter Onan Powered Units 26 8 7 Adjusting Engine Speed Onan Powered Units 27 SECTION 9 MAINTENANCE KOHLER POWERED UNITS 28 9 1 Maintenance Label Kohler Powered Units 28 9 2 Routine Maintenance Kohler Powered 29 9 8 Servicing Air Cleaner Kohler Powered 30 9 4 Overload Protection Kohler Powered 5 31 9 5 Servicing Optional Spark Arrestor Kohler Powered Units 31 9
5. OM 945 Page 18 SECTION 6 OPERATING THE WELDING GENERATOR NOTE gt If the unit is extremely overloaded weld and generator power will stop Turn unit off and restart to reset the generator protection circuit and restore weld and generator power output If the rated output of the unit is exceeded engine speed may vary rapialy until the weld or generator power load is reduced 6 1 Front Panel Controls A AMPERAGE RANGE a 3 32 1 8 5 32 3 16 6013 718 ELECTRODE Se 7014 v8 5 3 32 18 5 32 3 32 7024 VB 5 32 v8 1 Engine Control Switch Use switch to start engine select speed and stop engine In Run Idle position engine runs at idle speed at no load and weld power speed under load In Run position engine runs at weld power speed 2 Engine Choke Control Use control to change engine air fuel mix AMPERAGE ADJUST TOTAL ALL LOADS 10 000 WATTS 120 V 240 V NEUTRALBONDEDTO PM FRAME NEUTRE RACCORDE AU B TI 7 27 ON 120 240 AC POWER OFF To Start pull out choke and turn Engine Con trol swit
6. 10 4 4 Fuel Consumption All Models 11 4 5 Duty Cycle nox t Rz RE EX ERE ER ee ee ees RES E 11 4 6 Volt Ampere Curves 1 12 SECTION 5 INSTALLATION 22 ki ug c ck uk lx Rug ag 9 lg aki d kx deg 13 5 1 Installing Welding Generator 13 5 2 Engine Prestart Checks Onan Powered Units 14 5 8 Engine Prestart Checks Kohler Powered Units 14 5 4 Activating The Dry Charge Battery 15 5 5 Gonnecting II erdt pd 16 5 6 Installing Exhaust 16 5 7 Connecting to Weld Output Terminals 17 5 8 Selecting Weld Cable Sizes 17 5 9 Amperage Selection Table For Stick SMAW Electrodes 18 SECTION 6 OPERATING THE WELDING GENERATOR 19 6 1 Front Panel Controls e AE YR Dp As 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT 20 7 1 Standard Receptacles
7. 945 194 047N March 2003 Processes WELDING PRODUCTS Stick SMAW Welding Description ce Engine Driven Welding Generator Champion 10 000 OWNER S MANUAL Visit our website at www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide the exact part Hobart is registered to the may need to fix the problem Warranty and 4 ean Quality service information for your particular model are also provided 5 9001 2000 QUALITY SYSTEM Hobart offers a Technical Manual which provides more detailed service and parts information for your Hobart Welders manufactures a full line unit Tooblan a Technical of welders and welding related equipment Manual contact your local 5 distributor Your distributo
8. WELDERS HOBART 331 WARRANTY Effective October 1 1999 5 31 WARRANTY applies to all Handler 135 and 175 models Airforce 250 250A and 375 models and Champion 10 000 models This warranty also applies to the Beta Mig 1800 Champ 1435 2060 8500 models Ironman 250 Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial No KK200262 and newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart M
9. 1 dote 065 313 Gasket muffler 2 mine M Leo D d 7198 754 oe cto petiere must 198 755 Element air cleaner w precleaner 1 oa n 198 756 Pump f el uere eee MEE CREE S5 198 757 Switch low oil pressure 1 whl Ox coda 121 652 Filter fuel w clamps 1 edad died eiue aua 198 7 Plug spark usse ur nei pb re bet ve Phi ee res 12 Sue Das Solenoid w mtg bracket see engine parts list 1 NUTRIT 198 778 Regulator voltage 1 EL Mm 165271 Valve Drain 3 8 18 Nptf 1 M F6 021 718 Fuse Mintr GI 30 Amp 32 Volt 1 Saar gira RE PSE 190 827 Boot solenold kr EM eG Rees d Worcester p brem 199 062 Kit tune up and filter Onan includes air filter element and wrapper oil filter fuel filter and spark plugs 1 194 249 Engine Kohler Gas Elec Ch20s ps 64635 consisting of 1 Po CUNEO EAR TUE 193 856 Muffler Exhaust Engi
10. 4 802 343 Figure 13 1 Main Assembly Engine Shown OM 945 Page 52 Mkgs No Description Quantity Figure 13 1 Main Assembly pL 193 774 3 sis ame em pce EROR Es ate ed i pan d c reta 1 Uno udo re ree Deleted Cs ne M ut ori 192 042 Label Use Gasoline Only 1 DE 4E 181 881 Grommet Plastic Neck Filler Fuel 1 I DITS 147 601 Cap Tank Screw on W Vent 1 ix Oi ie rae 200 795 Label Warning General Precautionary Csa 1 UE 203 994 Pipe Exhaust Elbow 1 Ju dun A pL D Dd 196 252 Baffle engine air Kohler only 1 d An M 193778 Panel Rear 1 EL pm 194 263 Grommet Plastic Snap in Battery Access 1 zs e o Re SUE 168 385 Label Warning Battery Explosion Can Blind 1 os 42 xr heise 209 057 Clamp Muffler 1 625 Dia U Pld 1 ns dd uae ntes TN addu 195845 Engine Onan Gas Elec Start consisting of 1 has hun 193 845 Muffler Exhaust Engine Onan
11. 200 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 2 0 2ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2 2 0 2ea 3 0 2ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 2 0 2 3 0 2ea 3 0 2ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2 ea 2 0 2 ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 2 ea 2 0 2 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2 70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheating occurs normally you can smell it use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use 5 0007 For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 945 Page 17 5 9 Amperage Selection Table For Stick SMAW Electrodes lect correct amperage for the Use table on front panel to se electrode being used lt o a c Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual
12. 120 V x 20 A 240 V x 21 A 10 KVA KW approx 202 069 OM 945 Page 20 7 2 Optional Generator Power Receptacles gt NEUTRAL BONDED TO c TOTAL ALLLOADS 120v 240V ERREG Orv 6 A A LUI UU OFF V f V f Pp GENERATOR POWER If unit does not have GFCI re ceptacles use GFCI protected extension cord Combined output of all receptacles limited to 10 KVA kW rating of the generator GFCI Receptacle Option 1 120 V 20 A AC Recep tacles GFCI2 GFCI2 and GFCI3 supply 60 Hz single phase power at weld power speed Maximum output from GFCI2 is 2 4 KVA KW Cir cuit breaker protection is the same as standard receptacles If a ground fault is detected the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment Check for damaged tools cords plugs etc connected to the receptacle Press button to reset receptacle and resume operation F At least once a month engine at weld power speed and press Test button to verify is working properly 7 3 Wiring Optional 240 Volt Plug gt CP Current Available in Amperes 240 V Each 120 V Duplex R
13. order by model 4 serial no 1 TESCO EEE E 202068 Panel Front 1 4 POT 552 203 655 Circuit Card Assy Field Current Controller 1 db mas ui 204 709 Xfmr Current Sensing 1 M NE S2 ev 176 606 Switch Ignition 4 Position W Out Handle 1 TODO 204 707 Harness Wrg Ignition consisting of 1 SAL Apt PLG8 177859 Conn 5 Terminal 1 E PLG4 116045 Conn Rect Univ 084 6p S 3row Rept Housing Pins amp Skts urn ne Service votis sea o Sr eer ua avid Daten tl PLG5 066 104 Conn Rect Univ 084 9p S 3row Rept Housing Pins amp Skts Sevic remet vues 21 SOC PLG9 092670 Conn Rect Univ 084 3p S 1row Plug Cable Housing Pins amp uid e beste qe D ER ene opas ade td A ERE Skts Service Kit 7 RC2 RC3 141 432 Rept Str Dx Grd 2p3w 20a 125v 5 20r 2 7 GFCI2 GFCI3 151 981 Rept Str Dx 2p3w 15 20a 125v 5 20r GFI 2 Buon CB1 200 929 Circuit Breaker Man Reset 2p 50a 240vac Screw 90 1 9 CB2 093 996 Circuit Breaker Man
14. rateur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme sui vant e Mettre des lunettes de s curit et des gants placer un torchon sur le bou chon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon LA CHALEUR DU MOTEUR peut pro voquer un incendie Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures Ne pas touch
15. s possible de la soudure internes de l appareil sont galement sous tension ce s ilsaler la Bi d d is la sviter tact moment l En soudage semi automatique ou automatique le fil le d vidoir le Soler pince masse quand pas mis a pi ce pour eviter le contac avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apres avoir coup l alimentation logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maint
16. 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 12 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 945 Page 39 12 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9in 4500 1500 10 in 6300 1800 Ba
17. 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 945 Page 43 SECTION 13 STICK WELDING SMAW GUIDELINES ES 13 1 Stick Welding Procedure Tools Needed Lm Weld current starts when electrode touches work piece Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass stick 12 96 ST 151 593 OM 945 Page 44 13 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 100 150 200 250 300 350
18. 72 V fr et o gt 182 49 VE 43028 v fF THA 6 gt gt Tp 29 a gt gt 2 wj tle 928 2 2 cow LH ES zn ta ex 2 5 22 44 aA 5000 f 555 N CM 2 595 a w 09 282 09 12 _ gt AN ANN 1314 ONIATOARY we z gt 62949 dad 5 gt os L8d 2 gt fe NOLIVLIOX3 AA AI V V V No 22 TOU 1 2 uN 09 09 OF E 07 z omm NOlLdO HS OO f 1T 2 67 4 LL pe 319V143034 ME 9 79 Oc tO 15 ff ly 1949 lt 2 9 AAA oc 9 M A DER 22 ss OL 435012 X 221 zz X Iavas A os 25 x x x Nnu 2 IS 09 09 11 o gp ogeu zs a 9 8 Y yun siy 10 asn GHVZVH 2 5 suosiad peurjenb Ajuo e 91419273 SJ6A02 jou e Buroiuajes S dois Jo 19 od 1ndui 129 0281 e sued yono jou SNINHVM Y For Welding Generator Onan And Kohler Powered Units ircuit Diagram Figure 10 1 Ci OM 945 Page 36 SECTION 12 GENERATOR POWER GUIDELINES NOTE Cr The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Sele
19. D 3 in 76 mm F E E 31 1 2 in 800 mm F 37 1 2 in 953 mm G 13 32 in 10 mm Dia Weight Onan Powered Unit 445 Ib 202 kg Kohler Powered Unit 444 Ib 201 kg Engine End 802 855 4 3 Generator Power Curve The generator power curve shows the generator power in amperes available at the receptacles 300 250 200 d gt 150 X 100 50 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 AC AMPERES OM 945 Page 10 4 4 Fuel Consumption Models IMP GAL HR 4 D 9 U S GAL HR LITERS HR AC POWER DC WELD 4 75 1 04 1 25 5 78 0 84 1 00 2 84 0 63 0 75 1 89 0 42 0 50 IDLE 2200 RPM 0 95 0 21 0 25 0 25 50 75 100 125 150 175 200 225 250 275 WELD AMPERES 100 DUTY CYCLE LL 1 1 4 1 1 1 1 1 1 1 4 0 10 20 3 0 40 5 0 6 0 7 0 8 0 9 0 10 0 11 0 POWER KVA AT 10076 DUTY CYCLE 197 254 4 5 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit void warranty 230 210 WELDING AMPERES 170 10 20 50 40 50 60 70 80 90 100 DUTY CYCLE 3 Continuous Welding 100 Duty Cycle at 170 Amperes CC DC OW Te 2 6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting 60 Duty Cycle at 210 Amperes CC DC 30 Duty Cycle at 230 Ampere
20. DOZ 205 978 Stabilizer Assy 1 is dO add REED 204 704 Rectifier W Components consisting of 1 94 SR1 197 514 Rectifier Si 1ph 240 Amp 400 60 Duty Cycle 1 95 LEM 191 941 Transducer Current 1 mh PLG6 PLG7 204705 Cable Lem 1 96 SR2 035 704 Rectifier Integ Bridge 40 Amp 800v 1 iu d dae fecus 193 781 Bracket Mtg Generator 1 24196 les eed 193 627 Tank Fuel 10 Gal consisting 1 TECE a 178 632 Stand Pipe 250 X 7 375 Lg 1 40 124253 Bushing Tank 1 UY Listes 145 976 Hose Sae 250 Id X 500 Od X 4 500 1 mE hare 066 113 Filter Fuel Inline 250 included w engine 1 084 173 Clamp Hose 460 545 Dia Slfttng 3 ius 193810 Upright Base s sedet Rte ER mE RR ER 1 Ja Lis aw aw ey las 160 975 Seal Weather Lift Eye 1 2246 180 628 Panel Front Lower
21. N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 I2 aA Stariinath t ires 12 2 7 290 12 arting the motor requires 12 2 amperes 12 9 How Much Power Can Generator Supply 1 LimitLoad To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 945 Page 41 12 10 Typical Connections To Supply Standby Power T Properly install and ground this equipment according to its Owner s Manual and national state and local codes 1 2 3 4 Utility Di Welding isconnect Electrical Transfer Switch lt Switch Generator Service If Required Output 5 Essential Loads Have only qualified persons perform these connections according to all applicable codes and safety practic es Properly install and ground this equipment according to its Owner s Manual and national stat
22. away N 29 OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit 27 STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling AS boards or parts Ro Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER cause injury Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts Perform engine and air compressor if applica ble maintenance and service according to this manual and the engine air compressor if appli cable manuals 1 6 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Box 9101 1 Battery March Park
23. battery in warm area Use correct grade oil for cold weather 802 339 B OM 945 Page 14 5 4 Activating The Dry Charge Battery If Applicable ecu 5 A For 30 Minutes OR ES 30 A For 12 Minutes Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery EF When electrolyte is low add only distilled water to cells to maintain proper level Tools Needed SS px o rubbergloves E glasses drybatti 1 98 5 0886 OM 945 Page 15 5 5 Connecting the Battery Tools Needed Connect negative cable last Ref 202 069 A Ref 802 341 Ref S 0756 D 5 6 Installing Exhaust Pipe RP us RUN IDLE RUN START Tools Needed 3 e 1 2in Engine backfire can cause se vere
24. burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet Point exhaust pipe in desired di rection but always away from front panel and direction of travel 801 681 Ref 202 069 A OM 945 Page 16 5 7 Connecting to Weld Output Terminals 7 N 1 Negative Weld Output Terminal 2 Positive Weld Output O Terminal For Direct Current Electrode Posi tive DCEP connect work cable to Negative terminal and electrode holder cable to Positive o terminal For Direct Current Electrode Nega tive DCEN reverse cable connections Tools Needed 6 gin 1 2 NEGATIVE POSITIVE Ref 202 069 A 5 8 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100ft 30m orLess 45m 60m 70m 90m 105m 120 m Weld Output Terminals Turn off power before 10 60 60 100 connectingto weld out Welding buy Duty 10 10096 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 30 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95
25. des gaz de soudage poste souder manuel lectrode enrob e DC 3 un poste souder ma peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des nuel AC avec tension vide r duite Dans la plupart des cas un poste blessures ou des accidents mortels S assurer que l air de respiration ne courant continu de type CV est recommand Et ne pas travailler seul pr sente aucun danger Couper l alimentation ou arr ter le moteur avant de proc der l installation bug EE Pre ue la r paration ou l entretien de l appareil D verrouiller l alimentation 9 nettoyage o p y selon la norme OSHA 29 CFR 1910 147 voir normes de s curit l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Installer et mettre la terre correctement cet appareil conform ment son e pas souder des m taux munis d un rev tement tels que l acier galvani manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un r
26. filter See Replace fuel A Section 8 6 and filter See maintenance label Section 8 6 52661 Check Spark plugs gt D 2 Replace unreadable labels 945 23 e Every 500 h Repair or replace cracked cables 0 CT Service welding generator 7 brushes and slip rings Service NN 250 more often in dirty conditions Check valve clearance Every 1000 h Blow out or c vacuum inside During heavy OR service clean monthly 8 3 Servicing Air Cleaner Onan Powered Units Stopengine S D Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 9 22 1 VE RUN stant 2 Element Replace element if dirty oily or damaged aircleaner3 1 97 156 852 Ref 183 175 5 0759 OM 945 Page 24 8 4 Overload Protection Onan Powered Units Stop engine Disconnect negative battery cable 9 Tools Needed x If the unit is extremely over loaded weld and generator power will stop Turn unit off and restart to reset the genera tor protection circuit and re store weld and gener
27. for Welding and Cutting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection As sociation P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Cana dian Standards Association Standards Sales 178 boulevard Rexdale LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine Effectuer la maintenance du moteur et du compres seur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences Le rayonnement haute fr quence peut provoquer des interf rences avec les quipements de radio navigation et de communication les Services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisate
28. hors tension quand on ne l utilise pas rit num r es la section 1 5 Veuillez lire et respecter toutes Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou ces normes de s curit mal piss s mem i i Ne pas enrouler les c bles autour du corps instalation utilisation entretien etles reparations ne Si ae soud e doit tre mise la le faire directement avec un doivent tre confi s qu des personnes qualifi es c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Au cours de l utilisation tenir toute personne l cart et plus Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou particulierement les enfants une lectrode provenant d une autre machine e N utiliser qu un mat riel bon tat R parer ou remplacer sur le champ 2 les pi ces endommag es Entretenir l appareil conform ment ce Ee 4 UN CHOC LECTRIQUE peut tuer mantel Porter un harnais de s curit quand on travaille en hauteur Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves Maintenir Soigement en place tous les panpgauy et capot L lectrode et le circuit de soudage sont sous tension d s Fixer le c ble de retour de fagon obtenir un bon contact m tal m tal avec que l appareil est sur ON Le circuit d entr e et les circuits la pi ce souder ou la table de travail le plus pr
29. in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel 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 toxic fumes if welded OM 945 Page 1 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others fro
30. or 2 qt 1 9L with filter change Use only resistor spark plugs and wires Fuel Filter MILLER 066 113 Spark Arrestor Inspection and Service Fuel Grade Unleaded 87 Octane min Kohler 2505003 20 operating hours See Owner s Manual Gasoline OM 945 Page 28 9 2 Routine Maintenance Kohler Powered Units Note 7 extended period Follow the storage procedure in the engine owner s manual if the unit will not be used for an ey w eo EN Stop engine before maintaining See also Engine Manual and maintenance label Recycle Service engine more often if used in severe fluids tions To be done by Factory Authorized Service Agent e Every 8h Check fluid levels See Section 5 2 Wipe up spills Br Every 20h Check and clean optional spark arrestor screen See Section 9 5 Every 25 h Service air See Section 9 3 cleaner wrapper foam element Qo Every 50h terminals Clean and tighten weld 2 Every 100 h Change oil See Section 9 6 and maintenance label Check air cleaner element See Section 9 3 Clean cooling system See Engine Manual Clean and tighten battery connections Check spark plugs Gu Change oil filter See Section Replace fuel filter See gt BS 9 6 and maintenance lab
31. rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PIECES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chal
32. settings Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adjust if necessary see Section 8 7 or 9 7 Have Factory Authorized Service Agent check brushes and slip rings B Generator Power Trouble Remedy No output at generator power ac receptacles Reset circuit breakers see Section 7 1 or 7 2 Press optional GFCI receptacle Reset button see Section 7 2 Check fuse F1 and replace if open see Section 8 4 or 9 4 Unit overloaded Stop unit and reduce load Restart unit to reset generator protection circuit and resume operation Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings integrated rectifier SR2 and field control board PC1 High power output at generator power ac receptacles Check engine speed and adjust if necessary see Section 8 7 or 9 7 Low power output at generator power ac receptacles Check fuse F1 and replace if open see Section 8 4 or 9 4 Check engine speed and adjust if necessary see Section 8 7 or 9 7 OM 945 Page 34 Trouble Remedy Erratic power output at generator pow er ac receptacles Check fuel level Check engine speed and ad
33. 6 Changing Engine Oil Filter and Fuel Filter Kohler Powered Units 32 9 7 Adjusting Engine Speed Kohler Powered Units 33 SECTION 10 TROUBLESHOOTING 34 SECTION 11 ELECTRICAL 36 SECTION 12 GENERATOR POWER GUIDELINES 37 SECTION 13 STICK WELDING SMAW GUIDELINES 44 SEGTION 14 PARTS LIST ioeie date male dede iere fe tale tecti Eu E ele uia 52 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom nd 10 02 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 6 Read and follow all Safety Standard
34. 7in Hose 3 Oil Filter Change engine oil and filter accord ing to engine owner s manual Close valve and valve cap before adding running engine Fill crankcase with new oil to full mark on dipstick see Section 9 1 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up fuel 802 339 B S 0842 OM 945 Page 32 9 7 Adjusting Engine Speed Kohler Powered Units RP TE 2200 50 rpm e 3700 50 rpm Tools Needed B Q Ee 1 4 3 8 in Top View After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm Remove wrapper to access speed adjustments Idle Speed Adjustment Move Engine Control switch to Run ldle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust Solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn
35. 87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION Avertissement Prot gez vous et les autres des blessures lisez et suivez ce
36. Adjustment Screw Loosen jam nut and lock nut Turn adjustment screw until engine runs at weld power speed Tighten jam nut and then tighten lock nut Stop engine Reinstall wrapper Tools Needed e B 0mmL 3 T 8mm 802 353 802 457 945 27 SECTION 9 MAINTENANCE KOHLER POWERED UNITS 9 1 Maintenance Label Kohler Powered Units KOHLER CH18 CH20 CH23 GAS ENGINES Air Filter Service 100 hours or less see See Engine Manual for complete engine care Owner s Manual Give Engine Specification and Serial Number Air Filter Element MILLER 067 272 when ordering parts Kohler 4708303 Air Filter Wrapper MILLER 067 273 Kohler 2408302 Check daily 12 Volt Battery BCI Group 58 To Drain Oil Cranking Performance at 0 F 18 C 430 Amps Push And min Turn CCW 1 2 ID Hose Pull Engine RPM No Load Weld Power 3700 in d 3 is Recommended Oil Service Classification SF SG CC CD If using optional LP gas fuel use synthetic oil after first oil change Oil Change 100 hours Spark Plug Gap 0 030 in 762 mm Oil Filter Change 200 hours D Spark Plug Champion RC 12YC Oil Filter MILLER 066 698 Kohler 1205001 Oil Capacity 1 75 qt 1 7L
37. Engine See eae A Amperes Volts Engine Oil Fuel Battery Engine Ox Engine Engine Choke EE Circuit Breaker Temperature Positive 7 xe c Output h Hours S Seconds e Time seem E SECTION 4 SPECIFICATIONS 4 1 Note gt Weld Power and Engine Specifications This unit uses either an Onan or a Kohler engine Differences between models are noted throughout this manual Rated Maximum Welding Weld Output uen Single Phase Fuel Mode Range SE i Generator Power Rating Capacity Engine 230 A 25 V Onan 30 Duty Air Cooled Two Cylinder Cycle exo E Four Cycle 20 5 HP 210 A 25 V 120 240 V AC en Gasoline Engine CC DC 50 230A 60 Duty 73 60 Hz ga or Cycle 38 L Tank eee A ohler CH 170 A 25 V 5 di S Air Cooled Two Cylinder 100 Duty Four Cycle 20 HP Cycle Gasoline Engine OM 945 Page 9 4 2 Dimensions Weights and Operating Angles Dimensions EZ Height 33 1 2 in 851 mm A Width 18 1 2 in 470 mm c r B Do not exceed tilt angles or engine could Depth 38 in 965 mm be damaged or unit could tip 18 in 457 mm A t not move or operate unit where it could B 16 9 16 in 421 mm 23 32 in 18 mm
38. LE Close valve and valve before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 1 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten 4 connections as neces sary and wipe up fuel e Tools Needed cw 802 353 B S 0842 OM 945 Page 26 8 7 Adjusting Engine Speed Onan Powered Units After tuning engine check engine cu a T speeds with a tachometer see t3 i table If necessary adjust speeds as follows 4 2 2200 100 rpm Start engine and run until warm 3700 50 rpm Remove wrapper to access speed adjustments Idle Speed Adjustment Move Engine Control switch to Run ldle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw 4 Loosen mounting screws Adjust Solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Jam Nut 5 Lock Nut 6 Weld Power Speed
39. Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www Sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 7 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting OM 945 Page 4 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons famil
40. Reset 1p 20a 250vac Frict 2 203 993 Control Push Pull Snap in 36 000 W 1 750 Extension 1 deu ees ar on 119014 Lever Switch Black 1 173 734 Link Jumper 2 5 Ee npe 172 661 Block Stud Connection 6 Position 1 14 POS is 039 047 Terminal Pwr Output Red 1 15 NEG 039 046 Terminal Pwr Output Black 1 Uc 083 030 Stud brs 250 20 x 1 750 1 P oC 010 915 Washer flat brs 3 near eu 601 836 Nut 250 20 brs 3 19 RC1 182 954 Rept Str 3p4w 50a 125 250v Flush Mtg 14 50 1 188 039 Cover Receptacle W Gasket 1 toca sneha etse 159 921 4 Bezeli es cem tete teg eod escudo ea rate 1 HN DD angu Fx 027 660 Fuse mintr cer 20 Amp 250 Volt 1 RE ES 4 200 422 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 ah acie ice ae 097 924 Knob Pointer 1 625 Dia X 250 Id W Set Screwsplstc 1 sO PE EM 072 590 Lock Sh
41. Selecting Extension Cord Use Shortest Cord Possible gt Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have receptacles use GFCI protected extension Maximum Allowable Cord Length in ft m for Conductor Size AWG current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30
42. Stl Pld 3 iod sich e oes 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 3 Figure 13 3 Generator 1 aT niche 193 782 Cover Tank EUel acca aces ees ana 1 P ETT 082 319 Cable Bat Neg 17 750 No 4 Awg W Clamp amp 343 Rng 1 xp 168 037 Battery Stor 12v 430 Crk 75 Rsv Gp 58 Dry 1 ute Lt oet cete 173 921 Cable Bat Pos 28 000 No 4 Awg W Clamp amp 312 Rng 1 sx PD ce decano he EON 172 669 Cable Bat 11 000 6ga W 250 Rng amp 375 Rng 1 Nur 182 935 Hold Down Battery 1 193 780 Bracket Mtg Engine 1 MAO als tede tte 7193783 22 BASS MPH 1 Os deh 194 074 Label Engine Maintenance Onan Robin Eh63 1 DORA ne 173 088 Label Engine Maintenance Kohler Ch18 Ch20 1 80 197 930 Label warning do not weld base 2 OM 945 Page 53 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued DS ay 181 057 Cover Base ii dee eee aoa ed d 2 82
43. aft Pot 375 32 X 250 Dia Shaft 1 26 HM 145 247 Meter Hour 12 24vdc 1 25 X 2 12 Rect 1 Le DT uad Ris ies 201 486 Potentiometer w leads 1 28D iss nie 202631 Cover Circuit Breaker 1 254 2056 202 630 Brkt Mtg Breaker 1 Cet ee et ete 602 207 Washer Lock 255idx0 4890dx 062t Stl Pld Split 250 1 RS ee DERE 163 167 Washer Lock 254idx0 4890dx 062t Sst Split 250 1 Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 945 Page 55 Item Part No No Description Quantity Figure 13 3 Generator Figure 13 1 Item 20 TW EE E 203 925 Generator Assy Front consisting 1 of ath aces 183 419 O ring 1 984 Id X 139 Cs 70 Duro Viton 1 D a E 195 956 Screw 250 20x5 75 Hexwhd 50d Stl Pld 4 m 188 447 Washer flat 281idx0 5000dx 061t stl pld 4 T 202 984 Washer belleville 500 od x 255 id x 038 thk 4 Lu D ee er 013 367 Label Warning Moving Parts C
44. an Cause Serious Etc 1 du 4 185 148 Housing Generator Rear 1 RET 186 083 Screw 437 14 1 75 Hexwhd 93d Gr8 Pld 4 MO ti de eee 203 933 Rotor Generator consisting of 1 181 134 1 Fan Rotor 222200 Deer 1 E 181 143 Bearing Ball Sg Row 984 X 2 047 59 1 TEMA 205 725 Brushholder Assy Generator 1 ta cece oes 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 5 802 345 B Figure 13 3 Generator When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 945 Page 56 Warranty Questions Call 1 877 1 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART S
45. ants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hi cules de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge DES ORGANES MOBILES peuvent provoquer des blessures SE Ne pas approcher les mains des ventilateurs cour roies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil e Demander seulement un personnel qualifi d enlever les dispositifs
46. ator pow 9 er output RUN v START If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or generator power load is re duced 1 Fuse F1 See Parts List F1 protects the generator excitation circuit If F1 opens there is no low weld and generator power output 2 Fuse F6 See Parts List F6 protects the engine wiring sys tem If F6 opens the engine does not crank If F6 opens while the en gine is running the engine stops Replace any open fuses Reinstall cover before operating x If a fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorized Service Agent 802 342 Ref 802 353 B 8 5 Servicing Optional Spark Arrestor Onan Powered Units Stop engine and let cool Dep 1 Spark Arrestor Screen Clean and inspect screen Replace Spark arrestor if screen wires are broken or missing Tools Needed I 14 in uu Ref 801 682 A Ref 802 353 A OM 945 Page 25 8 6 Changing Engine Oil Oil Filter and Fuel Filter Onan Powered Units 2 l1 2IDx7inHose 3 Oil Filter Change engine oil and filter ac cording to engine owner s RUN manual Re y XY Stop engine and let cool we EY 1 Drain Valve RUN ID
47. ay be available but may vary from province to province hobart retail 4 00 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 9 2003 Hobart Welding Products 1 03 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 WELDING PRODUCTS
48. before starting engine the first time see maintenance label for speci fications Leave filler neck empty to allow room for expansion see fuel tank window on base Check fuel level on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dip stick add oil see maintenance label To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather 802 353 D Gasoline Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil pressure gets too low 3 Follow run in procedure in engine manual gt This unit has a low oil pressure shut down switch However some condi tions may cause engine damage be fore the engine shuts down Check oil level often and do not use the oil pres sure shutdown system to monitor oil level Fuel Add fresh fuel before starting engine the first time see maintenance label for speci fications Leave filler neck empty to allow room for expansion see fuel tank window on base Check fuel level on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dip stick add oil see maintenance label To improve cold weather starting Keep battery in good condition Store
49. ch to Start position Release switch and slowly push choke in when engine starts EF If the engine does not start let the engine come to a complete stop before attempt ing restart To Stop turn Engine Control switch to Off position 7 BENERATOR POWER 120V AC POWER Ref 202 069 A 3 Engine Hour Meter 4 Amperage Control Use control to select weld amperage Select amperage according to electrode being used see Section 5 9 Control may be adjusted while welding Control does not affect genera tor power output OM 945 Page 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT N OT E If the unit is extremely overloaded weld and generator power will stop Turn unit off and restart to reset the generator protection circuit and restore weld and generator power output If the rated output of the unit is exceeded engine speed may vary rapialy until the weld or generator power load is reduced The welding generator provides power while welding and with the Amperage control in any position However under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations It is recommended that only lamps be powered under these conditions 7 1 Standard Receptacles 2 AH funit does not have GFCI re ceptacles use GFCI 11 protected extension 1 120 240 V 50 AC Recep tacle RC1 RC1 supplies 60 Hz si
50. cting Equipment Be sure equipment has this symbol and or wording Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Do not use 2 prong plug un less equipment is double in sulated gen pwr 11 02 Ref ST 159 730 ST 800 577 gt Electrically bond generator H frame to vehicle frame by metal to metalcontact A Bed liners shipping skids an some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCl pro tected extension cord S 0854 OM 945 Page 37 12 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Ground generator to system earth ground if supplying power to a premises home shop farm wiring sy
51. ctrode Angle GROOVE WELDS End View of Work Angle FILLET WELDS o wl 10 30 Side View of Electrode Angle 5 0060 13 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 5 0053 13 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 NoOverlap 5 Good Penetration into Base Metal 5 0052 8 945 46 13 8 Conditions That Affect Weld Bead Shape NOTE Cr Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 410 30 Angle Too Large 1 ee 0 5 d prag ELECTRODE ANGLE L pm Rn pr s Too Short Normal Too Long ARC LENGTH lS Slow Normal Fast TRAVEL SPEED 13 9 Electrode Movement During Welding NOTE Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movem
52. de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d en tretien et de d pannage 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le coupa ge gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures 4 e Rel cherla pression d air de l outillage ou du sys t me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e pas approcher les mains cheveux v tements laches et outils des orga nes mobiles e Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n
53. derneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed OM 945 Page 50 13 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 13 20 Troubleshooting Waviness Of Bead g Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 13 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 945 Page 51 Hardware is common and not available unless listed SECTION 14 PARTS LIST 2
54. e and local codes gt Customersupplied equipment is re quired if generator will supply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Trans fer load back to electric utility when service is restored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 12 4 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 945 Page 42 12 11
55. e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance inflammable D L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT nn 7 Laisser l quipement refroidir respecter le facteur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s gt 22 e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut entrainer des blessures N e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant A 2 6 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation
56. eceptacle Receptacle 35 0 30 5 25 10 20 15 15 20 Watts One 240 V load or two 120 V loads The plug can be wired for a 240 V 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal 2 Amperes Available Using 120 240 V Plug Tools Needed 120 813 D OM 945 Page 21 SECTION 8 MAINTENANCE ONAN POWERED UNITS 8 1 Maintenance Label Onan Powered Units ONAN OHV See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oil Push And CCW Daily BG m Ve in ID Hose mum Pull Recommended Oil API Service Classification SF CC SG CE SH CONDITIONS Normal Severe Oil Change 100 hours 50 hours Filter Change 200 hours 200 hours Oil Filter MILLER 198754 ONAN 122 0737 03 1 6 qt 1 55L or 1 8 qt 1 75L with filter change Fuel Grade Unleaded Fuel Filter MILLER 066 113 Onan 149 2206 01 Fram G10E1 Air Filter Service 100 hours or less see Owner s Manual Air Filter MILLER 198755 ONAN 187 6068 12 Volt Battery BCI Gr
57. ed Air 4 3 1 5 Additional Symbols For Installation Operation And Maintenance 3 1 6 Principal Safety Standards 4 157 Les eR e 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Engine Hazards 24 e REA PEE Reds 6 2 4 Dangers li s l aiicomprim 00 ete eee eee 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement eta maintenance ues iive ten Riassunto eA AERE REDE 7 2 6 Principales normes de s curit 8 2 7 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS icici kn xag pl RR RE 9 SECTION 4 9 4 1 Weld Power and Engine Specifications 9 4 2 Dimensions Weights and Operating Angles 10 4 3 Generator Power
58. el Section 9 6 WARNIN Replace unreadable labels m OM 945 Page 29 Every 500 h Repair or replace cracked Q Service welding generator cables brushes slip rings Service vy ZAO more often in dirty conditions Every 1000 h Blow out or vacuum inside Pp d During heavy service clean OR monthly 9 3 Servicing Air Cleaner Kohler Powered Units Stopengine Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil amp RUN stant 2 Element Replace element if dirty oily or damaged aircleaner3 1 97 802 772 Ref 183 175 A S 0759 OM 945 Page 30 9 4 Overload Protection Kohler Powered Units Stopengine x If the unit is extremely over loaded weld and generator power will stop Turn unit off and restart to reset the genera tor protection circuit and re store weld and generator pow er output 1 gt ar Tools Needed oa RUN v START If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or ge
59. enance avant de toucher des compo sants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage Des pr cautions de s curit suppl mentaires sont requises dans des envi e Sila ventilation est insuffisante utiliser un respirateur alimentation d air XD amp homologu ronnements risque comme les endroits humides ou lorsque l on porte 9 PN 2 des v tements mouill s sur des structures m talliques au sol grillages et m e Me d de Securite CoS matenan MSDSs et i At ions du fabricant concernant les m taux les consommables les chafaudages dans des positions assises genoux et allong es ou rev tements les nettoyants et les d graisseurs quand il y a un risque important de contact accidentel avec la pi ce ou le z A m sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 6 Travailler Gens Un Espace ferm seulement s iest bien ventileou en par gt tant un respirateur alimentation d air Demander toujours un surveillant 1 un poste souder DC semi automatique de type CV MIG MAG 2 un d ment form de se tenir proximit Des fum es et
60. ent Along Seam 1 2 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 945 Page 47 13 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm 5 0662 13 11 Lap Joint 2 Single Layer Fillet Weld 30 Or Less KA 1 Or Less 3 Multi Layer Fillet Weld 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength S 0063 S 0064 13 12 Tee Joint 1 Electrode 2 Fillet Weld Keep arc s
61. equipment and CGA publication P 1 listed in Safety Standards FUEL can cause fire or explosion e Stop engine and let it cool off before checking adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling d MOVING PARTS can cause injury Keep away from fans belts and rotors Keep doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator components STEAM AND HOT COOLANT can burn e If possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator u
62. er le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et rel cher la pression avant d effectuer la maintenance 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 945 Page 7 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il ya lieu J LES TINCELLES VOLANTES ris quent de provoquer des blessures N y Porter un cran facial pour prot ger le visage et les yeux
63. es not have re ceptacles use GFCI protected extension cord Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Mounting Grounding Electrically bond generator frame to vehicle frame by metal to metal contact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Airflow Clearance 18 in 18 in 460 mm install2 11 02 Ref 800 652 Ref 800 477 803 274 OM 945 Page 13 5 2 Engine Prestart Checks Onan Powered Units Gasoline Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10 30 engine oil Engine stops if oil pressure gets too low 3 Follow run in procedure in engine manual gt This unit has a low oil pressure shut down switch However some condi tions may cause engine damage be fore the engine shuts down Check oil level often and do not use the oil pres sure shutdown system to monitor oil level Fuel Add fresh fuel
64. espirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 945 Page 5 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds LE SOUDAGE peut provoquer un in RER cendie ou une ex
65. eur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE Toujours porter une protection faciale des g
66. hort and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 13 9 Remove slag before making another weld pass 5 0060 5 0058 5 0061 OM 945 Page 48 13 13 Weld Test a 2703 51 76 fan 2103 b 61 76 mm c 1 4 in _4 2 6 4 mm See 1 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not break 5 0057 8 13 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long o
67. iar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area levard Rexdale Ontario Canada M9W 183 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z
68. idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Weld Power Speed Adjustment Nut 5 Lock Nut Loosen lock nut Turn adjustment nut until engine runs at weld power speed Tighten lock nut Stop engine Reinstall wrapper 802 339 B 801 209 A OM 945 Page 33 SECTION 10 TROUBLESHOOTING 10 1 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Check weld connections Check fuse F1 and replace if open see Section 8 4 or 9 4 Unit overloaded Stop unit and reduce load Restart unit to reset generator protection circuit and resume operation Be sure all equipment is disconnected from receptacles when starting unit Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings integrated rectifier SR2 and field control board PC1 Low weld output Check fuse F1 and replace if open see Section 8 4 or 9 4 Check control settings Check engine speed and adjust if necessary see Section 8 7 or 9 7 Service air cleaner according to engine manual Have Factory Authorized Service Agent check brushes and slip rings and field control board PC1 High weld output Check control settings Check engine speed and adjust if necessary see Section 8 7 or 9 7 Erratic weld output Check control
69. iller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors Rotors Stators and Brushes 2 Years Parts and Labor Drive Systems PC Boards Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tip
70. just if necessary see Section 8 7 or 9 7 Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes and slip rings C Engine Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 4 or 9 4 Check battery voltage Check battery connections and tighten if necessary Check plug PLG4 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine will not start Check fuel level Check battery voltage Check battery connections and tighten if necessary Check oil level see Section 5 2 or 5 3 Check low oil pressure shutdown switch see Parts List for location Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 Engine starts but stops when Engine Control switch returns to Run position Check oil level Check and refill crankcase with proper viscosity oil for operating temperature if necessary Check low oil pressure shutdown switch see Parts List for location Engine stopped during normal operation Check fuel level Check oil level see Section 5 2 or 5 3 Check fuse F6 and replace if open see Section 8 4 or 9 4 Check low oil pressure shutdown switch see Parts List for location Periodically recharge battery approximately every 3 months Replace battery Check voltage reg
71. le or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet APA This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cable
72. m flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection WELDING can cause fire or explosion m Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock a
73. nd s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Rexdale Ontario Canada M9W 13 t l phone 800 463 6727 ou To ronto 416 747 4044 site Web www csa international org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 7 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn tiques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lectro magn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plu
74. nd Saw 14 in 2500 1100 Bench Grinder 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 945 Page 40 12 8 Power Required To Start Motor 7 A MOTOR 1 Motor Start Code 2 2 Running Amperage 1 VOLTS 230 AMPS 254 ae 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage up 1 4 PHASE 1 To find starting amperage Step 1 Find code and use table to find If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motor s running amperage Motor Start Code G H J K L M
75. nd fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries e Disconnect negative cable first and connect it last OM 945 Page 2 E z working on a hot engine FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves and clothing when e Do not touch hot engine parts or ju
76. ne Kohler 1 LANES 189 477 Gasket muffler 2 ene atus 066 698 ma Filter 0ll scie UAI REL 1 067 272 Element air 1 Seb ahaa Sane etr eaa OR 121 652 Filter fuel w clamps 1 Vives 067 273 Wrapper air filter 1 reer 067 00 2 ic A 199 530 dlen uber ie AIRE REPRE I 165 271 Valve Drain 3 8 18 1 TT F6 021 718 Fuse Mintr GI 30 Amp 32 Volt 1 ETATEM EO 190 827 Boot Solenoid 1 m D E 180 096 Kit tune up and filter Kohler includes air filter element and wrapper M oil filter fuel filter and spark plugs 1 py MGs 196 778 Hose Vinyl Clear 500 Id X 625 Od X 7 000 drain 1 rap E 167 788 Nut 375 16 56hex 34h Stl Pld Sem Cone Wshr 88d 3 STO e rni Oe Runes 151 542 Washer Flat 438idx1 0000dx 125t
77. nerator power load is re duced 1 Fuse F1 See Parts List F1 protects the generator excitation circuit If F1 opens there will be no low weld and generator power out put 2 Fuse F6 See Parts List F6 protects the engine wiring harness If F6 opens the engine does not crank If F6 opens while the engine is running the engine stops Replace any open fuses Reinstall panel before operating unit x If a fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorized Service Agent Ref 801 221 B Ref 802 353 B Ref 183 175 A 9 5 Servicing Optional Spark Arrestor Kohler Powered Units Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace Spark arrestor if screen wires are broken or missing a EA c 1 e hos RUN START Tools Needed 1Ain Lum Ref 801 695 A Ref 802 339 A OM 945 Page 31 9 6 Changing Engine Oil Filter and Fuel Filter Kohler Powered Units ws Ber Tools Needed Se amp S uc 1 RUN DLE RUN D START Stop engine and let cool 1 Oil Drain Valve 2 1 21Dx
78. ngle phase power at weld power speed Maxi mum output is 10 KVA KW 5 2 6 3 2 120V 20A AC Duplex Recep tacle RC2 3 120 V 20A AC Duplex Recep gh tacle RC3 TOTAL ALL LOADS VRAMENEUTRE 10 000 120 V 240 V RACCORDE AU 120 V RC2 and RC3 supply 60 Hz single RA 89 phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW 4 Circuit Breaker CB1 protects the ac receptacles from overload If CB1 opens the ac receptacles do not work ON Move CB1 toggle switch to On position to reset circuit break er If breaker continues to open contact Factory Authorized Service Agent 5 Circuit Breaker CB2 J CQ J 6 Circuit Breaker CB3 CB2 protects RC2 and CB3 pro tects RC3 from overload If a circuit breaker opens the receptacle does i GENERATOR POWER not work OFF Press button to reset circuit 4 breaker If breaker continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 10 kVA kW rating of the generator EXAMPLE If 20 A is drawn from each 120 V duplex receptacle only 21 A is available at the 240V receptacle 2 x
79. nless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is over flow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury e Release air pressure from tools and system before servicing adding or changing attach ments or opening compressor oil drain or oil fill cap ENGINE EXHAUST GASES can kill Use equipment outside in open well ventilated areas e f used in a closed area vent engine exhaust outside and away from any building air intakes BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spa
80. oup 58 Cranking Performance at 0 F 18 C 430 Amps min Engine RPM No Load Valve Clearance Cold Weld 0 004 in 0 10 mm Power 3750 Ex 0 004 in 0 10 mm 2200 Spark Plug Gap 0 025 in 0 6 mm Spark Plug NGK BPR 4EY Use only resistor spark plugs and wires Spark Arrestor Inspection and Service 20 operating hours see Owner s Manual 194 074 E OM 945 Page 22 8 2 Routine Maintenance Onan Powered Units Note 7 Follow storage procedure in the engine owner s manual if the unit will not be used for an extended period e i ws Stop engine before maintaining RI R 9 See also Engine Manual and maintenance label POYCE Service engine more often if used in severe condi PA tions uias To be done by Factory Authorized Service Agent Every 8h Check fluid levels 3 See Section 5 2 Wipe up spills 20h Check and clean Service ar cleaner wrapper eiae spark arrestor Screan 3 foam element See Section 8 5 See Section 8 3 Every 50 h Clean and tighten weld terminals vil 2 Every 100 h Change oil See Section 8 6 and maintenance label Clean cooling system See Engine Manual Service air cleaner element See Section 8 3 Clean and tighten battery connections Every 200 h uy Change oil
81. plosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e pas souder dans un endroit l des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correc
82. r For information on other quality Hobart products contact your local Hobart can also supply you with He Welding P Manual distributor to receive the latest full line catalog or individual catalog sheets cus SMAW GTAW To locate your nearest distributor or service agency call 1 877 1 EMA EE TUM WELDING PRODUCTS WARNING This product when used for welding 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 amp Safety Code Section 25249 5 et seq WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling amp WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The following terms are used interchangeably throughout this manual Stick SMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage RR XXX ee PUN 1 1 2 Arc Welding Hazards 1 153 Engine Hazards sleek E DR ER Ye Ed Ee here 2 1 4 Compress
83. r voltage too high Reduce arc length or voltage OM 945 Page 49 13 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 13 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging un
84. rk arrestor in required areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Stop engine and release air pressure before servicing 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable OM 945 Page 3 FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables
85. s A Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away A ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic 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 Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid ab
86. s or parts that fail due to normal wear 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Millers option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation cost
87. s CC DC 197 148 OM 945 Page 11 4 6 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 80 70 RANGES MAX RHEO 60 50 RHEO 72 MIN RHEO 50 gt 40 O C 30 20 10 0 0 50 100 150 200 250 200 550 400 5 197 253 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 945 Page 12 SECTION 5 INSTALLATION 1 Installing Welding Generator Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes Do not lift unit from end Do not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards If unit do
88. s de 500 tudes qui ont t faites pen dant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumulation de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectri ques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la recherche il serait souhaitable de r duire l ex position aux champs lectromagn tiques pendant le soudage ou le coupage OM 945 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail respec ter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 Symbol Definitions D StopiEngine gt Run Welc Power lt Buide gt Slow die Start
89. s of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER 15 EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights m
90. s over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do nottouch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases e f ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers Work
91. s pr cautions Ce groupe de symboles si gnifie Mise en garde C3 Soyez vigilant 1 y a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PI CES CHAUDES Reportez vous aux symboles et aux directives ci des sous afin de conna tre les mesures prendre pour viter tout danger 2 1 un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du En effectuant les raccordements d entr e fixer d abord le conducteur de pr sent manuel pour attirer votre attention et identifier les ris mise la terre appropri et contre v rifier les connexions ques de danger Lorsque vous voyez un symbole soyez e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en vigilant et suivez les directives mentionn es afin d viter tout dommag ou d nud remplacer le cordon imm diatement s il est danger Les consignes de s curit pr sent es ci apr s ne font endommag un c ble d nud peut provoquer une lectrocution que r sumer l information contenue dans les normes de s cu Mettre l appareil
92. st welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated
93. stem Use ground device as stated in electrical codes ST 800 576 B 12 4 How Much Power Does Equipment Require VOLTS 115 AMPS 4 5 Hz 60 AMPERES VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax 115 V 520W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment 5 0623 945 38 12 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1
94. tement conform ment AWS 4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes 2 3 Engine Hazards LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu OM 945 Page 6 Suivre les recommandations dans OSHA 1910 252 a 2 iv et 518 pour les travaux chaud et avoir de la surveillance et un extincteur proxi mit DES PARTICULES VOLANTES Cute peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n
95. ulator and connections according to engine manual Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 Battery Discharges between uses Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check field control board PC1 and current transformer CT1 Engine speed varies rapidly under heavy generator power load Reduce generator power load at ac receptacles Unstable or sluggish engine speeds Readjust throttle linkage if necessary Check throttle solenoid TS1 for smooth operation Tune up engine according to engine manual Engine does not return to idle speed Remove weld and generator power loads Check throttle linkage for smooth non binding operation Have Factory Authorized Service Agent check current transformer CT1 Engine Control switch S2 throttle solenoid TS1 and field control board PC1 OM 945 Page 35 204 710
96. ur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi Encasd interf rences apr s avoir pris les mesures pr c dentes il in l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles bli

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