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10 - Hobart Welders

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1. 1 dB a Te thay aie EU UNE 097924 KNOB Control 1 494754 SWITCH ignition 1 1 176365 METER hour 1 Ec 494774 1 LABEL identification 22 1 iO sante JO iR 408902 RECEPTACLE 230 1 tie RES 403091 3 PLUG hole plastic 1 403091 9 PLUG hole plastic 1 Dunes 494613 TERMINAL 1 2 80 1 2213 HWH ST cc one sue tA Perte da 2 zd ox J1 J4 494755 RECEPTACLE duplex 20 2 12 65 1 495098 SWITCH circuit breaker 20 4 12 s CB1 CB4 495097 SWITCH circuit breaker 15A CSA 4 13 CB5 CB6 409527 2 SWITCH circuit breaker 35A 2 494898 100W 10 1 494914 NAMEPLATE overlay 1 494925 ROD 1 ppm 14
2. 1 494916 BASE mounting 1 L3 2s 494758 REACTOR filter cocer sse sce meta ER RR uae 1 E 25 ri 183 605 REACTOR 1 EC 494773 YOKE lifting assembly 1 N 493915 2 TANK f l e tete eoe Ree aeta 1 Putas 493965 1 CAP fuel gage 1 494795 GROMMET fuel tank 1 vin QO 494791 COVER fuel tank ens 1 494794 GUARD 2 bt E 494919 SUPPORT engine 1 PETIT 494920 SUPPORT generator 1 res 494932 FOOT mounting 1 Le so talon 184278 RESISTOR 225W 4 25 ohm 1 26 402037 13 GROMMET rubber 1 494924 TRANSFORMER current sensing 1 January 23 1998 8 5 Hobart Brothers Company PARTS LIST Troy Ohio 45373 Figure 8 3 Generator Group 8 6 January 23
3. Open circuit weld and power voltage low frequency low Engine speed too slow Adjust for 3720 Rpm or 62 Hz at NO Load Open circuit voltage and frequency high Engine speed too fast Adjust for 3720 Rpm or 62 Hz at NO Load No Fine Control of weld amperes in CC or volts in CV Engine will not go to slow idle Ignition on off switch not set correctly Set correctly Load on weld terminals or receptacles Remove load Defective diode on welding rectifier Replace defective diode CR2 Defective idle solenoid K2 Replace defective solenoid Engine stays in low idle when load is applied Loose connection from T1 to control PC Repair connection board Defective idle sensing transformer T1 transformer Engine will not crank Loose connection to battery or starter Repair connection Dead battery Charge and or replace battery Engine will not start or run Out of gas Fill tank as necessary Low Oil Check oil maintain level between ADD and FULL on dip stick Do not overfill 1 Oil overfull See low oil Loose connection on engine wiring Repair connection Defective engine component See authorized engine repair shop 7 2 October 6 1997 Hobart Brothers Company Troy Ohio 4537
4. de l air et ainsi causer Le soudage d gage des vapeurs et des fum es des malaises ou la mort Assurez vous que l air est propre la dangereuses respirer respiration 6 Nesoudez pas proximit d op rations de d graissage de net toyage ou de pulv risation La chaleur etles rayons de l arc peu vent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que sil espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au mo ment du soudage LES VAPEURS ET LES FUMEES SONT 1 Eloignez la t te des fum es pour viter de les respirer 2 A l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc 7 3 Silla ventilation est inadequate portez un respirateur adduc tion d air approuv 4 Lisez les fiches signal tiques etles consignes du fabricant rela tives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants 2 2 30 X 92 13 IV 88 R vis e Hobart Brothers Company PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Troy Ohio 45373 _ Instruction 910309 LE SOUDAGE PEUT CAUSER UN IN 4 M fiez vous des projections br
5. 059926 PIN SPrillg Dula era a eTa SERA ENN 1 aO sms 494778 BRACKET Mounting nier e See ec ae vee ee tee sa ie 1 ses 057084 BUSHING open closed 1 cune 494001 TUBE fuel assembly 1 Bea beet Ref HOSE fuel line rubber 1 4ID 2 ee 40897541 CLAMP hose VCI ent 4 D PE Ref FILTER fuel 22 Micron Onan 149 2206 01 or equivalent 1 Ref FILTER oil engine Onan 122 0645 Ref 8 7 January 23 1998 Hobart Brothers Company PARTS LIST Troy Ohio 45373 This page intentionally left blank 8 8 January 23 1998 Hobart Brothers Company Troy Ohio 45373 DIAGRAMS DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in the model and specification number columns below e Use only those diagrams and instructions that are applicable MODEL SPECIFICATION CONNECTION SCHEMATIC NUMBER NUMBER DIAGRAM DIAGRAM 494929 494929 CHAMPION 16 ALL SPECS October 6 1997 Page 1 626064 m aout ns 140 13395 ve 57 96 92 80 AN ES see m
6. WELDING PRODUCTS OM 932 495 369B September 1999 Processes MIG GMAW Welding Flux Cored FCAW Welding EG Stick SMAW Welding TIG GTAW Welding Description 23 Engine Driven Welding Generator Champion 16 OWNER S MANUAL Hobart Brothers Company Troy Ohio 45373 TABLE OF CONTENTS A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm INTRODUCTION How To Use This Manual 1 1 Equipment Identification 1 1 Receipt Of Equipment 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 Controls and Power Outlets 8 2 Tabulated Data qe gos BAe 3 2 Maximum Auxiliary Welding Power Combinations 3 6 INSTALLATION 4 General Engine Driven Welder Installation 4 1 Portable Installation 4 1 OCANON ea SUR Le AS 4 1 Salety o ue ei aure euet desto 4 1 Indoor USE su Rer 4 1 Initial Preparation for Use 4 1 OPERATION 5 Prestart instructions ve ERR wee QR SUM ARR S e Mass 5 1
7. Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and un der pressure ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 910081 1 Stop engine before checking or adding fuel Do not add fuel while smoking or if unitis near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is fin ished and before starting engine Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Obse
8. Storage Nightly Before storing welding machine for short periods of time 1 Clean up around work area Put all tools parts and supplies in proper places 2 Disconnect welding leads from machine Coil them and stow away 3 If unit is to be stored outside cover it with a tar paulin Extensive Storage Time If unit is not to be used for 30 days or more drain the fuel tank carbu retor fuel pump and fuel lines Cover the unit with tarpaulin to protect it from dirt dust and excessive moisture See Storage Instructions in Engine Op 5 Manual Operation In Extremely Cold Weather See engine operation in the Operators Manual furnished forthe engine Tune engine to best possi ble condition for cold weather operation 5 4 Fuel System and Fuel Clean the carburetor gasoline lines fuel pump and make sure that no water collects in gas tanks or fuel lines due to con densation A small amount of dry gas or dena tured alcohol added to the fuel will aid in preventing this condition Overrich fuel mixture causes excessive carbon deposits dirty and wet spark plugs as well as crankcase dilution Strain the fuel when storing it to remove water Keep fuel tanks and drums as full as possible Con tainer must e free from dirt and rust Fuel must be allowed to settle in container before drawing it out for use in the engine Never draw fuel fuel from the extreme bottom of t
9. Hobart Brothers Company Troy Ohio 45373 _ PARTS LIST Item Dia Part No Mkgs No Description Quantity Figure 8 2 Frame Group Se 494918 TOP canopy is 1 hate Mean 495096 LABEL precautionary 1 wow 409158 LABEL danger lifting eye 1 T M 494745 1 LABEL identification 2 494744 1 LABEL Hobart 3 NN 494776 PANEL side e deme s 2 EARUM 406000 LABEL warning fuel 1 494775 PANEL eas ages 1 LET 494799 GROMMET lifting 1 OC 494790 TRAY battery 1 494168 1 CLAMP 1 Rose RE MUS Ref BATTERY 12VDC group 24 1 bue Padua las V de HIP 494083 1 CABLE battery positive 1 494084 1 CABLE battery negative 1 lah eR 493797 2 PROTECTOR battery terminal 2 V A W 9648 67 CABLE bonding
10. 1998 Hobart Brothers Company Troy Ohio 45373 PARTS LIST Part No No Description Quantity Figure 8 3 Generator Group 406001 LABEL moving parts 1 vari dre Ee eg 494878 GENERATOR with stator assembly 1 495072 ARMATURE assembly 1 160567 ADAPTER 1 TM P W 11097 7 SCREW 3 8 16 2 5 4 DE qr 494882 STUD 3 8 16 4 C AN ered hs 180556 BRUSHHOLDER assembly 1 Sip Meek hie 50MS 732 2 NUT 3 8 16 KEPS 6 4 183936 ENDBELL d ODER don rares AERA 1 il VE 183419 O RING 1 TOR eae eters 494012 GROMMET generator 1 PO Seek aces Ref ENGINE Onan p216 16HP Gas Onan 216 G 1 11000B Ref Las 494797 MUFFLER dual outlet to engine 1 Ug dU id RE 165810 SOLENOID K2 erre Ree eet ERR pad ERE 1
11. 6 1 9 m d ta SR 31 ROMANS at am st nN OTD NOUO3NNOO E H svo di TWNOUdO HIW GONTIOS 4401QHS 1304 TaNVd 10 e UNO or AP apo S Quo SAVY v IMT pes Cad fl UNI SL 74 2 TNO 2 13NVd o oz 30041530 61 Sot ar f SO1VU3N3O 12 ONIQTIM GIONTIOS ERU YSA Q r mS pe que v ovo 5 8 02 Otis on 1 1 GNNOYD 3AV3J Ava WUO1V1n93N QNIOUVHO TRE qx52145 sm bam 96 972 1 ay 30193138 HOIWS 4055 84405 8015534 cu M 622 WHO 9 8015638 cu 6 WHO HV3NII NON LViSO3HY 3NION3 id NOH iii3N n 3 0H2 331113 19 3 e ONITUM u019Y38 5071313 IOAIY 2 1 YOLVIS NOLLY1DOX3 2 0 SGM NOlVIS 53409 8 11 7204 uoivis TM v n NO1VH3N32 n QIONTIOS 3NION3 YOLO3NNOD 9n vse AogZ Sii TOV IOIe st 52 vai OV ASH 1 43038 nt AG
12. DO NOT ATTEMPT TO WELD WITHOUT FIRST READING AND UNDERSTAND ING THE SAFETY WARNINGS CHAPTER INCLUDED IN THIS MANUAL Operation As AC Power Generator 1 Start engine per section on Starting Engine NOTE The engine governor setting is fac tory set at approximately 3600 RPM CAUTION Warranty is void if the gover nor setting is altered 2 Power may be drawn from any of the recepta cles to operate lights or small hand tools 3 The 115 Volt Duplex Receptacles Item 10 in Description of Equipment supply full 8000 watt capacity Connection to the generator is by stan dard three prong plugs attached to proper sized three wire cables Each receptacle supplies a maxi mum of 20 amperes on 500252 1 units or a maxi mum of 15 amperes on 500252A 1 units up toa total of 70 amperes The 115 230 Volt Receptacle Item 7 in Descrip tion of Equipment can be used to supply two 115 volt circuits of 35 amperes maximum each on either side of neutral or one 230 volt 35 amperes maxi mum circuit for a maximum of 8000 watts generator output The matching plug for this 4 prong recepta cle is available as an optional accessory or can be found at most electrical supply stores CAUTION Improper use of receptacle by exceeding load ratings can damage the receptacles and or the generator Set Fine Control dial to 7 or higher to obtain rated auxiliary power Construction Site Use Of Portable Welding Gene
13. MATERIAL SAFETY DATA SHEET EAST PENN DIAGRAMS WELDER REGISTRATION CARD HOBART POWER PROTECTION WARRANTY Page 2 Hobart Brothers Company October 6 1997 Hobart Brothers Company Troy Ohio 45373 INTRODUCTION How To Use This Manual This Owners Manual usually applies to just the underlined specification or part numbers listed on the cover If none are underlined they are all cov ered by this manual To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concern ing certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial number usually ap pear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies are identified only by the specification or part number p
14. SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 7 Use fully insulated electrode holders Never dip holder in water ELECTRIC SHOCK CAN KILL e to cool it or lay it down on ground or the work surface Do not Touching live electrical parts can cause fatal touch holders connected to two welding machines at the same shocks or severe bums The electrode and work time or touch other people with the holder or electrode circuit is electrically live whenever the output is on B Dsnotuse Mon damaned ndersizsd or oonv solicad ca In semiautomatic or automatic wire welding the u or poorly Spi wire wire reel drive roll housing and ail metal bles parts touching the welding wire are electrically 9 Do not wrap cables around your body live Incorrectly installed or improperly grounded 10 Ground the workplace to a goos electrical earth ground equipment is a hazard 11 Do not touch electrode while in contact with the work ground 1 Do not touch live electrical parts circuit 2 Wear dry hole free insulating gloves and body protection 12 Use only well maintained equipment Repair or replace dam 3 Insulate yourself from work and ground using dry i
15. preferred Other Protective Clothing or Equipment acid resistant aprons boots and protective clothing Work Hygienic Practices Good personal hygiene and work practices are mandatory Stability Stable Condition to Avoid Contact with metal may release explosive EAST PENN manufacturing co inc e Material Safety Data Sheet BATTERY FLUID ACID 8 UN2796 Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental 9 S 1 202 483 7616 Hazardous Components Specific Chemical Identity Common Name s Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity 0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure Hg 13 Flash Point Method Used non flammable Extinguishing Media N A Special Fire Fighting Procedures Sulfuric acid will not burn but is capable of igniting finely combustible material on contact Combustibles may be smothered by dry chemical extinguishing media Unusual Fire and Exp i i F 0 R 2 hydrogen gas Incompatibility Materials to Avoid Strong alkali materials carbides chlor
16. 2 WARNING DO NOT ATTEMPT TO WELD WITHOUT FIRST READING AND UNDERSTAND ING THE SAFETY WARNINGS CHAPTER INCLUDED IN THIS MANUAL Operation As A Welder CV WARNING Serious personal in jury could result if you connect or disconnect welding leads while the engine is running as open circuit voltage is present at the terminals Always stop en gine to connect or disconnect cables 1 Connect the welding lead from the wire feeder to the electrode terminal on the Control Panel see Description of Equipment Connect the welding work lead with the clamp on the end to the Work Terminal on the Control Panel 2 Select correct welding polarity for type of wire being used a For straight polarity DCEN set output se lector switch on the control panel to the CV position b For reverse polarity DCEP set output se lector switch on the control panel to the position 3 Set the coarse control selector on the control panel to the CV position 4 Set the fine control on the control panel or op tional remote for correct voltage setting for type size and wire feed speed of wire being used NOTE AC welding output is not applicable in the CV welding mode NOTE See Table 4 1 for size of welding leads required for various welding currents 5 Start engine per section on Starting Engine October 6 1997 Hobart Brothers Company Troy Ohio 45373 OPERATION WARNING
17. 2 Enchainez verticalement les bouteilles un support ou un 8 Lisez et respectez les consignes relatives aux bouteilles de gaz cadre fixe pour les emp cher de tomber ou d tre renvers es comprim et aux quipements connexes ainsi que la publication 3 Eloignez les bouteilles de tout circuit lectrique ou de tout sou P 1 dela CGA identifi e dans la liste de documents ci dessous dage LES GAZ D ECHAPPEMENT DES 1 Utilisez l quipement l ext rieur dans des aires ouvertes et TEURS PEUVENT ETRE MORTELS bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les Les moteurs produisent des gaz d chappement no fum es d chappement doivent tre envoy es l ext rieur loin cifs des prises d air du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue LE CARBURANT PEUR CAUSER UN IN Sic estpossible laissez le moteur refroidir avant de faire le plein CENDIE OU UNE EXPLOSION de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein 30 X 92 2 3 13 1V 88 R vis e PR
18. any structure where exhaust fumes will become a hazard to persons or animals 1 Connect proper sized cable from Transfer Switch to 115 230 Volt Receptacle Item 7 2 Start engine per Prestart Instructions 3 Turn OFF all loads including those to be sup plied by the unit 4 Set transfer switch to stand by and gradually turn on desired loads DO NOT exceed generator capacity 5 Some loads may need to be temporarily re duced in order to start freezers or refrigerator mo tors The plug for connecting to the 115 230 volts re ceptacle can be wired to supply 230 volts 2 wire load or a 115 230 volts 3 wire load see Figure 5 1 5 3 Hobart Brothers Company OPERATION Troy Ohio 45373 WARNING ELECTRIC SHOCK CAN KILL IMPROPER CON NECTIONS CAN DAMAGE EQUIPMENT DO NOT TOUCH LIVE ELECTRICAL PARTS Wire the 115 230 volts plug as follows a Strip cord jacket back only far enough to separate conductors Strip conductors back only enough to make good contact with plug ter minals Refer to Figure 5 1 b Make load and ground connections to plug c Reinstall insulated cap When Utility Power 1 Restored 1 Gradually reduce the loads on the unit 2 Set the Transfer Switch to the Utility Power Normal position 3 Allow the unit to run for 5 10 minutes at no load to cool cylinder head 4 Stop engine 5 Return all premises back to normal utility power operation
19. can produce carbon dioxide CO and carbon monoxide CO Hazardous Polymerization will not occur Conditions to Avoid not applicable Page 1 of 2 MSDS Battery Wet Filled with Acid 8 0942794 PGIII 2 of 2 Route s of Entry Inhalation skin contact and ingestion Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosion of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN respiratory system eyes skin amp teeth Carcinogenicity N A Signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated by Exposure Pulmonary edema bronchitis emphysema dental errosion and traceobronchitis Emergency and First Aid Procedures Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention If swallowed give large volumes of water NOT induce vomiting obtain medical treatment Eyewash and shower stations should be made avai
20. or October 6 1997 by oil on the rings Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are revolved slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with com pressed air 4 Install new brush assembly 5 To fit new brushes to the slip rings lay a strip of No 00 sandpaper smooth side down on slip ring surface and draw the sandpaper in the direction of the slip ring At the same time lift the brush on the return stroke Continue until the brushes have same curvature as the slip rings Blow all carbon dust out of the machine End View Replace Damaged Brushes 1 4 in 6 4 mm Minimum Length 1 2 in 12 7 New Length Figure 6 1 Brush Assembly Hobart Brothers Company MAINTENANCE OF POWER SOURCE Troy Ohio 45373 This page intentionally left blank 6 2 October 6 1997 Hobart Brothers Company Troy Ohio 45373 _ TROUBLESHOOTING TROUBLESHOOTING Troubleshootin ide Generator No welding and auxiliary power receptacle voltage does not build up Check for load on terminals or power re Remove load ceptacles dis Check for loose connections Reconnect and or tighten Check for worn brushes Replace brushes as necess
21. or injure personnel 6 Check throttle linkage at idle solenoid for free movement of linkage If linkage does move freely at idle solenoid do not start engine 7 Engine is now ready to be started Refer to Starting Engine sections Starting Engine Cold Start 1 Pull out choke choke on 2 Place Ignition Idle On Off switch in START po sition CAUTION Do not hold the ignition switch in START position for more than 30 seconds as this can damage starter If engine does not start in 30 sec onds return switch to off and wait 1 minute before attempting another start 3 When engine has started release Ignition Idle On Off switch It will automatically return to the run position Fast Idle October 6 1997 4 Slowly push choke in If engine begins to stall pull choke out again and slowly pushin Repeat as necessary until engine is running smoothly with choke control all the way in 5 Allow engine to warm up for a few minutes bef ore applying any load on 115 230 volt receptacles or welding Starting Engine Warm or Hot Starts 1 Place ignition in START Engine should start immediately If it does not some use of the choke may bee needed to clear vapor in the carburetor While engine continues to crank pull choke out CAUTION Do not hold the ignition switch in START position for more than 30 seconds as this can damage starter If engine does not start in 30 sec o
22. or drape cables around the body About Pacemakers 4 Keep welding power source and cables as far away from body as practical 5 Connect work clamp to workpiece as close to the weld as possible The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJuene 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 Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJuene Rd Miami FL 33126 National Electric Code NFPA Standard 70 from National Fire Pro tection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way 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 Protec tion ANS Standard 787 1 from American National Standards In
23. part numbers Crankcase Watch for dirty and gritty oil condi tions and change oil more frequently October 6 1997 Hobart Brothers Company Troy Ohio 45373 OPERATION Cooling System Clean cooling fins and chaff screen regularly Operation In Salt Water Atmosphere Canopy Wash canopy regularly to remove salt film Repaint damaged places Covering To protect the engine and generator from salt water atmosphere keep the unit covered with a tarpaulin while not in operation Wipe salt wa October 6 1997 ter from the engine and from all terminals and con nections in the electrical system Oil all linkage Brushes Regularly inspect the generator brushes to make sure they are free in the holders Wipe dry all parts or use compressed air of not more than 25 psi 172 kPa pressure See Mainte nance chapter for brush care Battery Terminals Thoroughly clean the bat tery terminals and connection Coat terminals and connections with petroleum jelly to retard corrosion 5 5 Hobart Brothers Company OPERATION Troy Ohio 45373 This page intentionally left blank 5 6 October 6 1997 Hobart Brothers Company Troy Ohio 45373 MAINTENANCE OF POWER SOURCE MAINTENANCE Lubrication Engine For detailed instructions on engine lubrication see Engine Operators Manual Inspection And Cleaning Every Day Check for oil and fuel leaks Also check for loose electric
24. 0 Duty 100 100 100 Power Data RE 8000 230 35 gt tend 60 Hz 1 Ph Dimensions see Figure 3 2 Weights Net No Fuel 580 Ibs 75035 Full PMB 633 16 604 Ibs Engine Specifications 216 16 DISplACeMent sus 43 3 cu in 710 Speed with 3600 RPM October 6 1997 Hobart Brothers Company Troy Ohio 45373 DESCRIPTION Idle 2100 RPM NOTE Spark plug gap is 025 Do not Fuel capacity 8 gallons purchase plugs with 060 preset gap as Oil Capacity si 2 5 quarts adjusting these could cause plug damage Charging 20 amp regulated or poor spark A 19 5 in 496 mm max B 32 437 in 824 mm max C 16 5 in 420 mm D 29 5 in 750 mm E 45 5 in 1156 mm max 25 in 635 mm 28in 712mm 152 mm HOLE MTG ile PATTERN NOTE Mounting holes located and G dimensions Figure 3 2 Dimensions October 6 1997 3 3 Hobart Brothers Co
25. 02 483 7616 Hazardous Components Specific Chemical Identity Common Name s TLV OSHA PEL ACGIE Percent Lead CAS 7439921 0 05 mg m 0 15 mg m xa 43 70 Sulfuric Acid CAS 7664939 1 00 mg m 1 00 mg m 20 44 Antimony CAS 7440360 0 50 mg m 0 50 mg m 0 4 PHYSICAL CHEM Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity 0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg 13 Flash Point Method Used non flammable Flammable Limits hydrogen gas Extinguishing Media Class ABC extinguisher CO and or Halon LEL 4 UEL 74 Special Fire Fighting Procedures Cool exterior of battery if exposed to fire to prevent rupture The acid mist and vapors a fire Situation are corrosive Wear special respiratory protection SCBA and clothing Unusual Fire and Explosion Hazards Hydrogen gas which may explode if ignited is produced by this battery especially when charging Use adequate ventilation avoid open flames sparks other sources of ignition yg DATA Battery Case Stability Stable Condition to Avoid Cases decompose at 160 410 C 322 770 Incompatibility Materials to Avoid Strong oxidizing agents such as hot nitric acid etc Hazardous Decomposition of By Products Combustion
26. 2503 RECTIFIER assembly 1 E E 494895 PANEL mounting rectifier 1 494891 DIODE BOARD 1 Ve 494892 HOLDER fuse 1 184731 MODULE idle 1 es 046819 SUPPRESSOR assembly 1 ensi NO RN dnt n 494894 RECTIFIER 1 galt ur quitte dens 401937 11 BLOCK terminal 8 station 1 MEET 494915 CLAMP 2 1 EIS 405278 17 CAPACITOR re di RE RA eR e ARE 1 494845 HANDLE switch to switches 2 DO iu ut SRM TEES 494900 SWITCH range 1 19 494910 SWITCH selector 1 BO PEDEM EET 494938 1 FUSE abc 25A 125 2 494646 KIT accessory Weld 1 a 8 3 January 23 1998 Hobart Brothers Company PARTS LIST Troy Ohio 45373 FOR DETAILS SEE FIG 8 3 Figure 8 2 Frame Group 8 4 January 23 1998
27. 3 PARTS LIST Equipment Identification All identification numbers as described in the Intro duction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to indicate any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into January 23 1998 PARTS LIST assemblies subassemblies and detail parts parts of the equipment are listed except for com mercially available hardware bulk items such as hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to another part The part descriptions may be indented to show part rela tionships To determine the part number description or quantity simply locate the item in question from the illustration and refer to that item number in the corre sponding Parts List 8 1 Hobart Brothers Company PARTS LIST Troy Ohio 45373 Figure 8 1 Control Panel Group 8 2 January 23 1998 Hobart Brothers Company Toy Ohio A53 ARS Item Dia Part No Mkgs No Description Quantity Figure 8 1 Control Panel Group Te Ap EET 494917 PANEL control
28. ECAUTIONS SECURITE EN SOUDAGE Instruction 910309 Hobart Brothers Company Troy Ohio 45373 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les pro tecteurs soient bien ferm s 2 Avantd installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER UN ACCUMULATEUR L ELEC TROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression pour charger un accumulateur ou survolter momen tan ment un v hicule 3 Seules des personnes qualifi es doivent d monter des pro tecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mouve ment elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez le
29. FIRE AND Flash Point Method Used N A Flammable Limits N A LEL N A UEL N A Extinguishing Media Dry chemical carbon dioxide water spray or foam Special Fire Fighting Procedures N A Unusual Pire and Explosion Hazards N A Stability Stable Conditions to Avoid N A Incompatibility Material to Avoid N A Hazardous Decomposition of By Products N A Hazardous Polymerization will not occur Page 1 of 2 MSDS Battery Electric Storage Dry page 2 of 2 Route s of Entry No applicable under normal use Health Hazards acute and chronic Internal components contain lead Repeated or prolonged exposure to lead can result in lead poisoning Lead accumulates in the bone and body organs and is eliminated from the body slowly Ref 29 CFR 1910 1025 Carcinogenicity N A IARC Monographs Group 2B carcinogen Regulated 29CFR1910 1025 Medical Conditions Generally Aggravated by Exposure Pregnant women and children must be protected from lead exposure Signs and Symptoms of Exposure Short term Skin and eye irritation headache nausea vomiting abdominal spasms fatigue weight loss anemia pain in legs arms and joints i Long term CNS damage kidney disfunctions and potential reproductive hazard Symptoms of lead exposure can be confirmed by the presence of elevated levels of lead in blood Emergency and First Aid Procedures Not applicable under normal use If lead exposur
30. LI 08 3dAL 350 a SZ ISNA 9 30010 32 30 3101 5 INIYYNI m ONOTM 104100 53131938 NOU VLIOX3 3381998 189 YSE VS9 VSL H3Wv3U8 LINDUID 799 185 OAN 056 DOA SL 52 HOLDVdY2 390319313 QN3511 E NE ZAC a 209 7 1 i 785 ee uibvis 3 ue xnv 15 HOLVIS e uw RUE PSS 40 Svo CP VPE EAST PENN manufacturing co inc Material Safety y Data Sheet BATTERY ELECTRIC STORAGE DRY Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental EL 5 11 1 202 483 7616 Hazardous Components Specific Chemical Identity Common Name s Appearance and Odor N A Solubility in Water N A Boiling Point N A Specific Gravity H 0 1 N A Evaporation Rate Butyl Acetate 1 N A Vapor Density AIR 1 N A Melting Point N A Vapor Pressure Hg N A
31. RPOSE WARNING At all times safety is an important consideration in the installation servicing and operation of the product and skilled qualified technical assistance should be utilized at all times Specific recom mendations are included in Safety in Welding and Cutting American National Standard No 2 49 1 Hobart Brothers Company April 1997 Troy Ohio 45373 U S A 910516
32. SA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 30 X 92 13 IV 88 R vis e Hobart Brothers Company Troy Ohio 45373 DESCRIPTION DESCRIPTION OF EQUIPMENT COARSE 59 TANEOUS WELDI LN pour i WITH FINE CONTROL SET AT 10 WELDING AMPS purpureus S 7 S ET ep ELE rev zen LE Efor s a me LA enom sv x mE AUXILIARY POWER 7 aes 1 Coarse Control 8 35 Amp Circuit Breakers 2 Fine Control 9 20 Amp Circuit Breakers Ignition Idle ON OFF 10 115 Volt Receptacles 4 Output Selector Switch 11 Electrode Welding Output Terminal 5 Choke Control 12 Work Welding Output Terminal 6 Engine Hour Meter 13 Frame Ground Terminal 7 115 230 Volt Receptacle 14 15 Optional Remote Fine Current Control Figure 3 1 Control Panel October 6 1997 3 1 DESCRIPTION Controls And Power Outlets Refer to Control Panel Figure 3 1 1 Coarse Control selects one of three Constant Current CC weldi
33. Starting Engine Cold Start 5 1 Starting Engine Warm Or Hot Starts 5 1 Automatic Idle Control System 5 1 Stopping ENGINE m wiae dos D Po RUE LT 5 2 Operation A Welder 5 2 Operation As Welder 5 2 Operation As AC Power Generator 5 3 Construction Site Use Of Portable Welding Generators 5 3 Standby Power Source 5 3 When Utility Power Is Restored 5 5 NS MR E a AL des 5 5 Operation Extremely Cold 5 5 Operation In Extremely Dusty Conditions 5 5 Operation In Salt Water Atmosphere 5 6 October 6 1997 Page 1 TABLE OF CONTENTS Troy Ohio 45373 MAINTENANCE 6 Lubrication Engine gb eee HONS ee ec Oy es 6 1 Inspection And Cleaning 6 1 Brush Inspection And Replacement 6 1 TROUBLESHOOTING 7 PARTS LIST 8 Equipment Identification o o 5 ays eR e e oe 8 1 How To Use This Parts List 2 n 8 1 How to Select Recommended Spares 8 1
34. UANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Op ration de Coupage ou soudage 9 Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage l arc avec electrode enrob es SMAW selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions moins de 1 po 25 mm de 1 6 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 3 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm Nuance de de filtre oculaire plus de 1 4 po 6 4 mm Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW Soudage l arc Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage l arc Plasma mince moins de 300 amp res moyen de 300 400 amp res pais plus de 400 amp res toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions toutes dimensions 5 Ne travaillez dans un espace confin que s il est bien ventil si DANGEREUSES POUR LA SANTE non portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer
35. al connections Every Week Wipe accumulated dust dirt and oil off engine and generator Check parts for loose ness and signs of wear If arcing has occurred at any electrical connection recondition it and se curely refasten Check engine oil level in crank case Every Month Blow out generator windings with compressed air not over 25 psi 172 kPa pressure or remove dirt with a suction type cleaner with a non metallic nozzle windings should become slightly damp use space heaters or electric light bulbs to effectively dry out the windings If damp ness is excessive apply external heat under a can vas cover well vented Heating should not exceed 194 F 90 C Brush Inspection And Replacement Inspection Every three months weekly during heavy usage in dust laden air inspect brushes If brushes are worn unevenly are shorter than inch 6mm long replace them See Figure 6 1 for location CAUTION Do not allow any brush to wear far enough that the wire lead em bedded in the brush can rub on the slip rings and cause excessive arching Replacement Procedure 1 Disconnect leads from connectors on brush holder caps 2 Remove screws which hold brushholder in place and remove brushholder assembly 3 Inspect slip rings whenever servicing brushes or brushholders Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes
36. allation The frame of a Hobart Brothers Company engine driven welder is intended to be a base to hold the welder components together This frame is not in tended to be the primary structure of a trailer or wagon This welder is intended to be installed on a rigid flat surface This surface must allow the weight of the welder to be distributed evenly along the length of the weider frame Before choosing an installation location make note of where the service items are located on the welder oil change fill battery air filter fuel fill etc Install the welder for best access to the important service items Allow sufficient room for cooling air intake and exhaust If you are unsure about any installation consult the factory Portable Installation CAUTION Do not use the frame assem bly of this welder as the frame of a trailer do not attach axles or tongues directly to this frame Trailer Installation When trailer is required use only trailers with its own support frame that has a gross weight rated to carry the weight of the welder and any other compo nents mounted on the trailer Be sure welder frame and trailer frame are electrically bonded together Truck Bed Installation When installing the welder on the bed of a truck allow the welder to sit flat on the bed or a surface which completely con tacts the bottom of the welder frame CAUTION Do not modify the welder frame by cutting or otherwise damaging
37. ary See Maintenance chapter Check for dirty slip rings Clean or refinish slip rings See Maintenance chapter Check for open revolving field L1 D Repair or replace armature if defective Check rectifier bridge CR1 Replace defective bridge Check for defective stator winding L1 C 5 or replace windings 6 7 8 Welding current OK no auxiliary power at receptacles Check stator windings L1 B 1 to 2 3 to 4 Repair windings or replace stator as necessary Check circuit breakers Reset breakers as necessary Loose connections Repair as needed Receptacle power OK but no weld power Check for loose connections in welding circuit Check Reactor L2 Defective Stator Winding L1 A 9 to 10 and 11 to 12 Range Switch 51 Output selector Set Switch properly Switch 52 not set properly Repair as necessary Replace Reacior if necessary Repair winding or replace stator Receptacle power weak welding output OK Fine Control not set properly Set to 7 or higher Loose connection Repair Defective Receptacle J1 42 J3 44 J5 Replace receptacle October 6 1997 7 1 Hobart Brothers Company TROUBLESHOOTING Troy Ohio 45373 Receptacle power OK welding output weak Loose connection in welding circuit Repair connection s
38. ates nitrates and pierates organic acid acetates anhydrites Hazardous Decomposition of By Products Thermal decomposition or combustion may produce a sulfur trioxide and or sulfur dioxide i Hazardous Polymerization will not occur S gt 1 of 2 MSDS Battery Fluid Acid 8 1012796 PGII page 2 of 2 Route s of Entry Inhalation skin contact and ingestion Carcinogenicity N A Signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated by Exposure Pulmonary edema bronchitis emphysema dental errosion and traceobronchitis Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosicn of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN System eyes skin amp teeth Emergency and First Aid Procedures 1 Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention 2 If swallowed give large volumes of water DO NOT indu
39. ce vomiting obtain medical treatment Eyewash and shower stations should be made available Steps to be Taken in Case Material is Released Spilled Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained breathing apparatus Reference DOT UN2796 Waste Disposal Method Neutralize and dispose in accordance with local state and federal regulations Precautions to be Taken in Handling and Storing Store away from reactive material as defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same general area for emergency use Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation When PEL is exceeded Mechanical general Local exhaust preferred Special Other Adequate ventilation to maintain exposure concentrations below the PEL Protective Gloves acid resistant for example rubber Eye Protection Mandatory during handling and transfer of acid recommend chemical goggles Other Protective Clothing or Equipment acid resistant aprons boots protective clothing and face shield Protective Gloves acid resistan
40. ch is not already in the auto idle second position place switch in auto idle position 3 Allow engine to run for a few minutes in low idle speed to cool down cylinder heads and oil 4 Place Ignition idie On Off switch OFF Operation As A Welder CC WARNING Serious personal in jury could result if you connect or disconnect welding leads while the engine is running as open circuit voltage is present at the terminals Always stop en gine to connect or disconnect cables 1 Connect the ELECTRODE lead to the Electrode Terminal on the Control Panel See Description of Equipment Connect the WORK lead with the clamp on the end to the Work Terminal on the Con trol Panel 2 For DC Welding determine which polarity is correct for the type of electrode being used a For STRAIGHT polarity DCEN switch the Output Selector Switch on the Control Panel to the position b For REVERSE polarity DCEN switch the Output Selector Switch on the Control Panel to the DC position 3 For AC welding switch the Output Selector Switch to the AC position NOTE See Table 4 1 for size of welding leads required for various welding currents 4 Set coarse control for correct amperage range 1 to 4 for the size electrode being used 5 Set fine control on control panel or optional re mote for amperage desired forthe job to be done 6 Start engine per section on Starting Engine 5
41. e is suspected seek medical attention Steps to be Taken in Case Material is Released or Spilled Avoid contact with internal components See Section VI Health Hazards Lead Waste Disposal Method Lead acid batteries are completely recycable For information on returning batteries to East Penn for recycle call 610 682 6361 Precautions to be Taken in Handling and Storing N A Respiratory Protection Specific Type For specific information see 29CFR 1910 1025 Lead Exposure Ventilation Local exhaust Mechanical general Special Sg Other Protective Gloves N A Eye Protection N A Other Protective Clothing or Equipment N A Work Hygienic Practices Always practice good personal hygiene habits and safe work practices Shipping Name Battery dry Identification Number N A non assigned Hazard Class N A This article is not applicable to 49CFR 172 101 Hazardous Materials and not subject to Parts 170 189 of this sub chapter bru U S Postal Service Regulations unrestricted EAST manufacturing inc Material Safety Data Sheet BATTERY WET FILLED WITH ACID 8 UN2794 PGIII Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental U S call 1 2
42. e porte lectrode dage automatique ou semi automatique avec fil ce AM E dernier le rouleau ou la bobine de fil le logement des 8 N utilisez pas de c bles lectriques us s endommag s mal galets d entrainement et toutes les pi ces m tal section trop petite liques en contact avec le fil de soudage sont sous 9 N enroulez pas de cables lectriques autour de votre corps tension Un quipement inad quatement install ou 10 N utilisez qu une bonne prise de masse pour la mise la terre de inad quatement mis a la terre est dangereux la piece a souder 1 Ne touchez pas des pi ces sous tension 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez ou rem placez aussit t les pieces endommag es 13 Dans des espaces confin s ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le a 99 Kant Amon gui 1 TU dud Teducteur 98 commutateur en circuit ouvert ou enlevez les fusibles tension Utilisez plut t Une Source de courantcontin tation afin d viter une mise en marche accidentelle 14 Portez un harnais de s curit si vous travaillez en hauteur 5 Veuillez installer cet quipement et le mettre laterreselonie 15 Fermez solidement tous les panneaux et les capots manuel d utilisation et les codes nationaux
43. eathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes lf inside ventilate the area and or use exhaust at the arc to re move welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manu facture s instruction for metals consumables coatings and Cleaners WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot work piece and hot equipment can cause fires and bums Accidental contact of electrode or welding wire to metal objects can cause sparks overheat ing or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc this is not possible tightly cover them with approved covers FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the weld ing process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechani cal shocks a
44. erefore shall be As to PRODUCTS 1 repair 2 replacement or 3 where authorized by Hobart payment of or credit for the purchase price less reasonable depreciation based on its actual use upon return of the product and as to SERVICES including repair under war ranty the sole and exclusive remedies therefore shall be payment or credit for Hobart s actual charge therefore or in the absence of any actual charge the customary or reasonable charge for such services and if such breach also involves impairment of Hobart products the remedies available for breach of warranty with respect to the product 8 Modification and Misuse This warranty does not apply to products which have been modified in any way by any party other than Hobart nor to products which have not been installed and operated in accordance with applicable industry standards nor to products which have been used other than under the usual conditions for which designed nor to products that have not received proper care lubrication protection and maintenance under supervision of competent personnel Use of a product after discovery of a defect voids all warranties DISCLAIMER OF WARRANTIES THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF EXCEPT AS SPECIFI CALLY PROVIDED IN THE EXPRESSED WARRANTIES SET FORTH ABOVE ALL PRODUCTS ARE SOLD AS IS HOBART MAKES NO WARRANTIES EXPRESSED OR IMPLIED OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PU
45. es autour de Parc ou couvrez les soigneusement avec des cuir une chemise paisse un pantalon revers des bottines de baches approuv es s curit et un casque Le piquage et le meulage produisent des particules m talliques vol antes En refroidissant la soudure peut projeter du clats de laitier LES ETINCELLES ET LES PROJEC 1 Portez un cran facial ou des lunettes protectrices approuv es TIONS BRULANTES PEUVENT Des crans lat raux sont recommand s CAUSER DES BLESSURES Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER soudage 5 N utilisez que des bouteilles de gaz protecteur des d tendeurs Les bouteilles contiennent des gaz protecteurs sous des boyauxs et des raccords con us pour chaque application haute pression Des bouteilles endommag es peu sp cifique ces quipements et les pi ces connexes doivent tre vent exploser Comme les bouteilles font normale maintenus en bon tat ment partie du proc d de soudage traitez les avec 6 Ne placez pas le visage face l ouverture du robinet de la soin bouteille lors de son ouverture 1 Prot gez les bouteilles de gaz comprim contre les sources 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou chaleur intense les chocs et les arcs de soudage lorsque raccord pour utilisation
46. f this manual may be pur chased by contacting Hobart Brothers Company at the address given above Include the Owner s Manual number and equipment identification num bers October 6 1997 1 1 Hobart Brothers Company INTRODUCTION __ Troy Ohio 45373 This page intentionally left blank 1 2 October 6 1997 Hobart Brothers Company ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Troy Ohio 45373 Instruction 910081 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARER KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and train ing before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard 749 1 entitled
47. gh 8 2 Parts and Labor For Motor driven guns High frequency Capacitor Discharge units Running gears Trailers Field options are warranted for one 1 year 3 Expendable Items Primary and secondary switch contacts cable connectors carbon brushes fuses bulbs filters nozzles contact tips liners cutting tips and wire feed rolls are worn or consumed in the normal process of welding or cutting and there fore warranted only if found to be defective prior to use 4 Replacement parts Replacement and exchange parts are warranted for the remainder of the original equipment warranty or for a period of ninety 90 days whichever is greater 5 Semiautomatic Items Mig welding guns and cables and plasma cutting torches tig torches and cables and remote controls and accessory kits are warranted for ninety 90 days 6 Engines Tires and Batteries Hobart does not warrant items furnished by Hobart but manufactured by others including with out limitation gasoline or diesel engines engine electrical equipment batteries and tires Such items are warranted directly by the manufacturer and Hobart may periodically inform customers of such warranty coverage however Hobart does not guarantee the accuracy or completeness of its information regarding such warranties 7 Exclusive Remedies In case of Hobart s breach of warranty or any other duty with respect to the quality of any product or serv ice the sole and exclusive remedies th
48. gs or ear muffs if noise level is too high Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Welding or Cutting Electrode Size Filter Welding or Cutting Electrode Size Filter Operation Metal Thickness Shade Operation Metal Thickness Shade or Welding Current No or Welding Currents No Torch Soldering 2 Gas metal arc welding MIG Torch brazing 4 Non ferrous base metal All 11 Oxygen cutting Ferrous base metal All 12 Light Under 1 in 25 mm 4 Gastungsten arc welding TIG All 12 Medium 1 to 6 in 25 150 mm 5 Atomic hydrogen welding All 12 Heavy Over 6 in 150 mm 5or6 Carbon arc welding All 12 Gas welding Plasma arc welding All 12 Light Under 1 8 in 3mm 40r5 Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm Light 12 Over 1 2 in 12 mm 60r8 Heavy 14 Shielded metal arc welding Under 5 32 in 4 mm 10 Plasma arc cutting stick 5 32 to in 4 to 6 4 mm 12 Light Under 300 Amp 9 Over in 6 4 14 Medium 300 400 Amp 12 Heavy 400 Amp 14 March 24 1993 2 1 Replaces April 1 1992 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 910081 Hobart Brothers Company Troy Ohio 45373 FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Br
49. he container Prevent entry of snow water and ice into fuel containers Lubrication Drain engine crankcase while en gine is warm and refill with a lighter grade of oil than that used in warm weather See oil viscosity chart in engine manual Drain oil more frequently to avoid harmful sludge forming in crankcase and possible damage to oil pump Electrical System Check the entire system for loose connections or indications of bad wiring or shorted connections Check spark plugs for proper gap For proper plug gaps consult the Engine Op erators Manual for the engine Battery Battery efficiency decreases sharply with lower temperatures Maintain the specific gravity of the battery between 1 275 and 1 300 fully charged condition Make sure of full charge before attempting to start engine in sub zero conditions Operation In Extremely Dusty Conditions Place unit in a sheltered area and take advantage of natural barriers which may offer protection from blowing dust If the installation is more than tempo rary erect a protection shield Fuel System Drain fuel pump sediment bowl often Keep all containers covered and protected against dust entry Oil Filter and Air Cleaner Check air cleaner daily Service or replace element as needed place oil filter as recommended in Operators Man ual Always use Onan approved replacement filters Contact the nearest Onan engine service center for correct replacement
50. it or the warranty may be voided Bolt the welder frame to the bed to secure it Be sure welder frame and truck frame are electrically bonded together Ground Installation The welder will operate per fectly fine just sitting on the ground with or without the shipping skid No special precautions are re quired October 6 1997 INSTALLATION NOTE Operate the unit in a level position and never at a tilt more than 15 from hori zontal Location When selecting an installation site take care to avoid exposing the unit to high humidity dust high ambient temperature or corrosive fumes Moisture condenses on electrical parts causing corrosion or short circuits Dirt on parts retains moisture and in creases wear on moving parts Provide at least 2 feet 610 mm of space on all sides for adequate air ventilation and servicing Make sure ventilator openings are not obstructed Safety Refer to additional installation instructions under Safety Warnings chapter included in this manual Indoor Use Provide adequate ventilation to carry off exhaust fumes and to provide an ample supply of oxygen Place unit so that short exhaust pipes may be used Avoid bends as back pressure can affect engine ef ficiency All exhaust connections must be gas tight Consider installation of an LPG propane fuel op eration kit Consult your distributor for propane kit number Initial Preparation for Use 1 Inspect unit
51. lable Steps to be Taken in Case Material is Released or Spilled SULFURIC ACID Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained breathing apparatus Reference DOT UN2796 Waste Disposal Method Lead acid batteries are completely recyclable For information on returning batteries to East Penn for recycling call 610 682 6361 Precautions to be Taken in Handling and Storing Store away from reactive material defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same general area for emergency use See Section IV on generation of hydrogen gas If battery case is broken avoid direct contact with internal components Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation Must be provided when charging in an enclosed area 29CFR1910 178 g and 305 3 7 Mechanical general acceptable at 1 to 4 air exchanges hour or to maintain air concentrations below the PEL Local exhaust preferred Special Other local building fire codes may require explosion proof fans and gt equipment m Protective Gloves acid resistant for example rubber Eye Protection
52. mpany DESCRIPTION Troy Ohio 45373 CHAMPION 16 WELD VOLT AMP COARSE CONTROL 50 100 AMPS 70 150 AMPS 85 225 AMPS FINE CONTROL MAX 10 MIN 0 LOAD VOLTS 0 50 100 150 200 250 300 350 400 LOAD AMPS Champion 16 AC CC Weld Volt Amp Curve 3 4 October 6 1997 Hobart Brothers Company Troy Ohio 45373 DESCRIPTION LOAD VOLTS 35 30 25 20 15 LOAD VOLTS 10 50 50 CHAMPION 16 DC CC WELD VOLT AMP 50 100 AMPS 70 150 AMPS 85 225 AMPS 10 0 100 150 200 250 300 LOAD AMPS CHAMPION 16 DC CV WELD VOLT AMP MAX FINE CONTROL MIN 100 150 200 250 300 LOAD AMPS Champion 16 DC CC And DC CV Weld Volt Amp Curve October 6 1997 350 350 400 3 5 Hobart Brothers Company DESCRIPTION Troy Ohio 45373 CHAMPION 16 AUXILIARY POWER 115 amp 230 VOLT 300 250 200 150 100 50 0 10 20 30 40 50 60 70 80 90 100 AC LOAD AMPS Champion 16 Auxiliary Power Volt Amp Curve Maximum Auxiliary Welding Power Combinations Welding CV 3 2 1 Not Welding Watts 1000 1000 4300 6000 8000 Amperes 115 volts 8 8 36 50 70 230 volts 4 4 18 25 35 NOTE Welding current fine control must be set at 10 to obtain full rated auxiliary power 3 6 October 6 1997 Hobart Brothers Company Troy Ohio 45373 INSTALLATION General Engine Driven Welder Inst
53. nd arcs 2 Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to pre vent falling or tipping WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 2 Wear proper body protection to protect skin 5 Work a confined space only if it is well ventilated or while wear ing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 7 Do not weld on coated metals such as galvanized lead or cad mium plated steel unless the coating has been removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metais containing these elements can give off toxic fumes if welded 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld on closed containers such as tanks or drums 8 Connect work cable to the work as close to the welding area as
54. nds return switch to off and wait 1 minute before attempting another start 2 When engine starts release Ignition idle On Off switch It will automatically return to the run High Idle position 3 Return choke quickly to the In position Automatic Control System This machine is equipped with an Electrome chanical Automatic Idling device This system when activated will automatically lower the engine speed from a fast idle of 3750 RPM to a slow idle of 2100 RPM when there is no external electrical load on the generator either from welding or from the 115 230 receptacle The engine will automatically slow after an approximate 10 15 second delay The engine will automatically accelerate upon applica tion of a welding or receptacle load To activate the automatic idle feature place the Ignition Idle On Off switch in the auto idle second position To override the automatic idle feature place the Igni tion Idle On Off switch in the fast idle third posi tion In this position the engine will continue to run at its fast idle speed of 3750 RPM This is the rec ommended operating position when using the ma chine for CV welding and for operation as an AC power generator particularly when starting motors from the 115 230 receptacles 5 1 Hobart Brothers Company OPERATION Troy Ohio 45373 Stopping Engine 1 Remove any load from 115 230 volt receptacles and or stop welding 2 If Ignition Idle On Off swit
55. ng ranges and one Constant Voltage CV welding range 2 Fine Control is used to make fine amperage ad justments in any of the CC ranges or fine voltage ad justments in the CV range Turn the knob clockwise to increase the welding current in CC or welding voltage in CV 3 Ignition Idie ON OFF The first position is OFF use this position to shut down the engine in the second position the engine will automati cally switch from normal speed to low idle under a normal load condition after a 10 to 15 second delay The engine will automatically return to normal speed when a load is applied either weld or auxil iary power This is known as Auto Idle On tion In the third position the engine will always run at normal speed this is also known as the posi tion The fourth position is the Start position It allows the starting motor to energize When the switch is released it will return to the Run position NOTE The Champion 16 is equipped standard with an engine protection shut down system In case of insufficient oil pressure the engine will shut down by itself During engine startup this system is auto matically bypassed 4 Output Selector Switch allows for easy switch ing from DC straight polarity DCEN to DC reverse polarity DCEP and to AC welding 5 Choke Control Push in for CHOKE OFF Pull out for CHOKE ON 6 Engine Hour Meter Operates onl
56. nsulating mats aged parts at once or covers 13 In confined spaces damp locations do not use a welder with 4 Disconnect input power or stop engine before installing or servic a pir with voltage reducer Use ing this equipment Lock input power disconnect switch open or quip M PUR E ur remove line fuses so power cannot be turned on accidentally 14 Wear a safety harness to prevent falling if working above floor 5 Properly install and ground this equipment according to it s Own level Manual and national state and local codes 15 Keep all panels and covers securely in place 6 Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service ARC RAYS can burn eyes and skin NOISE can damage hearing Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense 3 Use protective screens or barriers to protect others from flash and heat and strong ultraviolet rays that can burn eyes glare Warn others not to watch the arc and skin Noise from some processes can damage Wear protective clothing made from durable flame resistant ma hearing terial wool and leather and foot protection 5 Use approved ear plu
57. pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adres sent aux groupes lectrogenes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instruc tions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 6 Arr tez tout quipement apres usage Coupez l alimentation de L ELECTROCUTION PEUT ETRE MORTELLE 1 equipement s il est hors d usage ou 7 7 N utilisez que des porte lectrodes bien isol s Ne jamais Une d charge lectrique peut tuer ou br ler grave plonger les porte lectrodes dans l eau pour les refroidir Ne ja ment L lectrode et le circuit de soudage sont sous mais les laisser trainer par terre ou sur les pieces souder Ne tension d s la mise en circuit Le circuit d alimenta touchez pas aux porte lectrodes raccord s deux sources de tion et les circuits intemes de l quipement sont courant en m me temps Ne jamais toucher quelqu un d autre aussi sous tension d s la mise en marche En sou avec l lectrode ou l
58. practical to prevent welding current from traveling long possibly unknown paths and causing electrical shock and fire hazards 9 Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use 11 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields rec ommended Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cylinder 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA Publication P 1 listed in Safety Stan dards ENGINES can be hazardous 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes March 24 1993 Replaces April 1 1992 Hobart Brothers Company Troy Ohio 45373 ENGINE FUEL can cause fire or explo sion Engine fuel is highly flammable MOVING PARTS can cause injury
59. provinciaux et locaux applicables 2 Portez des gants et des v tements isolants secs et non trou s 8 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure LE RAYONNEMENT DE L ARC PEUT 2 Portez des lunettes de s curit approuv es Des crans lat raux BRULER LES YEUX ET LA PEAU LE sont recommand s BRUIT PEUT ENDOMMAGER L OUIE 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev L arc de soudage produit une chaleur et des ray ons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager 1 Portez une casque de soudeur avec filtre oculaire de nuance ap propri e consultez la norme ANSI 249 indiqu e ci apr s pour 30 X 92 2 1 13 IV 88 R vis e PRECAUTIONS DE SECURITE EN SOUDAGE Instruction 910309 Troy Ohio 45373 Hobart Brothers Company SELECTION DES N
60. rators It is the user s responsibility to insure that the use of this equipment conforms to all applicable local state and national codes The use of the 120 volt receptacies on this unit at construction sites for hand tools is covered by section 1910 304 of OSHA Safety and Health Standards 29CFR1910 and section 210 8 of NFPA Standard 70 National October 6 1997 i Electric Code Compliance with these codes will re quire the use of ground fault circuit interrupters Refer to the text of the above safety codes for de tails Standby Power Source In the event of a power failure the unit may be used as a standby power source The unit must be connected by a Licensed Electrician utilizing a proper transfer switch and complying with all appli cable electrical codes A transfer switch ensures that voltage is not fed back into the utility power lines This will protect linespersons working to correct the failure and pre vents damage to the generator when power is re stored The unit frame must be grounded to the premises system ground DO NOT exceed the maximum load handling capacity of the unit Apply and re move loads in gradual steps to reduce voltage tran sients from engine RPM variations WARNING EXHAUST FUMES CAN KILL Be sure of adequate ventilation for indoor operation Use a leakage proof exhaust line to the outside for safety op eration DO NOT place the unit an attached garage or
61. rinted on the shipping container Record these numbers for future reference INTRODUCTION Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to ship ping If there is any damage notify the carrier im mediately to file a claim Furnish complete information concerning damage claims or shipping errors to Hobart Brothers Company Order Depart ment 600 W Main St Troy Ohio 45373 Include all equipment identification numbers as described above along with a full description of the parts in er ror Move the equipment to the installation site before unpacking the unit A lifting eye extends through the top of the cabinet on most equipment to facili tate handling with a hoist or crane Use care to avoid damaging the equipment when unpacking the unit WARNING Falling machine due to lifting eye failure may cause death or serious injury e Lifting device may fail when overloaded e This lifting device is designed to lift the power source ONLY If the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by lifting eyes e Avoid sudden jerks drops or swinging e Check lifting device components visually for looseness and signs of metal fatigue e Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies o
62. rve correct polarity and on batteries Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric and Magnetic Fields Background Paper OTA BP 63 Washington DC U S Government Printing Office May 1989 there is now very large volume of scientific findings based on experiments at the cellular level and from studies from animals and peo ple which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single co herent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil
63. s portes apres des travaux d entretien et avant de faire d marrer le mo teur Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des cables d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un ac cumulateur 4 N utilisez pas une source de courant de soudage N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI 249 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme C
64. sti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51 from National Fire Protection Association Batterymarch Park Quincy MA 02269 March 24 1993 Replaces April 1 1992 2 3 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Hobart Brothers Company Instruction 910081 Troy Ohio 45373 This page intentionally left blank 2 4 March 24 1993 Replaces April 1 1992 Hobart Brothers Company PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Troy Ohio 45373 Instruction 910309 PRECAUTIONS DE SECURITE EN SOUDAGE A LARC MISE EN GARDE PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER Ni LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDE CIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTIL ISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant
65. t for example rubber hygiene and work practices are mandatory Work Hygienic Practices Good personal PE I TC _______ __ ________ OIYO jeans UIEN 159A 009 syonpold MLI 55 TIM 39visOd SSANISNG Ce 5 AOL Li uad WW SSV19 15914 pe 4 S31VIS QALINN JHL Ni Q3llvW al 5 39VISOd ON IMPORTANT PLEASE COMPLETE THE ATTACHED REGISTRATION CARD AND RETURN TO ITW WELDING PRODUCTS GROUP TO ESTABLISH WARRANTY COVERAGE AND RECEIVE A FREE PACKAGE OF HOBART BRAND FILLER METAL PLEASE COMPLETE ALL INFORMATION SR TN OOH maie REGISTRATION CARD PLEASE SEND ME CHECK ONE 1 LB SPOOL OF 030 Dia FLUX CORED SELF SHIELDED WIRE 5 LB BOX OF 1 8 418C 7018 ELECTRODES PRODUCT ________________ PARTNO n SERIAL __ DATE PURCHASED YOUR NAME COMPANY NAME ADDRESS CITY PRIMARY BUSINESS DEPT WHERE USED PRODUCT RECEIVED IN GOOD CONDITION IF NO WHAT WAS PROBLEM PURCHASED FROM Distributor Name POWER PROTECTION 3 YEAR WARRANTY 1 General Hobart s products are warranted for three 3 years following date of shipment to the original user with the exceptions of items listed in paragraphs 2 throu
66. thoroughly Secure all fuel and wire connections Tighten any loose screws nuts or bolts Check closely for any damage that may have occurred in transit 2 Remove all special tags from the unit read and carefully follow special directions Keep tags with manual for future reference 3 Engine crankcase has been filled with oil at fac tory Check dipstick Add oil if required Check en gine operators manual for correct type Do not overfill 4 All air passages and cooling fins must be free of foreign matter Use clean dry compressed air to blow dirt and dust out of cooling passages and con trol cabinet 25 psi 172 kPa maximum pressure 4 1 Hobart Brothers Company INSTALLATION __ Troy Ohio 45373 5 The Storage Battery is shipped dry and Automo tive Type Battery acid Spec Gr 1 265 must be added to activate the battery After adding the acid allow the battery to soak approximately 1 hour and top off with battery acid if necessary To bring the battery up to full charge boost charge for 1 hour at 15 amps 6 Attach negative battery cable to negative bat tery terminal 7 Fill fuel tank with recommended grade of fuel Consult Engine Operator s Manual Fuel must be free of water and other foreign matter WARNING See Safety Warnings chapter included in this manual relative to filling gas tanks 8 Proceed to Operation chapter For more infor mation refer to the Engine Operator s Man
67. ual TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding ELECTRODE PLUS WORK LEAD Current m 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet 15 240 mm 30 480 mm 45 720 mm 60 960 76 200 100 4 4 2 1 1 150 1 1 0 20 200 1 1 1 0 2 0 3 0 NOTE Cable size shown is 90 C 194 F cable insulation 30 C 86 F ambient and not over 4 5 volts cable drop Table 4 1 October 6 1997 Hobart Brothers Company Troy Ohio 45373 OPERATION OPERATION Prestart Instructions 1 Inspect unit to make sure ventilation openings are free of obstructions Remove any obstructions such as leaves paper plastic etc 2 Check air filter element 3 Check oil level Add oil as required Do not overfill Wipe up any spilled oil before starting en gine 4 Check fuel level Filltank as required with gaso line as recommended by engine manufacturer Do not overfill Wipe up any spilled fuel before starting engine If engine is hot allow it to cool for several minutes before adding fuel to tank Never add fuel to tank while engine is running 5 Connect welding leads power cables etc for intended operation See appropriate section for op eration as a welder or AC power generator WARNING Remove all loose items such as parts tools etc from on or around machine as they could damage machine
68. ulantes de soudage susceptibles CENDIE OU UNE EXPLOSION de dans des aires adjacentes de petites ouvertures ou fissures L arc produit des tincellies et des projections Les M fiez vous des incendies et gardez un extincteur port e de la particules volantes le m tal chaud les projections main de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact acci dente de l lectrode ou du fil lectrode avec un ob N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t jet m tallique peut provoquer des tincelles un chauffement ou un Ne soudez pas un r cipient ferm tel un r servoir ou un baril incendie Connectez le c ble de soudage le plus pres possible de la zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et Prot gez vous ainsi que les autres contre les tincelles et du d incendie m tal chaud Ne d gelez pas les tuyaux avec un source de courant Ne soudez pas dans un endroit o des particules volantes ou Otez l lectrode du porte lectrode ou coupez le fil au tube des projections peuvent atteindre des mat riaux inflammables contact lorsqu inutilis apr s le soudage 1 Enlevez toutes matieres inflammables dans un rayon de 10 7 Portez des v tements protecteurs non huileux tels des gants en metr
69. y while en gine is running 7 115 230 Volt Receptacle The 115 230 dual voltage receptacle is protected by two 35 amp cir cuit breakers The continuous load should not ex ceed 35 amps on this receptacle 8 35 Amp Circuit Breakers protect the 115 230 volt receptacle preventong over current and pro tecting generator windings Push to reset 9 20 Amp Circuit Breakers 15 Amp Circuit Breakers on CSA units Push to reset 3 2 Hobart Brothers Company Troy Ohio 45373 10 115 Volt Receptacles The load drawn from these 115 volt receptacles cannot exceed 20 amps per receptacle or a total of 70 amps On CSA units the load drawn from these 115 volt receptacles cannot exceed 15 amps per receptacle or a total of 60 amps 11 Electrode Welding Output Terminal see OP ERATION chapter for further details 12 Work Welding Output Terminal see OPERA TION chapter for further details 13 Frame Ground Terminal Use this terminal to ground the unit to your truck bed or trailer frame This is especially important if the unit is insulated from the truck or trailer in any way This is not a weld terminal 14 15 These holes for an optional remote fine current control Ask your dealer for details Tabulated Data Weld Data AC DC CV BO 32 5 210 200 Voisins DE 2

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