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Engine Driven Welding Generator

1. amp WARNING e Do not touch live electrical parts ke e Disconnect input power or stop 3 engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit r A B C D E F A B C D E F 1T Q Q O O 1T e OO O Ua ES a 3 51 eg 3 S 8 d E w 51 ME al 3 A E sl C d SA 3 S yo x Id u q iz ou a g E z CB4 8 ki G 06 to 3 E 5 E i o m kid EN lt g Ki 04 zon 8 o a a ome Io y to Lo a S CB3 cB1 5 CB1 55A 5 ka S EEN lo 55 cB3 55 CB1 C AUXILIARY PANEL 196914 2 120V DX 240V TWLK CSA d L AUXILIARY PANEL 495219 2 120V DX 240V TWLK AUXILIARY PANEL 495253 S AFRICA A B C D E F A B C D E F 1T Q C O O 1T i C O O Zw 8 11D Al ali sal 11D 5 9 9 ES N N 51 E El x o o E x e W 10 11E 51 D 2 3 11F RC2 ME 11F RC2 GND a S 2 5 A STE EH N E a BL ON E amp RC2 g cB4 8 518 2 3 H E PIE E L aj T B 6 3 G CB4 7 a Y S3 IT C W B ss L9 CB2 RC 57 Lo GRN 0 56 CBZ ro CB3 of 8 A Ps CB3 2 9 NO LINK a o 2 EE oae 51A CB3 51A CB1 CB Uss ca3 ss ca1 5 L J AUXILIARY PANEL 196921 2 120V DX 240V TWLK CSA L A
2. A B C D E F A B C D E F 1T F OO OO O 1T OO OO O a i i ME ME C N m s 8 d RC2 N a o o o o a 5 2 3 fa i Z 2 a RC2 ES 8 5 WE olo 5 2 5 LP eno El E e o oJ Bi e 15 CB1 a cB2 CB1 A E e 2 CB2 H E d OL 59 R61 lo al o 55trc1 _ lo 3 3 El 3 MF F up EN SA sf AUXILIARY PANEL 495283 S E ASIA AUXILIARY PANEL 495290 EUROPE A B C D E F A B C D E F 1T OO O O 1T F O O O 4 11D S A 11D 8 E 8 9 sl x 51 Doo 11 ME 11H RC1 11F RC1 er A 11F RC2 11G RC2 o e 8 11G RC3 E d 54 1T D E 2 z M A 3 Ef z _RC2 CB4 CB4 e S 58 RI ro e 6 ro o x 8 5 10 l D Q4 CB2 CB3 d 51A AUXILIARY PANEL 495315 2 120V DX 240V DX 51A A B C D E F 01010 1T NE r gt 5 CB3 al A cB4 o GK lo 58 o 5 CB1 Wy Y CB2 o co 8 cp D 55 i L 56 RC1 o 8 EL 54A 11F RC2 116 AUXILIARY PANEL 495289 AUSTRALIA 201 026 Figure 9 4 Wiring Diagram For Auxiliary Power Panels 2 Of 2 OM 498 Page 33 SECTION 10 AUXILIARY POWER GUIDELINES 10 1 Selecting Equipment 1 Auxiliary Power Receptacles Neutral Bonded To
3. USA 18 l o ol T o ce mam ro awa ce b b 19 N N O O S S DO O O o o mo o E o Auxiliary Power Panel 495 253 South Africa 22 Sal e RG RR e 23 A ava ava z O Auxiliary Power Panel 495 290 Europe 26 75 27 XE pulis ni NE c i e Auxiliary Power Panel 495 283 S E Asia Hardware is common and not available unless listed o de o tv A mn PO ces al ES E e 0 o 8 ou Auxiliary Power Panel 495 315 USA 15 Oo RCI 12 RC2 120 a Oo e D a w0 L Auxiliary Power Panel 495 279 17 ei Canada Silke S cat TD D i z i LO e 21 W s 21 NS W a an o Auxiliary Power Panel 495 289 Australia za 25 Auxiliary Power Panel 495 288 S America ix AL av A a a A an fan Q D ou EN EN e af a O J WO Auxiliary Power Panel 196 914 USA Figure 12 2 Auxiliary Power Panels OM 498 Page 52 30 196 921 Item Dia Part No Mkgs No Description Quantity Figure 12 2 Auxiliary Power Panels Figure 12 1 Item 31 Auxiliary
4. 1 16 CB1 495 183 Circuit Breaker 3OA 1 17 CB2 CB3 495246 Circuit Breaker 20A 2 Auxiliary Power Panel 495 253 South Africa deal EK 495 252 Panel auxiliary power assembly 1 19 CB1 CB2 495 245 Circuit Breaker 15A 2 Auxiliary Power Panel 495 289 Australia a Ae dc et erga 495 254 Panel auxiliary power assembly 1 21 CB1 CB4 495245 Circuit Breaker 15A 4 Auxiliary Power Panel 495 290 Europe cad dM E EN uu 495 282 PANEL auxiliary power assembly 1 23 CB1 CB2 495245 CIRCUIT BREAKER 15A 2 Auxiliary Power Panel 495 288 S America E EE 495 287 PANEL auxiliary power assembly 1 25 CB1 4 495245 CIRCUIT BREAKER 15A 4 Auxiliary Power Panel 495 283 S E Asia AO suu xt 495 282 PANEL auxiliary power assembly 1 27 CB1 CB2 495245 CIRCUIT BREAKER 15A 2 Auxiliary Power Panel 196 914 USA 2B dre ne Rs 495 220 PANEL auxiliary power assembly
5. ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and aw
6. la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e 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 e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine rom nd fre 11 98 AEN Ce groupe de
7. 1 29 CB1 CB2 495245 CIRCUIT BREAKER 15A 2 90 CB3 CB4 495246 CIRCUIT BREAKER 20A 2 scs AN vs Rod uvis 129 067 RECEPTACLE tw Ik grd 3P4W 30A 125 250V 1 a e E aS 088 898 PLUG tw Ik grd 3P4W 30A 125 250V 92 RC2 RC3 141432 RECEPTACLE str dx grd 2P3W 20A 125V 2 Gn iae 073 690 PLUG str grd armd 2P3W 15A 125V Recommended Spare Parts NOTE Replacement receptacles not listed can be found at your local hardware or electrical supply store 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 498 Page 53 Notes OM 498 Page 54 Warranty Questions Call 1 877 HOBART1 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 WELDERS HOBART 531 WARRANTY Effective October 1 19
8. FILTER air Kohler cs 8 5 8 12 1 E RR NER Aa oe te ERES 203 954 FILTER air pre Kohler cs 8 5 8 12 d 203 955 CAP fuel Kohler cs 8 5 amp 12 1 Rm 203 956 TANK fuel Kohler cs 8 5 8 12 d TE eiat EC 203 957 STRAINER fuel Kohler cs 8 5 amp 12 1 AUI OM da sheer iie A 203 958 MUFFLER exhaust engine Kohler cs 8 5 amp 12 1 RE 203 959 GASKET muffler Kohler cs 8 5 amp 12 1 C CE E EE NE 203 960 SPARK PLUG Kohler cs 8 5 amp 12 1 ud so serre 184 556 ENGINE Honda 9HP recoil start 1 TA taf tone 184 555 ENGINE Honda 9HP electric Start 1 Du 494 606 ADAPTER engine 1 liar ans 494 629 GUARD generator 1 dou tani RE ee 194 509 FAN generator Kohler 1 c eee es 493 868 FAN generator Honda 1 ME PEN 495 213 GENERATOR w stator assembly 1 udo mt Dus ou 494 574 ROTOR assembly 1 ee LO SAA eim 495 349 SCREW 1 4 20 HWH 4
9. Le lanual contact your local to receive the latest full line catalog or sul SCH Eer can also su ou Wit individual catalog sheets To locate your nearest Welding SE Manuals distributor or service agency call 1 877 Hobart1 Hobart offers a Technical Manual which provides more detailed service and parts information for your such as SMAW GTAW GMAW and GMAW P WELDING PRODUCTS 4 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 4 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 4 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 TIG GTAW Stick SMAW MIG GMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage vwe ke vw REIR Ex TAY TA teat tee EA PU 1 1 2 Arc Welding Hazards 1 1537 Engine Hazards EE 2 1
10. e Protect yourself and others from flying sparks and hot metal e 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 e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e 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 and fire hazards e Do not use welder to thaw frozen pipes e 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 FLYING METAL can injure eyes ai 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 shield
11. OM 498 197 849C April 2001 Processes WELDING PRODUCTS Stick SMAW Welding Description D a g Engine Driven Welding Generator CHAMP 1435 i 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 MA 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 Y k worksite We ve made E i installation and operation quick and easy With Hobart you can count on years of reliable service a WARRANTY maintenance And if for some reason the unit Working as hard as you l a i do every power source Hobart is registered to the needs repair there s a Troubleshooting section from Hobart is backed by Ge Penn Quality System that will help you figure out what the problem SE warranty in the is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTERED QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor e sod ase
12. mark on dipstick add oil see main tenance label Lx To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use correct grade oil for cold weather Ref 802 099 A A Turn Engine Switch to Off electric start models only A Connect negative cable last Tools Needed Ja 3 8 1 2 in 802 100 A Ref S 0756 D OM 498 Page 15 4 7 Connecting To Weld Output Terminals 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal For Direct Current Electrode Posi tive DCEP connect work cable to Negative terminal and electrode holder to Positive terminal For Direct Current Electrode nega tive DCEN reverse cable con nections si E E o z Ji z e Y M a POSITIVE NEGATIVE v T M Tools Needed JAZZ 3 4 in 196 921 495 179 4 8 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 150 ft 200ft 250ft 300ft 350ft 400 ft 100 ft 30 m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals Stop engine before 10 60 60 100 connectingto weld out Welding Duty Duty 10
13. 0 60 0 40 0 20 0 00 AUX POWER WELD IDLE RPM 50 75 100 125 150 175 DC WELD AMPERES AT 100 DUTY CYCLE 1 2 3 4 5 POWER KVA AT 100 DUTY CYCLE 25 200 802 121 3 5 Duty Cycle 200 175 150 125 100 WELD AMPERES a o8 OM cC 3 Minutes Welding 15 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Continuous Welding y 100 Duty Cycle at 80 Amperes CC DC 7 Minutes Resting 30 Duty Cycle at 140 Amperes CC DC 20 25 30 40 DUTY CYCLE 50 60 80 100 802 092 OM 498 Page 11 3 6 Auxiliary Power Curve The ac auxiliary power curves show the auxiliary power available in amperes at the receptacles 150 125 100 75 LOAD VOLTS 50 25 0 5 10 15 20 25 30 35 40 45 50 LOAD AMPS 802 129 3 7 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 LOAD VOLTS 0 25 50 75 100 125 150 175 200 LOAD AMPS 198 453 OM 498 Page 12 SECTION 4 INSTALLATION 4 1 Installing Welding Generator Movement Airflow Clearance install 1 97 802 512 A Ref 151 556 158 936 A S 0854 4 2 Gro
14. 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 chaleur 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 e Ne 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 Ne jamais souder une bouteille pressuris e risque d explosion 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
15. and adjust if necessary see Section 7 4 or 7 5 Check throttle governor linkage for smooth non binding operation Tune up engine according to engine manual OM 498 Page 29 SECTION 9 ELECTRICAL DIAGRAMS VSN 862564 ed AMVTIIXDV vs2 126961 ANVI Apr vivallsnv 68ZS6 I3Nvd AMVIIIXDV o o pe ay EH a aozi sou LI nosz zou d P e d 4 g 89 89 A021 Sou FT d M 9 seo 5 Fel r lt 8 5 Ae 5 5 aozi f a OZL zou 4 o o 77 4 Weg mm eo l 7 I 9 A021 zou E o o EH ki 180 za x 9 M A e M 9 8 I 2 Y I oz o X 5 e o A0rz 198 o o Ti o F l 96 11 sg T o o ECH 180 7 p Ve 180 ae e ES 4 15 l Su T 4 4 5 Tu eth aaah ad Mo 20 au ou a 1I v u l WSO 622969 ANVI iere NvadOUNa 062967 INVA AUVITIXNY vs2 842967 Med Aueren VO S GZG6 Manva AMVTIXDV viSV 3 S 8ZG6 1INVA AMVTIIXNV ES 3mon 9 a ger zou Iz l I 3 4 Y L za nazi zou 4 amp 4 ze I E nozi zou L rs M SS 16 H Ce ve Sech cao l L P 280 oer lou fe 7 J wee D 9 8 189 x 9 A A l sE M 9 8 ee li I U Y ss x 9 a A0Z1 Lou 7 nove o rz z e Lt L P Lcd l E 15 E ze f QUO 1 8 15 a e 4 L l e 4 3 11 Ou ou 8 1 v LI 3 au ou 8 1 vu voRIaWW
16. 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 85 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 2 ea 2 0 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 ey e 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 S 0007 E For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 498 Page 16 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Controls Kohler Powered Units OP a Fi ae NS A x Weld and auxiliary power output stops if generator overheats or engine speed is too low 1 Engine Switch Use switch to open ignition circuit and to stop engine 2 Throttle Control Lever Use lever to select engine speed Move lever to idle position far left for idle speed Move le ver to Run position far right for weld power speed Always place lever in Run position far right for auxiliar
17. 4 Additional Symbols For Installation Operation And Maintenance 3 1 5 Principal Safety Standards 4 1664 EMF Information epe xen A nn SE d EE ERI EUN dut 4 SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers existant en relation avec le moteur 6 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement etla maintenance NN res imei ue R ELS IR RR eee EX ER eee 7 1 5 Principales normes de s curit 8 1 6 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS 2 e245 fee eg d ex Me dure PEE ELEME die met Du E EEN d 9 SECTION 3 SPECIFIGATIONS 2255225258 a yeas oe 9 3 1 Weld Power And Engine Specifications 9 3 2 Dimensions Weights And Operating Angles 10 3 3 Fuel Consumption Kohler Powered Units 10 3 4 Fuel Consumption Honda Powered Units 11 93 5 Duty Cycle este tests be RO decos 11 3 6 Auxiliaty Po
18. Frame 2 8 Prong Plug From Case Grounded Equipment 3 2 Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and or wording aux pwr 2 99 Ref ST 159 730 ST 800 577 10 2 Grounding Generator To Truck Or Trailer Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire A funit does not have GFCI re ceptacles use GFCI pro tected extension cord e 1 Generator Base 2 Metal Vehicle Frame GND PE J OR S Electrically bond generator H 2 frame to vehicle frame by metal to metalcontact S 0854 OM 498 Page 34 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 3 VOLTS 115 AMPS 4 5 Hz 60 GO AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 Ax 115 V 2 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads t
19. IR ates da 494 587 CARRIER bearing 1 Lc 495348 SCREW 5 16 24 HWH 1 Rc 494 628 PANEL end generator 1 S22 v E austr e 495 113 LEAD b nding e oci ueniet ki ma ERE D os 1 Si A ee asou eus it 495 257 MOUNT shock w bushing 2 22 aba IAS 495 256 MOUNT shock generator 1 29 i near 194 504 FRAME mtg assembly Kohler 1 EE 495 132 FRAME mtg assembly Honda 1 24 PCT 148 608 BOARD PC filter CSA only 1 uud veia eei dn 494 613 TERMINAL output 2 ads cis Bl us 494 618 RHEOSTAT 35 ohm 100W 1 KER S las Becke iie 495 214 SEAL air duct 1 m cites E YN AN AN 495255 s DUCT ali entente a Preterea na 1 esa cud aet ue dibus 097924 2 KNOB POINTE rs 3 cde ed hel ke uet cc RE aie aaa wal IS dd Ee 1 CU vs ce debe a Duce d NAMEPLATE overlay order by model and serial number 1 ECH ees ted pt Figure 12 2 PANEL aux power assembly CSA 1 Ee PLACENT ER nee 172 661 BLOCK terminal 1 AN OO ds 495 193 BRACKET mtg te
20. Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment O 2001 Hobart Welding Products 1 01 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
21. S Cep INV AMNTIIXDV YSN 612986 Manva Aavnixnv vs0 16961 ANYA AUVIIIXAY YO Y d x A0Z1 cou A UA T Lg sou LI A A ADEZ zou d F wee zz a 80 EH Ei 8 9 M gg M 5 8 1 L6 a Y A0Z1 zou Lay I L6 A0 Z Lou a o o e A0ZI zou Ga V 39 77 Rap i 1 NT geo EH tao 89 m a 9 ya y Bo DW x 9 MA 1 Se y l a se Ap LOU Se ran I f A0pz 198 tss zo l 15 i zao Leo l l ae 46 A yo ee Ce 45 15 i l 3 14 8 4 vu 3 11 a L 211 SL Wt v I 11 14 mem Le mx TANVd ABVITIXAY NO OLIVA3HOS JIS 3 a gt NN OWA OCL e r AINO NOILdO E l FNIKOVWN VSO a n SWHO ZE 198 016 C E Tz OF z 9 11 A 9 APTV ATV ATV xe xe ES LA LJ L4 LA a 4 La LJ L e 6 Kei Wl gun SIU adas Jo esn GHVZVH MOOHS iesu suosJed payijenb JUO SABH e 91419273 PeAOLUSI S18A09 YIM eje1edo jou oq e Buroiujes 8410J8q euiBuo dois Jo Jamod indu pouuoosiq e NE sued eou109ja eA Yona JOU od e 9NINHVM Y SC 495 297 For Welding Generator it Diagram Ircul Figure 9 1 C OM 498 Page 30 gun SIU adas Jo esn GHVZVH HDOHS resul suosied peurpenb Ajuo 81EH e 91419373 PARO RO O O O SO p9AQUJ8J S18A09 UJIM eje1edo jou oq e AINO 130OW LYVLS OlMIO3T3 Buroiujes 910j9
22. Slow Normal Fast TRAVEL SPEED Seier 11 9 Electrode Movement During Welding NOTE EC 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 Movement 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 498 Page 44 11 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 S 0662 11 11 Lap Joint 30 o 30 Or Less Or Less MA 2 3 Single Layer Fillet Weld Multi Layer Fillet Wel
23. danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o 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 e 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 e 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 correctement conform ment AWS F4 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 e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des g
24. 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 1 3 Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro li voquer un incendie ou une explo sion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Nepas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e 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 OM 498 Page 6 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 e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autre ment dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e Met
25. engine 4 Starter Handle Recoil Start Models Only To Start Recoil open fuel valve turn engine switch to On move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Start Electric open fuel valve move throttle lever to Idle set choke and turn en gine switch to Start position Open choke as engine warms A If the engine does not start let engine come to a complete stop before at tempting restart To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Label Use label to determine correct weld amper age based on electrode size type and mate rial thickness 6 Current Control Use control to select weld amperage Control may be adjusted while welding To Set Current Control Use label to deter mine correct size electrode for material thick ness Select electrode type and set current control to corresponding amperage range on nameplate Adjust control within selected range to obtain desired weld performance EXAMPLE Material Thickness 1 8 to 1 4 in Electrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A Notes OM 498 Page 19 SECTION 6 OPERATING AUXILIARY EQUIPMENT NOTE gt The welding generat
26. plus particulierement les enfants pa UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension a ce moment l En soudage semi automatique ou automatique le fil le d vidoir le 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 e Siisoler 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 e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l installation
27. system to monitor oil level Gasoline 1 Fuel Valve Open valve Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Cil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see mainte nance label Lx To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use correct grade oil for cold weather Ref 802 512 A OM 498 Page 14 4 5 Engine Prestart Checks Honda Powered Units Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil level gets too low 1 2 in 13 mm Full e Gasoline 1 Fuel Valve Open valve Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Cil After fueling check oil with unit on level surface If oil is not up to full
28. 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 11 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath 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 498 Page 47 11 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 11 20 Troubleshooting Waviness Of Bead LG SE 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 11 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
29. 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 S 0050 OM 498 Page 42 11 5 Positioning Electrode Holder 907 90 Y d y End View of Work Angle d 5 Side View of Electrode Angle GROOVE WELDS End View of Work Angle FILLETWELDS o o wl 10 30 Side View of Electrode Angle S 0060 11 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration OD BR GON S 0053 A 11 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 S 0052 B OM 498 Page 43 11 8 Conditions That Affect Weld Bead Shape NOTE KE 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 li ee S am 7 3 prag ELECTRODE ANGLE LI Een A EA ge Too Short Normal Too Long ARC LENGTH pam eee ete
30. 12 See See Note 2 Note 2 15A 240 V 3500W 15A Duplex Se See 3500W Note 2 240 V 15A Duplex CB3 4 3500W 230 V CB1 15A 15A 15A Single 3500W 3500W 3500W 230 V cB2 15A 15A 15A Single 3500W 3500W 3500W 230 V 15A Single CRE 3500W 230 V 15A Single CB3 4 3500W 120 V CB1 30A 30A Twist Lock 3500W 3500W 120 V CB1 2 30A Duplex CB1 3 3500W 120 V 20A Duplex CB 2400W 20A 20A 20A 120 V CB3 2400W 2400W 20A 2400W Duplex See See 2400W See Note 3 Note 3 Note 3 20A 20A 20A 120 V CB4 2400W 2400W 2400W Duplex See See See Note 3 Note 3 Note 3 Total Power NOT 3500W 3500W 3500W 3500W 3500W 3500W 3500W 3500W 3500W 3500W to exceed Notes 1 Each receptacle of the duplex can provide 15A 1800W Do not parallel the two 120V duplex receptacles 2 Do not parallel the two 120V circuits 3 Do not parallel the two duplex outlets Calculating total power provided by generator For example for the 495 218 Auxiliary Power Panel See Section 10 Auxiliary Power Guidelines 120V 1500W heater 1500W Each receptacle can provide the watts or amps as shown 120V 10A chain saw 1200W above However the total power can not exceed 3500W 120V 500W halogen lamp 500W The rating plate on electrical apparatus will contain the watts UEL ME De consumed or the rated input amps Watts may be calculated by multiplying the rated voltage by the rated input amps 120V 1500W heater 1500W 120V 10A chain saw 1200W watts volts x amps 120V 5A router 600W 120V
31. 4 in 793 mm be damaged or unit could tip 10 1 2 in 268 mm A Do not move or operate unit where it o 0 o could tip B C 13 45 64 in 348 mm D 22 3 4 in 577 mm E F G 1 3 4 in 44 mm 19 1 2 in 495 mm gt ij oo 13 32 in 10 mm Dia o o O Q o Weight Kohler Powered Units T 222 Ib 101 kg n 94 Weight Honda Powered Units M Je holes Ie F Electric Start Model 226 Ib 103 kg E Engine End 802 096 802 512 A Recoil Start Model 201 Ib 91 kg 3 3 Fuel Consumption Kohler Powered Units S a a a aL I L m m oi lt 69 E D e a 2 5 7 57 1 67 2 00 E Fuel consumption at low idle 6 81 1 50 1 80 2000 rpm 0 17 U S gal hr 6 06 1 33 1 60 5 30 1 17 1 40 4 54 1 00 1 20 3 79 0 83 1 00 gt 3 03 0 67 0 80 FP AUX POWER 2 27 0 50 0 60 1 51 0 33 0 40 WELD 0 76 0 17 0 20 HIGH IDLE 0 00 0 00 ooo l it tt pt tr tt 0 25 50 75 100 125 150 175 200 DC WELD AMPERES AT 10026 DUTY CYCLE T T T T T 1 0 1 2 3 4 5 6 POWER KVA AT 100 DUTY CYCLE 198 573 OM 498 Page 10 3 4 Fuel Consumption Honda Powered Units tr T E MEE 3 7 57 1 67 6 81 1 50 6 06 1 33 5 30 1 17 4 54 1 00 3 79 0 83 3 03 0 67 2 27 0 50 1 51 0 33 0 76 0 17 0 00 0 00 U S GAL HR 2 00 1 80 1 60 1 40 1 20 1 00 0 80
32. 500W halogen lamp 500W Total 3800W This loading is not OK It exceeds 3500W OM 498 Page 22 6 4 Wiring Instructions For Optional 120 240 Volt Twistlock Plug NEMA L14 30P SSC 1 Plug Wired For 120 240 V 3 Wire Load When wired for 120 V loads each du plex receptacle shares a load with one half of the 240 V receptacle 2 Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Cord Grip Strip cord jacket back enough to sep arate conductors on P Oo Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not overtighten Tools Needed plug3 11 99 802 527 Notes OM 498 Page 23 SECTION 7 MAINTENANCE Routine Maintenance 7 1 259 1 4 e A Stop engine before maintaining Recycle See Engine Manual and Maintenance Label Service more often if used in severe conditions ws engine fluids To be done by Factory Authorized Service Agent 8h 20h Check fluid levels See Section 4 4 or 4 5 qu Wipe up spills Check and clean spark arrestor screen See engine manual a Ong O 50h Service air cleaner Clean and element See engine tighten weld A ma
33. 99 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 OF 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 Miller shall honor warranty claims on warranted equipment listed below i
34. DUTY MOTORS 1 8 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 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 498 Page 36 10 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 in 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 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 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 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifug
35. Power Panel 196 921 CSA Tos CBT CB2 495 245 Circuit Breaker 15 ica celts dene aeri p el E ira 2 oder TACT AS 407 749 Receptacle Twistlock 240V U S 1 9 RC2 RC3 408898 Receptacle Duplex 115V 20A U S 2 Macs ux cet a etae vios 196 909 Label 120 240V Aux Power Panel 1 MENS OR ree ree a 196 911 Panel 120 240V Aux Power 1 6 CB3 CB4 495246 Circuit Breaker 20A 2 m FTIIT 188 039 Cover Receptacle W Gasket 1 Auxiliary Power Panel 495 315 a SE 495 314 Panel auxiliary power assembly 1 9 CB1 CB2 495245 Circuit Breaker 15A 2 10 CB3 CB4 495 246 Circuit Breaker 20A 2 Auxiliary Power Panel 495 218 ex NAN este de mes 495 220 Panel auxiliary power assembly 1 ve VO iube Ld ei es 495 216 Overlay i sieut ete EE 1 2139522 GBT 2 495 183 Circuit Breaker 30A 1 14 CB2 CB3 495 246 Circuit Breaker 20A 2 Auxiliary Power Panel 495 279 Canada SAS cactus sot 495 284 Panel auxiliary power assembly
36. ROVIDED 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 IS 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 may be available but may vary from province to province hobart retail 4 00
37. UXILIARY PANEL 495298 2 120V DX 240V TWLK AUXILIARY PANEL 495278 120V DX 240V TWLK CSA A B C D E F A B C D E E TOO O 1T CNN O a al A Q O o oO E S gd 51 o EU B Fe ME ME MF nr 116 ces RC2 e i L e zl 3 bei LE n ke B a Ed o DN O4 RU 5 oi Sat w B SCH D A RC1 S CB2 e HO To 3 5 ai AE D 9 G s EA RC3 gj CB1 3 te Ho 54070 S e 2 ka od g NO unk ka E g 2 CB 51A CB1 CB2 55A CB2 55A CB1 J G J AUXILIARY PANEL 495218 2 120V DX 120V TWLK AUXILIARY PANEL 495279 120V DX 120V TWLK CSA Figure 9 3 Wiring Diagram For Auxiliary Power Panels 1 Of 2 OM 498 Page 32 201 026 WARNING Do not touch live electrical parts 9 ei e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC SHOCK HAZARD Have only qualified persons install use or service this unit 56 AUXILIARY PANEL 495288 2 240V DX S AMERICA
38. 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 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away pa 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 e 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 e 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 Disconnect input power or stop engine before installing or Se
39. al Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 in 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 498 Page 37 10 8 Power Required To Start Motor A A MOTOR 1 Motor Start Code 2 2 Running Amperage 1 ON VOLTS 230 AMPS 25477 ae el 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 KVA HP 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 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 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 10 54 Staring th t ires 12 2 7 290 5 l arting the motor requires 12 2 amperes onis 10 9 How Much Power Can Generator Supply 1 LimitLoad To 90 Of Generator Output Always
40. anel 495 289 Auxiliary Power Panel 495 290 Auxiliary Power Panel 495 283 Australia Europe S E Asia A If unit does not have GFCI recep tacles use GFCl protected exten sion cord A Power may still be present at a re ceptacle when a circuit breaker trips Unplug power cord before attempt ing to service accessories or tools x Auxiliary power decreases as weld current increases Set Amperage control at max for full auxiliary power Place throttle lever in Run position far right for auxiliary power Ref ST 802 124 H 495 290 H 495 283 Circuit breakers protect the generator from overload EF Press button to reset circuit breaker If breaker continues to open contact Factory Authorized Service Agent OM 498 Page 21 6 3 Auxiliary Power Panel Ratings AE NOTE Es Unless otherwise stated the rating of duplex outlets is the combined load of all receptacles Total power from generator NOT to exceed 3500 Watts 60 Hz Panel Panel Panel Panel Panel Panel Panel Panel Panel Panel Receptacle Projected 196921 495315 495218 196914 Canada 405253 South 405289 495290 495283 y CSA USA USA USA CSA S Africa America Australia Europe S E Asia 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 15A 15A 240 V 3500W 3500W Twist Lock cB
41. ants 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 DES PARTICULES VOLANTES f p peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce ala brosse en fil de fer et le meulage g n 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 e Porter des lunettes de s curit avec crans lat raux ou un cran facial 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 e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e 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
42. aust outside and away from any building air intakes 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 e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories e 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 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 e Sparks can cause fires keep flammables away N 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 i OVERUSE can cause OVERHEAT ING z a7 Nc A e Allow cooling period follow rated duty cycle Reduce current or
43. ay 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 possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 Signification des symboles 44 A dentifie un message de s curit particulier 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 1 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit A L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et
44. ctrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A OM 498 Page 17 5 2 Controls Honda Powered Units See Section 5 3 Recoil Start s 1 Electric Start WELDING RANGE CHART DIAMETER 1 16 3 32 1 8 5 32 E6010 50 80 75 130 110 MAX a E sO11 50 70 75 130 120 MAX E 6013 MIN 40 50 85 90 120 130 MAX O E 7014 70 90 120 MAX o E 7018 75 100 90 MAX 115 MAX E 308L 16 35 80 55 115 85 MAX 494976 802 099 A 802 100 A 953T 5 4 OM 498 Page 18 5 3 Description Of Controls Honda Powered Units See Section 5 2 TW d SUN A FF Weld and auxiliary power output stops if generator overheats or engine speed is too low 1 Engine Switch On models with recoil start use switch to open ignition circuit and to stop engine On models with electric start use switch to open ignition circuit and to start and stop en gine 2 Throttle Control Lever Use lever to select engine speed Move lever to idle position far right for idle speed Move lever to Run position far left for weld power speed Always place lever in Run position far left for auxiliary power and for maximum weld output 3 Choke Control Lever Use lever to change engine air fuel mix Move lever to left if starting a cold engine Move le ver to right if starting a warm
45. d 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 11 12 Tee Joint 1 Electrode 2 Fillet Weld Keep arc short 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 11 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 498 Page 45 11 13 Weld Test a 2To3 51 76 fh ke wo 2103 id b 61 76 mm c 1 4 in 4 2 6 4 mm Del UR 1 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not break S 0057 B 11 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 bef
46. e Speed Adjustment 3 Pilot Screw 4 Throttle Stop Screw Move lever to idle far right posi tion Turn pilot screw until engine runs at highest idle speed Turn stop screw until engine runs at rated idle speed normally about 2 1 4 turns out A Stop engine Close fuel valve Tools Needed gt E 2 1 4 3 8 in 802 101 A OM 498 Page 27 SECTION 8 TROUBLESHOOTING 8 1 Troubleshooting A Welding Trouble Remedy No weld output Check Amperage control setting Check weld connections Be sure all equipment is disconnected from receptacles when starting unit Have Factory Authorized Service Agent check brushes slip rings rotor stator reactor L2 output rectifier CR3 stabilizer L3 integrated rectifiers CR1 and CR2 and amperage control R1 Low weld output Check Amperage control and throttle lever settings Check engine speed and adjust if necessary see Section 7 4 or 7 5 Service air cleaner according to engine manual Check weld cable size and length Have Factory Authorized Service Agent check brushes slip rings capacitor C1 reactor L2 and recti fier CR2 High weld output Check Amperage control setting Check engine speed and adjust if necessary see Section 7 4 or 7 5 Erratic weld output Check Amperage control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes f
47. e exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work 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 e 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 498 Page 1 FRA WELDING can cause fire or explo LA sion 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
48. ed Units After tuning engine check engine ER Cy speeds See table for proper no load speeds If necessary adjust speeds as follows lt gt 2000 150 rpm Start engine and run until warm Weld Power Speed 3720 50 rpm 60 Hz Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far right posi tion To increase speed turn screw out counterclockwise while lightly pushing lever to the right To de crease speed turn screw in clock gt wise Idle Speed Adjustment 3 Adjustment Screw Move lever to idle far left position To increase idle speed turn screw in clockwise To decrease idle Speed turn screw out counter clockwise Stop engine Close fuel valve Top View Top View S E un Sa TIT E Lg P RIM ren Ces Tools Needed eu 802 512 A Kohler Dwg OM 498 Page 26 7 5 Adjusting Engine Speed Honda Powered Units After tuning engine check engine ERO Cy speeds See table for proper no Ca load speeds If necessary adjust speeds as follows lt gt 1400 150 rpm Start engine and run until warm Weld Power Speed 3720 50 rpm 60 Hz Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far left position Turn screw and move lever until en gine runs at weld power speed Idl
49. erican Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 6 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 To reduce magnetic fields in the workplace use the following procedures OM 498 Page 4
50. erie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie 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 hicules 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 L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau LES GAZ D CHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels e Utiliser l quipement l ext rieur dans des zones ou vertes et bien ventil es e En cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distance des entr es d air dans les b ti ments LA CHALEUR DU MOTEUR peut pro voquer un incendie e 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 1 4 Dangers suppl mentaires en relation avec
51. 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 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 498 Page 40 SECTION 11 STICK WELDING SMAW GUIDELINES PY ae E 11 1 Stick Welding Procedure A Weld current starts when electrode touches work piece A 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 11 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
52. ge dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 498 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque do
53. 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 Tools Needed Lm stick 12 96 ST 151 593 OM 498 Page 41 11 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 100 150 200 250 300 350 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 d y ALL LOW CAST IRON 308L d 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 11 4 Striking an Arc Tapping Technique n Il Il LI L Z p a
54. i cal shocks slag open flames sparks and arcs e 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 e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards STEAM AND HOT COOLANT can burn e f 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 unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no overflow tank follow the next two statements e 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 d MOVING PARTS can cause injury e Keep away from fan
55. iary Power Panels 21 6 3 Auxiliary Power Panel Ratings 22 6 4 Wiring Instructions For Optional 120 240 Volt Twistlock Plug NEMA L14 30P 23 SECTION 7 MAINTENANCE sseseee n ka won n anka she hene 24 7 1 Routine Maintenance 24 7 2 Maintenance Label irai RIS ARE Aes BR eed REED Xon e Aen e E 25 7 3 Overload Protection Honda Powered Units Only 25 7 4 Adjusting Engine Speed Kohler Powered Units 26 7 5 Adjusting Engine Speed Honda Powered Units 27 SECTION 8 TROUBLESHOOTING lt L Lt tt tt n nn nn nn n knn n n hf n nnn 28 SECTION 9 ELECTRICAL DIAGRAMS 30 SECTION 10 AUXILIARY POWER GUIDELINES 34 SECTION 11 STICK WELDING SMAW GUIDELINES 41 SECTION 12 PARTS LIST is A A ea mE dm Du 50 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 44 A 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 A The symbols shown below are used throughout this manual to call attention to and identify possible hazards
56. ivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Symbol Definitions o Engine Choke a ee an A Amperes V Volts SETA Engine Oil Fuel Battery Engine DA Engine Positive Negative NU jour a gt Output h Hours S Seconds e Time D MOI UT Wo Circuit Breaker Temperature SECTION 3 SPECIFICATIONS NOTE gt This unit uses either a Kohler or a Honda engine Differences between models are noted throughout this manual 3 1 Weld Power And Engine Specifications l Weld Maximum se Welding Rated EUR Auxiliary Fuel A Mode anos Welding Output SE Oe Power Rating Capacity Engine Kohler CS8 5TG Air Cooled One Cylinder 140 A 25 V Kohler Four Cycle 30 Duty Cycle Single Phase 1 8 gal 6 9 L 8 5 HP 300 CC 100 A 25 V 3 5 KVA KW Tank Gasoline Engine CC DC 40 140 A 60 Duty Cycle 70 30 15 A OR atu nd 120 240 V AC Honda Honda GX270 80 A 25 V 60 Hz 1 6 gal 6 L Air Cooled 10095 Duty Cycle Tank One Cylinder Four Cycle 9 HP 270 CC Gasoline Engine OM 498 Page 9 3 2 Dimensions Weights And Operating Angles Dimensions Ex Height 20 3 4 in 527 mm Width 22 3 4 in 577 mm 2 A SR SE A Do not exceed tilt angles or engine could A 31 1
57. 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 e Utiliser un quipement de levage de capacit suffi sante pour lever l appareil 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 N gt LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux 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 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e 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 L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT marche nominal e R duire le couran
58. le 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 1 5 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Weld ing Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 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 e 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 c bles de souda ge aussi courts q
59. ller 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 HOBART 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 costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES P
60. ls 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 after stopping engine on inverters e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 Weara 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 from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection 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 e f inside ventilate the area and or us
61. n is already present in welding generator auxiliary power output circuit 240 V 120 240 Volt Y 60 Hz i z V Three Wire Service A A E 2 3 z 240 V i JO Y 120V Load lt A 7 i 120 V SY A QO 7 CB iu s or N F1 6 240 V ecce 120 240 Volt Y 120V Single Phase A Three Wire 120 V Generator Output A Connection Ground i S 0405 A OM 498 Page 39 10 11 Selecting Extension Cord Use Shortest Cord Possible A Cord Lengths for 120 Volt Loads A 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 A funit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in
62. n 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 3 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 HF 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 tips or parts that fail due to normal wear 2 Items furnished by Hobart Mi
63. nual terminals il 2 100 h Change oil See Check engine manual and spark maintenance label plugs Clean Fuel sediment cup Clean and tighten battery connections Electric Start models only 200 h Clean fuel Replace tank and unreadable strainer labels Check valve clearance 500 h 2 Service welding generator ee ads d O A brushes and slip rings Service cables d YN G more often in dirty conditions 1000 h Blow out or La vacuum inside d During heavy y OR service clean monthly OM 498 Page 24 NOTE tes Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period 7 2 Maintenance Label ENGINE MAINTENANCE Ty Unleaded 86 Octane 6 5 1 1 7 US Gal 11 4 Imp pt 0 7 0 8 mm 0 028 0 031 in Ref S 175 679 A SN 1 Ignition Circuit Breaker Electric Start Models Only The circuit breaker protects the en gine battery charging circuit A short circuit or a battery connected in reverse polarity will trip the circuit breaker Press button to reset breaker x If a switch or breaker opens it usually indicates a more seri ous problem exists Contact a Factory Authorized Service Agent Ref 802 099 A OM 498 Page 25 7 4 Adjusting Engine Speed Kohler Power
64. o 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 watis 1 Resistive Load A light bulb is a resistive load and requires a constant amount of pow er 2 Non Resistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment S 0623 OM 498 Page 35 10 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 1 HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 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 10 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De lcer 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 2HP 10500 2800 FARM
65. oad If CB1 or CB2 opens RC1 does not work 120 volts may still be present at RC1 5 Circuit Breakers CB3 And CB4 CB3 protects RC2 and CB4 protects RC3 from overload If a circuit breaker opens the receptacle does not work E Press button to reset circuit breaker If breaker continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 3 5 KVA KW rating of the generator See Section 10 Auxiliary Power Guidelines EXAMPLE If 5 A is drawn from each 120 receptacle only 9 A is available from the 240 V receptacle 2 x 120 Vx 5 A 240 V x 9 A 2 3 5 KVA KW OM 498 Page 20 6 2 Optional Auxiliary Power Panels o aa A taw AN PEN cas e e PEN taw A m cue O wi wi ou o o 2 AN M ai gj en 30 amp e DE e e e o me mO m0 l L L o o 7 7 Auxiliary Power Panel 495 315 Auxiliary Power Panel 495 218 Auxiliary Power Panel 196 914 USA USA USA 9 e e 25 A ey k mo mo Auxiliary Power Panel 495 279 Auxiliary Power Panel 495 253 Auxiliary Power Panel 495 288 Canada South Africa South America a SEM d d A T e A E D D MA AE D se go Auxiliary Power P
66. or Stick 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 7 4 or 7 5 Check throttle governor linkage for smooth non binding operation B Auxiliary Power Trouble Remedy No output at auxiliary power Reset circuit breakers see Section 6 1 receptacles Check receptacle wiring and connections Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Have Factory Authorized Service Agent check stator windings High power output Check engine speed and adjust if necessary see Section 7 4 or 7 5 Low power output Check Amperage control setting Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Move throttle lever to Run far right position see Section 5 1 or 5 2 Erratic power output Check fuel level Check receptacle wiring and connections Check throttle governor linkage for smooth non binding operation Service air cleaner according to engine manual Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low OM 498 Page 28 C Engine Trouble Remedy Engine will not crank Honda electric start models only Reset ignition circuit breaker see Sec
67. or provides power while welding and with the Current 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 6 1 Auxiliary Power Panel 196 921 CSA NEUTRAL Ne P BONDED w TO FRAME l ou NEUTRE O K RACCORD z AU BATI O A lf unit does not have GFCI recep tacles use GFCI protected exten sion cord A Power is still present at the 240 volt receptacle when only one circuit breaker trips Unplug power cord before attempt ing to service accessories or tools x Auxiliary power decreases as weld current increases Set Amperage control at max for full auxiliary power Place throttle lever in Run position far right for auxiliary power 1 240 V AC Twistlock Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 3 5 kVA kW 2 120 V 20A AC Duplex Receptacle RC2 3 120 V 20 A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 KVA kW Each receptacle of the duplex can pro vide 15A 1800W CS Do not parallel the two 120V duplex receptacles 4 Circuit Breakers CB1 and CB2 196 921 CB1 and CB2 protect RC1 from overl
68. ore welding 11 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 or voltage too high Reduce arc length or voltage OM 498 Page 46 11 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead y AN 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 11 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
69. oudage muni d un cran de filtre appropri pour pro 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 e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds 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 e Eloigner votre t te des fum es Ne pas respirer les fum es e 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 e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage pe
70. q euiBuo dois Jo Jamod 1ndui pouuoosiq e NEL I e sued e911199 9 3A1 Yonoj JOU O ped e2uioeje anj Yona jou od e 9NINHVM Y e so CIONTIOS AYILAVIS 3NION3 Atiauiva LIOA ZL 3AUISOd 3AUV93N AINO NOlLdO 3NIHOVW VSO I l l l l emmer Ou FO z AYOM 3AILISOd R l Lod I l ONS T o Com O Q3 Sg d ee d ki IN m la E E 3 A 8 O o 001 y Wa i s a J T S 1 E d T ov zuo e C 7 7 at Le ci D gos gt H KZ 11 x ht J N t r 1 L ak O e GES po ICON ILL E L 4 zx KE L 4 vd mm Ww LL L Dated X Gr L EA O4 198 014 C OM 498 Page 31 Figure 9 2 Wiring Diagram For Welding Generator
71. reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards 3 e Puton grounded wrist strap BEFORE handling ASS boards or parts Eo e Use proper static proof bags and boxes to store move or ship PC boards IN TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer Be READ INSTRUCTIONS e Use only genuine MILLER replacement parts e Perform engine maintenance and service according to this manual and the engine manual OM 498 Page 3 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 familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion 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 1 5 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from Am
72. rminal block 1 EAD ka EZ ats 495 202 REACTOR weld assembly 1 95 R2 VR1 046 819 SUPPRESSOR assembly 1 36 CR3 495 188 RECTIFIER assembly 1 SL oe ee renee 201 223 LABEL warning electric shock power still present 1 SOOO au aua as 494 976 LABEL current selection 1 cp 495 112 LEAD battery neg electric start 1 wr BATTERY 12V electric start 1 noi T 494 604 BOLT hold down electric start 1 E EE 493 057 CLAMP battery electric start 1 rd gea eMe Eb 495 111 LEAD battery pos electric start 1 244 1 ee EE 494 039 COVER battery cable electric start 1 When ordering a part displaying a precautionary label order label also 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 Recommended Spare Parts OM 498 Page 51 o w Lj e BR o Ja gt O si
73. rvicing 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 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 cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual rom nd 11 98 AEN 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 Wear a safety harness if working above floor level Keep all pane
74. s belts and rotors a e Keep all 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 e 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 e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while working on generator components 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 Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last 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 EXHAUST GASES can kill e Use equipment outside in open well ventilated areas e If used in a closed area vent engine exh
75. s even under your welding helmet 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 ap proved air supplied respirator 1 3 Engine Hazards li y FUEL can cause fire or explosion die Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames e Do not overfill tank allow room for fuel to expand e Do not spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container OM 498 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine e Do not touch hot engine parts or just 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 pacemak ers 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 e Protect compressed gas cylinders from excessive heat mechan
76. 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 498 Page 38 10 10 Typical Connections To Supply Standby Power A CL A Fx Customersupplied equipment is required if generator is to supply standby power during emergencies or power outages 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double Pole Double Throw Transfer Switch Obtain and install correct switch Switch rating must be same as or greater than the branch overcurrent protection 4 Circuit Breakers or Fused Disconnect Switch Obtain and install correct switch 5 Extension Cord Select as shown in Section 10 11 6 Generator Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices 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 volt age and frequency 7 Load Connections Sy Item 4 is not necessary if circuit protectio
77. symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS LECTRIQUES aux PI CES EN MOUVEMENT et aux PI CES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixerle c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apres avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants 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 e Porter un casque de s
78. t ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste L N T e Laisser l quipement refroidir respecter le facteur de LU LES CHARGES ELECTROSTATIQUES peuvent endommager les circuits imprim s 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 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 LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effecteur la maintenance et la mise en service d apr s le manuel et celui du moteur OM 498 Page 7 LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence HEI 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 utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signa
79. tion 7 3 Check battery voltage Check battery connections and tighten if necessary Have Factory Authorized Service Agent check engine ignition circuit Engine will not start Check fuel level see Section 4 4 or 4 5 Open fuel valve see Section 4 4 or 4 5 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check battery voltage Honda electric start models only Check battery connections and tighten if necessary Honda electric start models only Check oil level see Section 4 4 or 4 5 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil level shutdown switch Engine stopped during normal operation Check fuel level see Section 4 4 or 4 5 Open fuel valve see Section 4 4 or 4 5 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check oil level see Section 4 4 or 4 5 Engine stops if oil level is too low Battery discharges between uses elec tric start models only 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 Unstable or sluggish engine speeds Check engine speed
80. 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 498 Page 48 Notes OM 498 Page 49 SECTION 12 PARTS LIST Figure 12 1 Main Assembly OM 498 Page 50 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Ede nto odes oe 495 247 TOP control box specify color 1 Rue ld iras ie eid 495 096 LABEL precautionary 1 3 CR1 CR2 200 759 RECTIFIER SIICON onte rt A ER URS 2 SEE Cena des sese GAN 134 201 STAND OFF support 4 Dan idee 495 236 BASE control HOX s sez een en UE aca cat e 1 6 ES tin 495 200 REACTOR stabilizing 1 e diesen acer wacked 204 140 LABEL moving parts 1 E oed adoret ores 493 509 BRUSHHOLDER assembly 1 E TJ 204 138 LABEL warning fuel also supplied with engine 1 altes se ius 195 557 ENGINE gas Kohler 8 5HP recoil start 1 eke iik gati i is 203 952
81. tre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon N DES ORGANES MOBILES peuvent provoquer des blessures a e 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 Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d entretien et de d pannage Pour emp cher tout d marrage accidentel pendant les travaux d entre tien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des or ganes mobiles 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 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 rateur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batt
82. ue possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passa
83. unding Generator To Truck Or Trailer Frame EZ A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding 3 Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire A lf unit does not have GFCI receptacles use GFCI protected extension cord Electrically bond generator frame to vehicle frame by metal to metal contact install 1 97 Ref 151 556 S 0854 OM 498 Page 13 4 3 Grounding Generator When Supplying Building Systems 1 2 1 Equipment Grounding GND PE Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device A Ground generator to sys tem earth ground if supply ing power to a premises Use ground device as home shop farm wiring stated in electrical codes Q system 800 576 B 4 4 Engine Prestart Checks Kohler Powered Units EF Follow run in procedure in en gine manual LA CL Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil 1 2 in 13 mm Engine stops if oil level gets too low EF This unit has a low oil level shut down switch However some conditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil level shutdown
84. uvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvani 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 respirateur 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 498 Page 5 LE SOUDAGE peut provoquer un in NEAR cendie ou une explosion 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
85. wWer Q IVe e vost VE Saree di Pe BA ER SIN aH de ERU AN Anal 12 3 7 Volt Ampere Curves 12 SECTION 4 INSTALLATION cece e g v II um A E EIE dE 13 4 1 Installing Welding Generator 13 4 2 Grounding Generator To Truck Or Trailer Frame 13 4 3 Grounding Generator When Supplying Building Systems 14 4 4 Engine Prestart Checks Kohler Powered Units 14 4 5 Engine Prestart Checks Honda Powered Units 15 4 6 Connecting The Battery Honda Electric Start Models Only 15 4 7 Connecting To Weld Output Terminals 16 4 8 Selecting Weld Cable Sizes 16 SECTION 5 OPERATING THE WELDING GENERATOR 17 5 1 Controls Kohler Powered Units 17 5 2 Controls Honda Powered Units See Section 5 3 18 5 8 Description Of Controls Honda Powered Units See Section 5 2 19 SECTION 6 OPERATING AUXILIARY EQUIPMENT 20 6 1 Auxiliary Power Panel 196 921 CSA 20 6 2 Optional Auxil
86. y power and for maxi mum weld output 3 Choke Control Lever WELDING RANGE CHART SCH DIAMETER 1 16 3 32 1 8 5 32 E6010 50 80 75 130 110 MAX a E sO1 50 70 75 130 120 MAX E 6015 MIN 40 50 85 90 120 130 MAX O E 7014 70 90 120 MAX o E 7018 75 100 90 MAX 115 MAX E 308L 16 35 80 55 115 85 MAX 494976 Use lever to change engine air fuel mix Move lever to left if starting a cold engine Move le ver to right if starting a warm engine 4 Starter Handle To Start open fuel valve see Section 4 4 turn engine switch to On move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Label Use label to determine correct weld amper age based on electrode size type and mate rial thickness 802 512 A 495 179 6 Current Control Use control to select weld amperage Control may be adjusted while welding To Set Current Control Use label to deter mine correct size electrode for material thick ness Select electrode type and set current control to corresponding amperage range Adjust control to obtain desired weld performance EXAMPLE Material Thickness 1 8 to 1 4 in Ele

Engine Driven Welding Generator

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