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Manual - Northern Tool + Equipment

1. 5 7 Selecting Weld Cable Sizes 2 SECTION 6 OPERATING THE WELDING GENERATOR 0000cccoccccccc 6 1 Front Panel Controls 2 254548 asso REOR be ee be nae ee bat RUN REA EE 6 2 Cold Weather Engine Operation 422 6 3 Typical Stick Welding Connections And Control Settings SECTION 7 OPERATING AUXILIARY EQUIPMENT seeenn Hm 7 1 Standard Receptacles cuicos cbe xx RR XU pe EXER Ree car RC CR A Rane dies 7 2 GFCI Receptacle Information Resetting And Testing 7 3 Simultaneous Weld And Power 7 4 Wiring Optional 120 240 Volt Plug SECTION 8 MAINTENANCE 00 cece eee RII n nnn 8 1 Maintenance Label ss ssis oki Re mer trae hoes ERR EXE Rx read toad ed aes 8 2 Routine Maintenance ooocoocccccccc e Ih en 8 3 Servicing Air Cleaner ierte nnter cede herr esa genase QURE RE nA SER PAR RR n 8 4 Changing Engine Oil Oil Filter and Fuel Filter 0 0 eee 8 5 Adjusting Engine Speed e lee tied ru eR FR rea EYE SR RO a VR RU ded 8 6 Overload Protection 1 42 yee ra per krasni ioe LP eT UNDER RquAAqEK EDI ES RE qe NNNO OO OO WOW HA Ad dd ea a ek ds OO O O1 O1 O1 GH noo o oco 150 8001
2. Trouble Remedy Low or no weld output generator pow er output okay at ac receptacles Check control settings Check weld connections Check fuse F1 and replace if open see Section 8 6 Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 No weld output or generator power out put at ac receptacles Be sure all equipment is disconnected from receptacles when starting unit Check fuses F1 and F2 and replace if open see Section 8 6 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 Low weld output Check fuse F1 and replace if open see Section 8 6 Check control settings Check engine speed and adjust if necessary see Section 8 5 Service air cleaner according to engine manual Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 High weld output Check control settings Check engine speed and adjust if necessary see Section 8 5 Erratic weld output Check control settings Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and ou
3. 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insulated copper wire EF Electrically bond generator frame to ve hicle frame by metal to metal contact A Bed liners shipping skids and some running gear insulate the welding generator from the vehicle 800 652 D frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Use GFCI protection when operat ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equipment OM 266 040 Page 41 12 3 Grounding When Supplying Building Systems ES GND PE 1 Equipment Grounding Terminal 2 Grounding Cable Use 8 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 12 4 How Much Power Does Equipment Require SN 60 VOLTS 115 AMPS 4 5 Hz 60 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resis
4. EM AN A 9 A Weld current starts when By A arz A Se 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 Tools Needed Equipment Needed F Always wear appropriate per sonal protective clothing 1 Workpiece Lm M Make sure workpiece is clean be fore welding 2 Work Clamp Place as close to the weld as Constant Current possible Welding Power Source 3 Electrode Before striking an arc insert an electrode in the electrode holder A small diameter electrode requires less current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound Correct arc length is related to electrode di ameter Examine the weld bead to determine if the arc length is cor rect Arc length for 1 16 and 3 32 in dia meter electrodes should be about 1 16 in 1 6 mm arc length for 1 8 and 5 32 in electrodes should be about 1 8 in 3 mm 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before making another wel
5. e Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La protection du corps comporte des v tements sans huile comme par ex des gants de cuir une chemise solide des pantalons sans revers des chaussures hautes et une casquette em LE SOUDAGE peut provoquer un RER incendie 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 danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud 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
6. 5 3 Installing Exhaust Pipe ESP Tools Needed IL 1 2 in A Stop engine and let cool Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet A Do not point exhaust pipe to ward LP fuel tank if equipped Do not point exhaust pipe to wards shielding gas tank if equipped Point exhaust pipe in desired direction but always away from front panel and direction of travel 253 857 A OM 266 040 Page 19 A complete Parts List is available at wwwHobartWelders com 5 4 Engine Prestart Checks Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Follow run in procedure in en gine manual gt This unit has a low oil pressure shutdown switch However some conditions may cause en gine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Fuel Open left side access door Add fresh fuel before starting engine the first time see maintenance label for specifications Stop fueling when fuel level reaches Max Fill Level mark on tank Do not top off tank Al ways leave room for expansion Check fuel level on a cold engine be fore use each day Close left side access door Open top service door Oil
7. R1 40 4 j 7 00 FOR OIL FILTER AND SPARK PLUG ACCESS Support Assembly Dimensions bte a l LL MOUNTING HOLES 1 75 E 406 DIA e mo 325 T L e I 2 00 E ue Y 255 356 255 349 10 00 3 50 j 6 00 FOR SPARK PLUG ACCESS f 0 o 32 69 OM 266 040 Page 15 A complete Parts List is available at wwwHobartWelders com 4 4 Duty Cycle 275 260 Jen Na LI i DC CC i M N MINA td 150 Welding Amperes Duty Cycle 10 20 30 40 50 60 70 80 90100 1 100 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating EF This unit is rated for welding at 225 amperes CC DC continu ously NOTICE Exceeding duty cycle can damage unit and void warranty 254 768 B 4 5 Fuel Consumption i i I T T 3 5 3 3 d 5 E 3 7 57 167 2 00 662 146 1 75 5 67 1 25 1 50 AUX POWER 473 104 125 le n WELD 378 0 84 1 00 2 84 0 63 0 75 1 89 0 42 0 50 IDLE 2400 0 95 0 21 0 25 Power KVA At 100 Duty Cycle Weld Amperes At 100 Duty Cycle 0 25 50 75 100 125 150 175 0 10 2 0 30 40 50 60 7 0 On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty cycle expect about 20 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 3
8. A PRE VAE 9 sg CN MEC Champion ELITE 225 Amp DC Welder 11 000 Watt Generator Electrode Selection Table AMPERAGE 0 6011 6013 7014 7018 7024 Os 308 1 8 g ORR LR o Elo 3 13 e Jo Po fa fo amp Iv fo z o 6 2 ELECTRODE 3 For best arc starts and best results us ing weld and generator power together use a low Coarse Range setting and the Fine control set at 7 or higher A Stop engine gt This section provides general guidelines and may not suit all applications The control panel shows the typi cal settings for welding with a 7018 1 8 in electrode Consult the amperage selection tables below if welding with other elec trodes 1 Work Clamp 2 Electrode Holder Connect Work cable to Work terminal and Electrode holder cable to Elec trode terminal on welding generator gt Be sure to use the correct size weld cables see Section 5 7 For best performance set the Coarse Range switch to the low est range that covers the desired weld amperage Use the Fine control to select the desired am perage within the range se lected When properly set the Fine control is normally set at 7 or higher Typical Settings For 7018 1 8 in Electrode gt Set Coarse Range switch to 50 140 1 8 in position gt Set Fine control at 7 or higher for best results POSITION PENETRATION ITI m
9. OM 266 040A 2013 11 Processes Stick SMAW Welding Description D a acc Champion Elite o n OWNER S MANUAL Find us on E Facebook La Tube www HobartWelders com File Engine Drive Pa TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage eer rA ERE Ya eee eee PY CP PRU RI PUR quivis arae 1 2 Arc Welding Hazards 2x ts eae ans os ERE RE che en Ya Rye Y Rr Rap Ra es 1 3 Engine Hazards ee tira paar Te dee vi epe Dour hdmi anus de 1 4 Compressed Air Hazards soi cea Ee Xl Gite baka ike Nba deae dew bate dada oes 1 5 Additional Symbols For Installation Operation And Maintenance 1 6 California Proposition 65 Warnings 1 7 Principal Safety Standards sick ee yx e ER ERR nenteneet eee 1 8 EMF Information 2 22 ee nh x E A eR RR UR RR RE RR he RP RE SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles 2 2 2 Dangers relatifs au soudage l arc 2 8 Dangers existant en relation avec le moteur 2 4 Dangers li s Pair comprim 2 5 Dangers suppl mentaires en relation avec l insta
10. BATTERY ACID can BURN SKIN and EYES e Do nottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer s in structions Do not modify or alter compressor or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the compressed air system Use only components and accessories approved by the manufac turer Keep away from potential pinch points or crush points created by equipment connected to the compressed air system Do not work under or around any equipment that is supported only by air pressure Properly support equipment by mechanical means OM 266 040 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion CL e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby COMPRESSED AIR can injure or kill e Before working on compressed air system turn off and lockout tagout unit release pres Sure and be sure air pressure cannot be acci dentally applied e Relieve pressure before disconnecting or con necting air lines e Check compressed air system components and all connections and hoses for damage leaks and wear
11. Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can injure e Keep away from moving parts such as fans NS belts and rotors e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified persons remove doors panels covers or guards for maintenance 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 doors panels covers or guards 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 1 4 Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air system Design compressed a
12. EF Do not exceed the Full mark on the oil level dipstick The fuel pump may operate erratically if crankcase is overfilled 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 Expansion Space Full B Gasoline Lx To improve cold weather starting Keep battery in good condition Oil Fill Store battery in warm area Use correct grade oil for cold weather Close top service door Oil Check Y 266 064 OM 266 040 Page 20 FF A complete Parts List is available at www HobartWelders com 5 5 Connecting Or Replacing the Battery A Connect negative battery L 4 Du cable last To connect battery open right side en gine access door 1 Battery Holddown To change battery remove rear panel with baffle and battery holddown Be sure battery cables are not pinched when installing battery 1 Tools Needed 1 2 in 266 064 OM 266 040 Page 21 A complete Parts List is available at wwwHobartWelders com 5 6 Connecting To Weld Output Terminals A Stop engine A Failure to properly connect weld cables may cause exces sive heat and start a fire or damage your machine Do not place anything between weld cable terminal and cop per bar Make sure that the
13. Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les por tes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 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 e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression pneumatique Soutenir l quipement de facon appropri e par un moyen m canique M TAL CHAUD provenant du d cou page ou du gougeage l arc risque de provoquer un incendie ou une explo sion Ne pas d couper ou gouger proximit de produits inflam mables e Attention aux risques d incendie tenir un extincteur proximit L AIR COMPRIM risque de provoquer ES des blessures ou m me la mort SX A e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis Sous pression par inad
14. REGISTERED QUALITY SYSTEM v Hobart is registered to the ISO 9001 Quality System Standard TABLE OF CONTENTS SECTION 9 TROUBLESHOOTING 44 4444 suisses cesse 9 1 Welding Troubleshooting i iimiiziice cake inm eer re rb EE rap us 9 2 Generator Power Troubleshooting 9 3 Engine Troubleshooting 2255 ix Res exem mes Raub son dati Mie neces dace de SECTION 10 PARTS LIST 52x pis si e YE ROO ed b x ades unte Dade Sara db Dune date 10 1 Recommended Spare Parts SECTION 11 ELECTRICAL DIAGRAMS 0 cece cece SECTION 12 GENERATOR POWER GUIDELINES sisse SECTION 13 STICK WELDING SMAW GUIDELINES 0 c cee cece eee eee me SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom 2013 09 A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injur
15. by leaving the engine off and flip ping Engine Control switch from Run Idle to Run three times Oil Fill Tools Needed Ss Un gt 266 064 OM 266 040 Page 33 8 5 Adjusting Engine Speed paw _ As MA E EXOn VE Tools Needed E IZ 1 4 3 8 in A complete Parts List is available at wwwHobartWelders com After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds AC 3 as follows 2300 2400 rpm 38 3 40 0 Hz Start engine and run until warm Turn Fine Control to 10 3675 3750 rpm 61 3 62 5 Hz Open top and side access doors Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screws 3 Remote Idle Speed Screw Loosen mounting screw Adjust so lenoid position so engine runs at idle speed Tighten mounting screw Be sure solenoid linkage works smoothly Turn idle speed screw for fine ad justments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Weld Power Speed Adjust ment Nut 5 Lock Nut Loosen lock nut Turn adjustment nut until engine runs at weld power speed Tighten lock nut A Stop engine Close side and top access doo
16. 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 LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher des parties chaudes mains lit nues e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de sou dage et des v tements pais pour viter les br lu res LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler 2 4 Dangers li s l air comprim EE Un QUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou m me la mort e Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer utiliser et entretenir cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux e Ne pas d passer le d bit nominal ou la capacit du compresseur ou de tout quipement du circuit d air comprim Concevoir le circuit d air comprim de telle sorte que la d faillance d un composant ne risque pas de provoquer un accident mat
17. pr voir de l espace pour son expansion Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage 4 Les PIECES MOBILES peuvent causer des blessures E e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors Maintenir ferm s et verrouill s les portes recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Lorsque cela est n cessaire pour des travaux d lentretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qualifi panneaux OM 266 040 Page 9 e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles e Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LES TINCELLES L CHAPPEMENT
18. 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Portable Generators Safety Alert U S Consumer Product Safety Com mission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website www cpsc gov cpscpub pubs port gen pdf Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to work
19. 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 84 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 Use GFCI protection when operating auxiliary equipment If unit does not have GFCI receptacles use GFCI protected exten sion cord Do not use GFCI receptacles to power life support equipment Maximum Allowable Cord Length in ft m for Conductor Size AWG PS Load Watts 4 6 8 10 12 14 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 266 040 Page 47 SECTION 13 STICK WELDING SMAW GUIDELINES 13 1 Stick Welding Procedure
20. 4 gal lon per hour or about 16 hours of operation 250 10 0 254 772 A OM 266 040 Page 16 FF A complete Parts List is available at www HobartWelders com 4 6 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown RANGES A 80 225 B 50 140 C 40 100 a o DC VOLTS 3 ww o 0 50 100 150 200 250 300 350 DC AMPERES OM 266 040 Page 17 A complete Parts List is available at wwwHobartWelders com SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Do not move or operate unit where it could tip A Do not lift unit from end A Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes NOTICE Do not install unit where air flow is restricted or engine may over heat See Section 4 3 for lifting eye rat ing Mounting A Do not mount unit by support ing the base only at the four mounting holes Do not use flexible mounts Use cross supports to adequately sup port unit and prevent damage to bas
21. 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 Centrifugal 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 266 040 Page 44 12 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage A r OND Step 1 Find code and use table to 4 AC MOTOR find kVA HP If code is not listed 1 s VOLTS 230 AMPS 25 2 multiply running amperage by six to find starting amperage ODE UM ak ee Step 2 Find Motor HP and Volts HP 1 4 PHASE 1 Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motor s running amperage KVA HP x HP x 1000 Volts Starting Amperage K Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2
22. TU MIN PREP ROUGH HIGH SPATTER GENERAL STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Tools Needed 3 e 3 4in 265 985 266 064 087 985 A Ref S 0653 OM 266 040 Page 26 A complete Parts List is available at www HobartWelders com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Standard Receptacles o_o CBI A Use GFCI protection when operat ing auxiliary equipment If unit does not have GFCI receptacles use GFCl protected extension cord Do not use GFCI receptacle to power life support equipment A Unplug power cord before attempt ing to service accessories or tools gt Generator power decreases as weld current increases Set Fine Control R1 at 10 for full gen erator power 1 240 V 50A AC Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 11 KVA KW 2 120V 20A AC GFCI Receptacle GFCI2 120 240V V 50A MAIN BREAKER on IJIf amp yorr S7 5 120V y lt a MAIN BREAKER 3 120 V 20 A AC GFCI Receptacle GFCI3 GFCI2 and GFCI3 supply 60 Hz sing le phase power at weld power speed Maximum output from GFCI2 or GFCIS is 2 4 KVA KW A Test GFCI monthly See Section 7 2 for information resetting and test ing of GFCI receptacles 4 240 V 50A AC Re
23. Test Button GFCI Receptacle Reset Button GFCI Indicator Light LED GFCI Receptacles BR ND GFCI receptacles protect the user from electric shock if a ground fault occurs in equipment connected to the receptacle A ground fault occurs when electrical current takes the shortest path to ground which could be through a person rather than fol low its intended safe path If a ground fault is detected the GFCI Reset button pops out and the circuit opens to disconnect power to the faulty equipment A GFCI receptacle does not protect against circuit overloads short circuits or shocks not related to ground faults Reset and test GFCI receptacle according to the following procedures Resetting Testing GFCI Receptacle A Test GFCI monthly See Testing GFCI Receptacle A Do not test or reset GFCI recept acles at idle speed low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault If LED blinks stop using GFCI re ceptacle and have it replaced by a Factory Authorized Service Agent Resetting GFCI Receptacles If a GFCI fault occurs stop engine and dis connect equipment from GFCI receptacle Check for damaged or wet tools cords plugs etc connected to the receptacle Start engine and operate at Run weld 5 6 4 7 3 8 2 9 1 10 A A Test and reset GFCI only at Run speed and with controls set for full generator power RotGFCI2 2012 05 power
24. approuve il est recommand de suivre les proc dures pr c dentes OM 266 040 Page 13 A complete Parts List is available at wwwHobartWelders com SECTION 3 DEFINITIONS 3 1 Additional Safety Symbols And Definitions Some symbols are found only on CE products Warning Watch Out There are possible hazards as shown by the symbols Safe1 2012 05 Never use generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 3 2 Symbol Definitions Stop Engine Fast Fast Slow Run Weld Power pes Run Idle lt gt Slow Idle Read Operator s A j Start Engine Manual Amperes i Fuel Battery Engine Ox Engine jV CUm Engine Oil x Engine Choke p pA EY A Do icd While Y Work Connection e 2 Alternating Current a Direct Current Positive Negative AC DC Welding Arc if MIG GMAW l E Electrode d Wire ra Stick SMAW Output h Hours S Seconds e Time D de Air Filter Engine RPM gt On gos Sdn I Call dad Rated No Load U Rated Welding U O Voltage Average 2 Load Voltage 2 Current X Duty Cycle ar ris Circuit Protector Temperature H Z Hertz 1 Ny Single Phase OM 266 040 Page 14 A complete Parts
25. base metal Correct Angle Angle Too Small 109 30 Angle Too Large Electrode Angle 2 e 3 amas g 2 5 Drag a L P Arc Length CA a poli a Too Short Normal Too Long i i Travel Speed SSS ee e Slow Normal Fast S 0061 13 8 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld 1 2 joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady E Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 3 Weave Patterns S Use weave patterns to cover a wide area in one pass of the elec UC DIN trode Do not let weave width ex ceed 2 1 2 times diameter of electrode S 0054 A 13 9 Welding Lap Joints 1 Electrode 2 Single Layer Fillet 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 30 Or Less S 0063 S 0064 OM 266 040 Page 51 13 10 Welding Groove Butt Joints CRUS 1 Tack Welds Prevent butt joint distortion by tack welding the materials in position before
26. bouchon de vidange ou de remplissage d huile du compresseur Les PIECES MOBILES peuvent causer des blessures CE e S abstenirde toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e 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 Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche DES PIECES CHAUDES peuvent provoquer des brilures graves e Ne pas toucher de pieces chaudes du compresseur ou du circuit d air e Pr voir une p riode de refroidissement avant d intervenir sur l quipement Ne pas toucher aux pi ces chaudes utili ser les outils recommand s et porter des gants de soudage et des v tements pais pour viter les br lures LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi ava
27. era F6 215621 Fuse 30 Amp Ato Type 1 ER M EH EE 215984 Filter Fuel In line 250 1 sad gine kara AR iara 770666 Tune up amp Filter Kit Includes d Saut rto ME nee a 230016 Air Filter Element Kohler 1 RE a re M shes DE 066698 Oil Filter Kohler 1 TT CI V e 215985 Filter Fuel w Clamps amp 1 4 in Fuel Line 1 AS AE pM da ie 0670072 Spark Pl g sce LE dae da 12 det utis i erst 2390017 Air Filter Wrapper 22 2 iG Ie Res c ee d NOTICE This equipment meets US EPA Evaporative Standards Be sure fuel system replacement parts meet EPA Evaporation Standards FF A complete Parts List is available on line at www HobartWelders com OM 266 040 Page 38 SECTION 11 ELECTRICAL DIAGRAMS 105 ji 101 PLG6 RC6 N sR X 110 2 42 7 102 gt 2 104 gt 4 gt 103 Fa gt 3 106 PLc6 Rce 103 104 LAKE uo 3 EN Ran l EXCITATION e DMA 111 K 455 45 REVOLV 42 48 pLG12 42 S1 PLG8 45 d
28. final weld Workpiece distortion occurs when heat is applied locally to a joint One side of a metal plate will curl up toward the weld Distortion will also cause the edges of a butt joint to pull together ahead of the elec trode as the weld cools 2 Square Groove Weld 3 Single V Groove Weld 4 Double V Groove Weld Materials up to 3 16 in 5 mm thick can often be welded without special preparation using the square groove weld However when welding thicker materials it may be necessary to prepare the edges V groove of butt joints to ensure good welds The single or double V groove weld is good for materials 3 16 3 4 in 6 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thickness you can weld from one side only Create a 30 degree bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels S 0062 13 11 Welding Tee Joints ER 29 1 Electrode 2 Fillet Weld Keep arc short and move at defi nite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 13 8 Remove slag b
29. goods at customer s risk and expense Hobart s Millers 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 PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y 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 l
30. processes or equipment can damage hearing e Wear approved ear protection if noise level is high ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should con sult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Compressed gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Do not stand in front of or behind the regulator when openi
31. terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut y HJ provoquer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installati
32. 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 Assistance Visit the Hobart website www HobartWelders com HOBART S31 WARRANTY Effective January 1 2013 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MD or 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 Brothers Co Troy Ohio and 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 wa
33. x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 266 040 Page 45 12 10 Typical Connections To Supply Standby Power SN Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install ground and operate this equipment ac cording to its Owner s Manu al and national state and lo cal codes Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch ra
34. 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 glare and sparks warn others not to watch the arc e Wear body protection made from durable flame resistant material leather heavy cotton wool Body protection includes oil free clothing such as leather gloves heavy shirt cuffless trousers high shoes and a cap H WELDING can cause fire or explosion AN 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 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 Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal OM 266 040 Page 2 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on conta
35. 37 857 Subaru 263 6501 2 A3 12 Volt Battery BCI Group 58 Cranking Performance at 0 F 18 C 430 Amps min i Air Filter Service 100 hours see Owner s Manual KOHLER CH730 MILLER 230 016 Kohler 2408303 S ECH730 MILLER 230 016 Kohler 2408303 S CH730 LP MILLER 067 272 Kohler 4708303 S KOHLER CH730 MILLER 230 017 Kohler 2408305 S ECH730 MILLER 230 017 Kohler 2408305 S CH730 LP MILLER 067 273 Kohler 2408302 S Air Filter SUBARU MILLER 198 755 Subaru 263 32610 A1 Includes Air Filter Wrapper Air Filter Wrapper KOHLER CH730 MILLER 215 984 Kohler 2505022 S Tune up and Filter Ki Includes Air O and Fuel Filters and 2 Spark Plugs Keep free of dirt and deb LOCK OFF FILTER ASSEMBLY 500 hours Replace filter Clean internal magnet Fuel er MILLER 252 837 Kohler 2405004 S LPG REGULATOR 500 hours Drain residue from secondary chamber 1500 hours Complete disassembly cleaning and resetting Note Check with your local propane dealer for certification requirements needed to work on LP systems Authorization varies from state to state KOHLER CH730 MILLER 230 015 HOBART 770 666 ECH730 MILLER 246 115 CH730 LP MILLER 252 838 SUBARU MILLER 199 062 Engine Speed High Speed 3675 3750 RPM No Load Idle 2300 2400 RPM KOHLER MILLER 067 007 Kohler 1213202 S Champion RC 12YC SUBARU MILLER 198 777 Subaru X65 01407 30 NGK BPR4EY Use only resistor spark plugs an
36. Agent check fuel shutoff solenoid FS1 OM 266 040 Page 37 A complete Parts List is available at wwwHobartWelders com Trouble Remedy Battery discharges between uses Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check hour meter idle module and current transformer CT1 Unstable or sluggish engine speeds Readjust throttle linkage if necessary Check throttle solenoid TS1 for smooth operation Check oil level Oil level should not exceed Full mark on dipstick Fuel pump will operate erratically if crankcase is overfilled Tune up engine according to engine manual Engine does not return to idle speed Remove weld and generator power loads Check throttle linkage for smooth non binding operation Have Factory Authorized Service Agent check hour meter idle module current transformer CT1 Engine Control switch S1 and throttle solenoid TS1 SECTION 10 PARTS LIST 10 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts TERES F1 F2 169296 Fuse Mintr Gl 25 Amp 125 Volt 2 Met er d
37. Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation A Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for Welding and Cutting Containers that h
38. E LA BATTERIE peut provoquer des blessures e Toujours porter une protection faciale des gants en caoutchouc et v tements de protec tion lors d une intervention sur la batterie de batterie d entretien la batterie destin e cet usage e Observer la polarit correcte et sur les batteries dernier lieu fonctionnementnormal et en cours de charge sur une batterie ou proximit Arr ter le moteur avant de d brancher ou de brancher des c bles de batterie des c bles de chargeur de batterie le cas ch ant ou Eviter de provoquer des tincelles avec les outils en travaillant sur Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie D brancher le c ble n gatif en premier lieu Le rebrancher en Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces derni res produisent des gaz explosifs en Respecter les consignes du fabricant de la batterie pour travailler LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d tincel les ou d une flamme nue Ne pas faire le plein de carburant ras bord
39. If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install ground and operate this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect
40. List is available at www HobartWelders com SECTION 4 SPECIFICATIONS 4 1 Serial Number And Rating Label Location The serial number for this product is located on the front The rating information for this product is located on the back Use rating label to determ ine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 2 Specifications Rated Maximum ioc S Welding Open Circuit Generator Power Rating ms Engine 9 Output Voltage pacity Peak 11 0 kVA kW Continuous 9 5 kVA kW po don S k Single Phase 12 gal _ Kohler CH 730 40 225 o Duty 80 80 40 A 120 240 VAC 45 L Tank Air Cooled Two Cylinder Cycle 60 Hz Four Cycle 23 5 HP while not welding Gasoline Engine 4 3 Dimensions Weights And Operating Angles uw m 7 Do not exceed tilt angles or Le engine could be damaged or ERO unit could tip E 260 24 A Do not move or operate unit F where it could tip 5 07 507 9 22 312 MOUNTING HOLES X 5 12 Cm 27 99 27 540 1 00 40 84 4 00 MIN TO REMOVE _ B00 BACK PANEL REMOVED FOR BATTERY ACCESS Weight 490 Ib 222 kg Lifting Eye Weight Rating 1280 Ib 580 kg PANEL TYP BOTH SIDES
41. NDED TO FRAME NEUTRE BACCURD AU BAN o 1 Engine Control Switch Use switch to start engine select speed and stop engine In Run ldle position engine runs at idle speed at no load and weld power speed under load In Run position engine runs at weld power speed 2 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Con trol switch to Start position Release switch and slowly push choke in when engine starts FF If the engine does not start let engine come to a complete stop before attempt ing restart To Stop turn Engine Control switch to Off pos ition 3 Engine Hour Meter Idle Control A maintenance interval is reached when the wrench icon appears in the display Hour Meter With engine off place Engine Control switch in Run Idle position to view en gine hours Oil Change Interval With engine off place En gine Control switch in the Run position to see hours before next oil change Oil hours start at 100 and count down to 0 zero oil change due E Negative hours indicated when past rec ommended oil change interval To reset cycle Engine Control switch from Run Idle to Run three times within five sec onds engine off 4 Coarse Range Switch NOTICE Do not switch under load HOBART BROTHERS CO TROY OHIO USA 265 985 A Use switch to select weld amperage range gt For best arc starts and when using weld and generator p
42. V Each 120 V Duplex with one half of 240 V receptacle Receptacle Receptacle 2 Plug Wired for 240 V 2 Wire 0 20 Load 5 20 3 Neutral Silver Terminal 10 20 4 Load 1 Brass Terminal 15 20 5 Load2 Brass Terminal 20 20 6 Ground Green Terminal 25 15 3 7 Amperes Available using 30 10 120 240 V Plug 35 5 amp 40 0 V x A Watts One 240 V load or two 120 V loads Tools Needed plug1 11 03 120 813 D OM 266 040 Page 29 A complete Parts List is available at wwwHobartWelders com SECTION 8 MAINTENANCE Maintenance Label 8 1 KOHLER CH730 ECH730 SUBARU EH65 GAS ENGINES KOHLER CH730 LP ENGINES See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts Recycle Used Oil SG or higher If using LP fu use synthetic 100 hours 200 hours KOHLER MILLER 066 698 Kohler 1205001 S SUBARU MILLER 198 754 Subaru 248 65801 00 Oil Capacity w filter change Approximately 1 5 quarts DO NOT OVERFILL KOHLER Keep oil level between L F marks on dipstick SUBARU Keep oil level between 2 holes on dipstick NO SOBRELLENE KOHLER Mantenga el nivel del aceite entre las marcas L y F del medidor SUBARU Mantenga el nivel del aceite entre los dos huecos del medidor Oil Filter Change Oil Filter METER MAINTENANCE FUNCTIONS HOUR METER with engine off place Engine Control switch
43. Wash hands after handling A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Cana
44. aciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher des c bles de batterie des c bles de chargeur de batterie le cas ch ant ou de batterie d entretien Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces derni res produisent des gaz explosifs en fonctionnementnormal et en cours de charge Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou proximit Les op rations de charge de batterie ne doivent tre effectu es que par des personnes qualifi es Pour enlever la batterie d un v hicule pour la recharge d brancher tout d abord le cable n gatif et le rebrancher en dernier lieu Pour viter un arc s assurer que tous les accessoires sont d branch s Ne charger que des batteries plomb acide Ne pas utiliser le chargeur de batterie pour al
45. as un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der a l installation 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 Installez mettez la terre et utilisez correctement cet quipement conform ment son Manuel d Utilisation et aux r glementations nationales gouvernementales et locales 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 conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation et le conducteur de mise la terre afin de s assurer qu il n est pas alt r ou d nud le remplacer imm diatement s il l est Un fil d nud peut entrain er la mort e Mettre l appareil hors tens
46. ating auxiliary equipment Do not test or reset GFCI receptacles at idle speed low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER stopping engine FT Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 266 040 Page 1 FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed e f ventilation is poor wear an approved air supplied respirator e Read and understa
47. ation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne passe tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standar
48. atts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 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 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 266 040 Page 43 12 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 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 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 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
49. ave Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 2 8 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant issu d un soudage l arc et de proc d s connexes y compris le soudage par points le gougeage le d coupage plasma et les op rations de chauffage par induction cr e un champ lectromagn tique CEM autour du circuit de soudage Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valu
50. ay from moving vehicles when working from an aerial location e Followthe guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OM 266 040 Page 4 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 FLYING SPARKS can injure 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 MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls BATTERY CHARGING OUTPUT and BATTERY EXPLOSION can injure Battery charging not present on all models e Always wear a face shield rubber gloves and protective clothing when working on a battery Stop engine before disconnecting or connecting battery cables battery charging cables if applicable 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 un less it has a battery charging feature designed for this purpose Observe corr
51. before operating unit Do not direct air stream toward self or others e Wear protective equipment such as safety glasses hearing pro tection leather gloves heavy shirt and trousers high shoes and a cap when working on compressed air system e Use soapy water or an ultrasonic detector to search for leaks never use bare hands Do not use equipment if leaks are found e Reinstall doors panels covers or guards when servicing is finished and before starting unit e If ANY air is injected into the skin or body seek medical help im mediately BREATHING COMPRESSED AIR can in jure or kill e Do not use compressed air for breathing e Use only for cutting gouging and tools TRAPPED AIR PRESSURE AND WHIPPING HOSES can injure e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap a MOVING PARTS can injure e Keep away from moving parts such as fans AJ belts and rotors e Keep all doors panels covers and guards closed and securely in place e Keep hands hair loose clothing and tools away from moving parts e Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied e Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e Reinstall doors panels covers or guards when se
52. box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or repaired cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal Disconnect cable for process not in use Use GFCI protection when oper
53. ceptacle RC5 RC5 supplies 60 Hz single phase power at weld power speed Maximum output is 11 kVA kW 5 Supplementary Protector CB1 CB1 protects receptacles RC1 GFCI2 GFCIS3 and RC5 from overload If CB1 opens the receptacles do not work Place switch in On position to reset 240V V Y MAIN BREAKER 265 985 266 064 6 Supplementary Protector CB2 7 Supplementary Protector CB3 CB2 protects GFCI2 and CB3 protects GFCI3 from overload If a supplementary protector opens the receptacle does not work EF Press button to reset If supplementa ry protector continues to open con tact Factory Authorized Service Agent Combined output of all receptacles limited to the rating of the generator Example If 20 A is drawn from each 120 V duplex receptacle only 26 A is available at the 240V receptacle 2x 120 V x 20 A 240 V x 26 A 11 0 kVA KW OM 266 040 Page 27 7 2 GFCI Receptacle Information Resetting And Testing A complete Parts List is available at wwwHobartWelders com k LJ ry 7 Use GFCI protection when operat ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacle to power life support equipment A Unplug power cord before attempt ing to service accessories or tools 120 V 20 A AC GFCI Receptacle GFCI Receptacle
54. d y Y 45 y 3 gt START rh HOUR METER gt BAT 48 IDLE CONTROL RUN IDLE 2 FVS 134 5 6 gt GROUND AAA NA No RUN gt o F 49 43 45 52 46 45 Fi 47 A rca A RC4 A RC4 RC4 A 2 6 5 3 1 4 A PLG4 PLG4 PLG4 PLG4 A 4 DI Low oL BRN o PRESSURE EL WHT Mm BLU N O City y ri S5 peur 2 VOLT D amp STARTER 19 Tsim E M igs a FS1 A ALTERNATOR FUEL m SUNSET ARE VOLT VOLT 0 PUMP RECT TE rH rh M om ELECTRIC FUEL KOHLER ENGINE ROME PETER 48 GFCI 3 80 83 85 8 Y 81 OO Hc z cH F E D C B A 90 90 30 ym 110 0 o 6 b o 42 GND ON 42 82 80 90 81 Ae A 42 82 80 90 81 42 42 42 1 CB2 du 2 on Las 86 Hc z H 30 ym 2 270 0 O 42 GND N 83 84 Lagon tLogag rh B x 83 B4 POWER 82 a 83 84 NG FIELD ES 80 81 lan 83 WELD 12 doc 84 j pi POSITION A E RC1 S2 e 42 cn Y WX 6 5 a2 5 240V 3 RUN IDLE O X 2 RUN x x x 84 E START X 83 42 GROUND O z rh X CLOSED TO B BOR TERMINAL X Y G O CLOSED TO BASE 240V GROUND DC Z 24 26 AR 29 E T 26 VR1 TM m 24 10 X L SR1 T RE T 27 o amp WARNING O Do not touch live electrical parts me om BASE PANEL GROUND GROUND Disconnect input powe ELECTRIC 0 Have on
55. d pass stick 2013 11 151 593 OM 266 040 Page 48 13 2 Electrode and Amperage Selection Chart AS x ELECTRODE DIAMETER AMPERAGE RANGE 100 150 200 250 300 350 POSITION PENETRATION A DEEP MIN PREP ROUGH ALL DEEP HIGH SPATTER ALL LOW GENERAL SMOOTH EASY ALL MED FAST LOW HYDROGEN ALL MED STRONG FLAT SMOOTH EASY DORE LOW FASTER NI CL EP ALL LOW CAST IRON 308L EP ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 13 3 Striking an Arc FA A Weld current starts when elec trode touches workpiece 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted too high If elec trode sticks to workpiece use a quick twist to free it Tapping Technique 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 work
56. d wires Spark Plug Gap 0 025 251161 C OM 266 040 Page 30 A complete Parts List is available at www HobartWelders com 8 2 Routine Maintenance fluids information Service engine more often if pe T Y ES Stop engine before maintaining GD 3 Bacche encina See Engine Manual and Maintenance Label y 9 for important start up service and storage used in severe conditions 17 Check Change Q Clean Replace Reference Every Section 5 4 8 P Ps Hours Fuel Level Y Oil Level Q Oil Fuel Spills Every 20 Hours Q Spark Arrestor Screen Every p H y Section 8 3 25 y Orgy Hours Q Air Cleaner Wrapper Every 50 Z Hours A 2 Q Weld Terminals Every Engine 100 Manual Hours Sections 8 3 and 8 4 Q Battery Terminals Q Cooling System x Air Cleaner Element Every o gg Oa Engine 200 S E 4 B a Manual Hours gt 2 e Section 8 4 Unreadable Labels Y Spark Plug Gap O Oil Filter Fuel Filter Every Engine 500 Manual Hours a X Weld Cables C Slip Rings x Brushes To be done by Factory Authorized Service Agent NOTICE This equipment meets US EPA Evaporative Standards Be sure fuel system replacement parts meet EPA Evaporation Standards OM 266 040 Page 31 FF A complete Parts List is available at wwwHobartWelders com 8 3 Servicing A
57. da LAW 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 1 8 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF The current from arc welding and allied pro cesses including spot welding gouging plasma arc cutting and induction heating operations creates an EMF field around the welding circuit EMF fields may interfere with some medical implants e g pace makers Protective measures for persons wearing medical implants have to be taken For example restrict access for passers by or con duct individual risk assessment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 266 040 Page 6 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm
58. ds for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Portable Generators Safety Alert U S Consumer Product Safety Com mission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website www cpsc gov cpscpub pubs port gen pdf Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin
59. e 1 Cross Supports Mount unit on flat surface or use cross supports to support base see Section 4 3 Mounting install2 2008 01 Ref 800 652 Ref 800 477 A 803 274 A 804 712 OM 266 040 Page 18 A complete Parts List is available at www HobartWelders com 5 2 Grounding Generator To Truck Or Trailer Frame A A A Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators Bed liners shipping skids and some running gear insulate the welding generator from the vehicle A 1 2 aD GND PE FE 3 cD frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Use GFCI protection when operat ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equipment 2 3 rot grnd1 2012 03 800 652 D Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insulated copper wire gt Electrically bond generator frame to vehicle frame by metal to metal con tact
60. e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins quijils n amp jaient t pr par s correctement conform ment AWS F4 1 et AWS A6 0 voir les Normes de S curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle cable de masse 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 chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La protection du corps comporte des v tements sans huile comme par ex des gants de cuir une chemise solide des pantalons sans revers des chaussures hautes et une casquette e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allume
61. e length in the weld circuit is 200 ft 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size Il Weld Cable Size and Total Cable Copper Length in Weld Circuit i ke Weld Output Not Exceeding Terminals A Turn off power be fore connecting to weld output termi nals 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft By bo not use worm 100 ft 30m orLess 45m 60m 70m 90m 105 m 120 m damaged under sized or repaired cables soon 60 100 Welding uy Duty 10 100 Duty Cycle Cycle Amperes ud Cycle AWG mm mm AWG mm 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 S O 95 4 0 120 4 0 120 250 2 85 1 50 1 0 60 210 70 3 0 95 4 0 120 Bx 290 300 1 50 1 0 60 2 0 70 3 0 95 4 O 120 GU ue ios 2x2 2 2 2x4 350 1 0 60 2 0 70 3 0 95 4 0 120 50 des e xi 2 2x2 2 2x4 2x4 400 1 0 60 2 0 70 3 0 95 4 0 120 530 5 gt a Sn 25 2x2 0 2x3 0 2x4 0 3x3 0 3x3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a curr
62. ect polarity and on batteries Disconnect negative cable first and connect it last Keep sparks flames cigarettes and other ignition sources away from batteries Batteries produce explosive gases during normal operation and when being charged Follow battery manufacturer s instructions when working on or near a battery Have only qualified persons do battery charging work If battery is being removed from a vehicle for charging discon nect negative cable first and connect it last To prevent an arc make sure all accessories are off Charge lead acid batteries only Do not use battery charger to supply power to an extra low voltage electrical system or to charge dry cell batteries Do not charge a frozen battery Do not use damaged charging cables Do not charge batteries in a closed area or where ventilation is restricted Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover Before charging battery select correct charger voltage to match battery voltage Set battery charging controls to the Off position before connect ing to battery Do not allow battery charging clips to touch each other Keep charging cables away from vehicle hood door or moving parts WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire e Allow c
63. efore making another weld pass S 0060 S 0058 A S 0061 OM 266 040 Page 52 13 12 Weld Test ZA 2 To 3 n 51 76 mm 1 4in 4 gt 6 4 mm Sn Es 1 Vise 2 Weld Joint 3 Hammer Strike the weld joint in the direction shown A good weld bends over but does not break If the weld breaks examine it to determine the cause If the weld is porous many holes the arc length was probably too long If the weld contains bits of slag the arc may have been too long or the electrode was moved incorrectly which wo 2 To 3 inl allowed molten slag to be trapped in the weld This may 51 76 mm happen on a V groove joint made in several layers and 2 calls for additional cleaning between layers 1 If the original beveled surface is visible the material was not fully melted which is often caused by insufficient heat or too fast a travel speed S 0057 B d 13 13 Troubleshooting Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead P
64. egislation 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_warr 2013 01 Thank you for purchasing Hobart Our trained technical support team is dedicated to your satisfaction For questions regarding performance op eration or service contact us Resources Available Always provide Model Name and Serial Style Number To locate a Service Center Call 1 800 332 3281 or visit our website at www HobartWelders com wheretobuy For Technical Assistance Call 1 800 332 3281 7 AM to 5 PM EST Monday through Friday Find us on E Facebook Yoi Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip ORIGINAL INSTRUCTIONS PRINTED IN USA 2013 Hobart Brothers Co 2013 01 Hobart Brothers Co An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Assistance Call1 800 332 3281
65. ent density of at least 300 circular mils per ampere mm for metric use For distances longer than those shown in this guide call a factory applications rep at 920 735 4505 Miller or 1 800 332 3281 Hobart Ref S 0007 K 2013 09 Notes OM 266 040 Page 23 6 1 aile Panel Controls FF A complete Parts List is available at wwwHobartWelders com SECTION 6 OPERATING THE WELDING GENERATOR Ch e A NES METER MAINTENANCE FUNCTIONS HOUR METER with engine off place Engine Control switch in RUN IDLE position to view engine hours OIL CHANGE INTERVAL with engine off place Engine Control switch into the RUN position to see hours before next oil change Oil hours start at 100 wrench icon f displays and count down to 0 wrench icon f flashes and oil change is due NOTE Negative hours indicated when past 4 recommended oil change interval TO RESET Cycle Engine Control switch from the RUN IDLE to RUN position 3 times within 5 seconds engine Off DO NOT SWITCH WHILE WELDING NO CAMBIE CUANDO SE ESTE SOLDANDO WP Set at 7 10 for Power While Welding Set at 10 for Full Auxiliary Powar Fijelo en 7 10 para potencia el ctrica mientras suelda Fijelo en 10 para potencia auxiliar el ctrica completa 8 orr Champion ELITE 225 Amp DC Welder 11 000 Watt Generator GND PE NBITPAL BO
66. es fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage Pour d terminer la bonne ventilation il est recommand de proc der un pr l vement pour la composition et la quantit de fum es et de gaz auxquels est expos le personnel e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les fiches de donn es de s curit et les instruc tions du fabricant concernant les adh sifs les rev tements les nettoyants les consommables les produits de refroidissement les d graisseurs les flux et les m taux e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent 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 for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium
67. imenter un autre circuit lectrique basse tension ou pour charger des batteries s ches Ne pas charger une batterie gel e Ne pas utiliser de c bles de charge endommag s Ne pas charger des batteries dans un espace ferm ou en l absence d une ventilation Ne pas charger une batterie dont les bornes sont desserr es ou pr sentant une d t rioration comme par exemple un boitier ou un couvercle fissur Avant de charger une batterie s lectionner la tension de charge correspondanta la tension de la batterie R gler les commandes de charge de batterie sur la position d arr t avant de brancher la batterie Veiller ce que les pinces de charge ne se touchent pas Ranger les c bles de charge distance du capot des portes et des pi ces mobiles du v hicule LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geantle fil de soudage 3 i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Pd e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste OM 266 040 Page 12 LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de
68. in RUN IDLE position to view engine hours OIL CHANGE INTERVAL with engine off place Engine Control switch into the RUN position to see hours before next oil change Oil hours start at 100 wrench icon Y displays and count down to 0 wrench icon f flashes and oil change is due NOTE Negative hours indicated when past recommended oil change interval TO RESET Cycle Engine Control switch from the RUN IDLE to RUN position 3 times within 5 seconds engine Off KOHLER CH730 LP ENGINES LIQUID WITHDRAWAL AN SYSTEM ONLY VAPORIZER ASSEMBLY Frequently inspect fins FUNCIONES DE MANTENIMIENTO DE LOS MEDIDORES HOR METRO con el motor apagado ponga el control del motor en la posici n RUN IDLE marcha ralent para ver las horas en el motor INTERVALO DEL CAMBIO DE ACEITE con el motor apagado ponga el CONTROL DEL MOTOR en la posici n RUN marcha para ver las horas que quedan antes del cambio de aceite Las horas del aceite comienzan en 100 pantalla muestra el icono de llave T y disminuye hasta cero la llave Y parpadea cuando se necesita cambiar el aceite NOTE Horas negativas indican que se a sobre pasado el intervalo del cambio del aceite PARA REARMAR le el control del motor de la posici n RUN IDLE a RUN tres veces dento de 5 segundos con el motor apagado Fuel Grade Unleaded 87 Octane min 10 Max Ethanol Fuel Filter ECH730 MILLER 246 110 Kohler 2505021 S MILLER 246 112 Kohler 2505042 S SUBARU MILLER 2
69. iners that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear body protection made from durable flame resistant material leather heavy cotton wool Body protection includes oil free clothing such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby Read and understand the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals NOISE can damage hearing Noise from some
70. ion quand on ne l utilise pas e Ne pas utiliser des cables us s endommag s sous dimension n s ou r par s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un cable distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e 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 Fixer le cable 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 pos sible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage D brancher le c ble pour le proc d non utilis OM 266 040 Page 7 e Utiliser une protection diff rentielle lors de l utilisation d un quipe ment auxiliaire Ne pas tester ni r armer les p
71. ir Cleaner A Stop engine ESP e NOTICE Do not run engine with s E out air cleaner or with dirty element lt 7 1 Precleaner ki Wash precleaner with soap and wa ter solution Allow precleaner to air o Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze dry completely out excess oil 2 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 S 0759 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 266 040 Page 32 A complete Parts List is available at www HobartWelders com 8 4 Changing Engine Oil Oil Filter and Fuel Filter Lay C A A Stop engine and let cool Oil ES EA Drain Valve 1 Change engine oil and filter OFF according to engine owner s manual NOTICE Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 2 Fuel Filter 3 Fuel Line Replace line if cracked or worn Install new filter with arrow pointing in the direction of fuel flow Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe up fuel Reset oil maintenance countdown
72. ir system so failure of any component will not put people or prop erty at risk e Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied 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 HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ada ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 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 If the engine is warm checking is needed and there is no over flow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents
73. is extensively Frequently idled This may cause vacuum line freezing oil breather tube freezing or ice in the Loaded carburetor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to above freezing OFF ga RUN IDLE nun S START Load engine and reduce idle times to prevent engine shutdowns Use an electric fuel pump to avoid pulse line freezing e Install engine cold weather kit Kohler 1 800 544 2444 offers a kit for cold weather operation The user can install the kit The kit pulls heated air from the muffler surface into the carburetor and shuts the cold air off This increases engine temperature during operation in both idle and high speed Ref 236 615 A C3 When the ambient temperatures become warmer above 45 F the air flow will have to be returned to normal Synthetic Oil For temperatures below zero 0 F synthetic oil improves engine starting After the first 50 hours of operation with non synthetic oil the engine can be switched to synethic oil Do not extend the 100 hour recommended oil change interval In severe cold use synthetic grade 5W30 oil See engine maintenance label for additional information Notes OM 266 040 Page 25 6 A complete Parts List is available at wwwHobartWelders com Typical Stick Welding Connections And Control Settings
74. l level Check engine speed and adjust if necessary see Section 8 5 Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes and slip rings 9 3 Engine Troubleshooting Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 6 Check battery voltage Check battery connections and tighten if necessary Check plug PLG4 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine will not start Check fuel level Check battery voltage Check battery connections and tighten if necessary Check oil level see Section 8 4 Check low oil pressure shutdown switch Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8 Engine starts but stops when Engine Control switch returns to Run position Check oil level Check and refill crankcase with proper viscosity oil for operating temperature if necessary Check low oil pressure shutdown switch Engine stopped during normal operation Check fuel level Check oil level see Section 8 4 Check low oil pressure shutdown switch Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Have Factory Authorized Service
75. llation le fonctionnement et la maintenance 2 6 Proposition californienne 65 Avertissements 2 7 Principales normes de s curit 2 8 Informations relatives aux CEM 22 SECTION 3 DEFINITIONS cisi re Re a ease ste khu RARE ER mes e DDE ss sens 3 1 Additional Safety Symbols And Definitions SECTION 4 SPECIFICATIONS ooooooooo eee nnne eee nnn nnnm 4 1 Serial Number And Rating Label Location 4 2 Specifications arto Rene poe d eee ao seit eco rtt e e rr a ella t t vu Rc 4 3 Dimensions Weights And Operating Angles 4 4 Duty Cycle eene ovS NET nade AERE RENNES PUER INEEPEUN US TERRE 4 5 Fuel Consumption 6 e tated UAE Ren ddd es Ae 4 6 Volt Ampere CUIVeS terere nor ex RECTE I SC YR TER PIRE APERIT ened SECTION 5 INSTAELATION 23 51 A a a ERI A EE IEEE 5 1 Installing Welding Generator ooocccccccccccccc erarnan 5 2 Grounding Generator To Truck Or Trailer Frame 5 3 Installing Exhaust Pipe 0 00 cette m hn 5 4 Engine Prestart Ghecks ia teita eaa sane de va E Ra UR on vale dat DA al CR PR i 5 5 Connecting Or Replacing the Battery 0 cece ccc ees 5 6 Connecting To Weld Output Terminals
76. ly qualified pei SHOCK HAZARD engine before servicing Do not operate with covers removed use or service this unit r or stop rsons install 256 993 A For Welding Generator ircuit Diagram Figure 11 1 C OM 266 040 Page 39 Notes OM 266 040 Page 40 SECTION 12 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment P 1 Generator Power Receptacles Neutral Bonded To Frame 2 8 Prong Plug From Case Grounded Equipment 3 2 Prong Plug From Double Insulated Equipment CF Be sure equipment has double insulated symbol and or word ing on it A Do not use 2 prong plug un less equipment is double in sulated gen_pwr 2012 03 ST 800 577 12 2 Grounding Generator To Truck Or Trailer Frame pA A Always ground generator frame to A 1 2 vehicle frame to prevent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied 1 2 GND PE ign E
77. moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et 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 266 040 Page 8 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermerl alimentation du gaz comprim en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent provoquer 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 soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot 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 Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc
78. n Excessive Penetration weld metal melting through base metal and hanging underneath weld Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 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 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 Base metal moves in the direction of the weld bead Distortion contraction of weld metal during welding that forces base metal to move Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 266 040 Page 54 Warranty Questions Call 1 800 332 3281 7AM 5PMEST 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
79. nd the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded a BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87
80. ng the valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can injure 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 battery charging cables if applicable or servicing battery e Do not allow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles un less the unit has a battery charging feature designed for this pur pose e Observe correct polarity and on batteries e Disconnect negative cable first and connect it last e Keep sparks flames cigarettes and other ignition sources away from batteries Batteries produce explosive gases during normal operation and when being charged e Follow battery manufacturer s instructions when working on or near a battery FUEL can cause fire or explosion e 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 Do not overfill tank allow room for fuel to expand
81. nt l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section E PR N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que Pali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service Lh LA CHUTE DE L EQUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l illeton voir les sp cifications e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e Enutilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de to
82. on Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65
83. ooling period follow rated duty cycle lt e Reduce current or reduce duty cycle before L starting to weld again e Do not block or filter airflow to unit OVERUSE can cause OVERHEATING 27 STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can injure a e Use tongue jack or blocks to support weight 2 0B e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using
84. ossible 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 A Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding OM 266 040 Page 53 CTO EY Lack of Penetration Good Penetration Lack Of Penetration shallow fusion between weld metal and base metal Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed Ca CY gt Excessive Penetration Good Penetratio
85. ower together use a low Coarse Range setting with the Fine con trol set at 7 or higher 5 Fine Control Use control to select weld amperage within the range selected by the Coarse Range switch Control may be adjusted while welding Set control at 10 for maximum generator power Weld output would be about 112 A DC based on control settings shown 80 of 50 to 140 A Settings shown are typical for welding with a 7018 1 8 electrode EF See Sections 6 3 for typical process con nections and control settings OM 266 040 Page 24 FF A complete Parts List is available at www HobartWelders com 6 2 Cold Weather En Operation ine DRAW AEN ho pay 1 Engine Control Switch Carburetor Icing Infrequently Loaded Carburetor icing causes the unit to drop below the normal idle speed and then stall This condition occurs when the temperature is near freezing and the relative hu midity is high Ice forms on the throttle plate and inner bore of the carburetor The engine typically restarts without problems but soon stalls again RUN IDLE nun S e Treat gasoline with a fuel de icer product isopropyl alcohol e Place the Engine Control switch in the Run position Run engine only when expecting to frequently load it Breather Icing Oil breather pulse line icing occurs in severe cold continuously below 0 F Mois ture accumulates in the oil from piston ring blow by if the engine
86. piece use a quick twist to free it S 0049 S 0050 OM 266 040 Page 49 13 4 Positioning Electrode Holder 1 End View Of Work Angle 2 Side View Of Electrode Angle After learning to start and hold an arc practice running beads of weld metal on flat plates using a full electrode ATO A pay Hold the electrode nearly per pendicular to the work although tilting it ahead in the direction of travel will be helpful EF To produce the best results E t hold a short arc travel at a S g 5 uniform speed and feed the electrode downward at a Groove Welds constant rate as it melts S N S Fillet Welds S 0060 13 5 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration OO ND S 0053 A 13 6 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 Ops WA awe being welded 4 5 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 266 040 Page 50 13 7 Conditions That Affect Weld Bead Shape ER PIN A o EF Weld bead shape is affected by electrode angle arc length travel speed and thick ness of
87. piece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Do not weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre rom 2013 09 A Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu sir ces consignes relatives 2 aux pr cautions de s curit et au mode op ratoire 1 Signification des symboles A DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Pb Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel po
88. r emp cher le contact physique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder L Indique des instructions sp cifiques e A PF Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger manuel AC avec tension vide r duite Dans la plupart des c
89. riel ou corporel e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e Ne pas intervenir sur le circuit d air comprim lorsque l appareil fonctionne Seul un personnel qualifi est autoris et appliquant les consignes du fabricant e Ne pas modifier ou alt rer le compresseur ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliserles quipements de s curit du circuit d air comprim e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Se tenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit d air comprim OM 266 040 Page 10 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 autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant e Mettre 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 L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES
90. rises femelles avec diff rentiel au r gime de ralenti en basse tension cela endom mageraitle disjoncteur diff rentiel qui ne remplirait plus son r le de protection contre une lectrocution caus e par un d faut de masse Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coup e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chau li aps e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de sou dage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES SALETES peuvent provoquer C des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial n LES FUM ES ET LES GAZ peu vent tre dangereux lt Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te d
91. rranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Reactors Stabilizers Transformers 2 3 Years Parts and Labor Drive Systems Idle Module PC Boards Rotors Stators and Brushes Solenoid Valves Spot Welder Transformer Switches and Controls 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Accessories Batteries Trek 180 Only Contactors 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 Flowgauge and Flowmeter Regulators No Labor HF Units MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Regulators Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Water Coolant Systems 4 Engines batteries except Trek 180 and tires are warranted separa
92. rs 254 297 A 266 064 A OM 266 040 Page 34 8 6 Overload Protection A complete Parts List is available at www HobartWelders com ZW Ne x Fuses F1 F2 located on bracket behind right side panel A Stop engine Disconnect negative battery cable OFF 1 Fuse F2 See Section 10 1 F2 protects the weld excitation winding from overload If F2 opens weld output stops or is low 2 FuseF1 See Section 10 1 F1 protects the generator power excitation winding from overload If F1 opens generator power output stops or is low 3 Fuse F6 See Section 10 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating FF If a fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorized Service Agent O Tools Needed BU 7 IZA IZ 3 8 in 266 064 A 254 014 A OM 266 040 Page 35 A complete Parts List is available at wwwHobartWelders com SECTION 9 TROUBLESHOOTING 9 1 Welding Troubleshooting A
93. rvicing is finished and before starting engine HOT PARTS can burn e Do not touch hot compressor or air system parts e Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes EPR 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords aw
94. speed Set front panel amperage controls at Max to achieve full generator power see Section 6 1 Press GFCI Re Set button Reconnect equipment to GFCI receptacle If GFCI Reset button pops out again check the equipment and repair or replace if faulty Testing GFCI Receptacles GFCI testing must be done with engine running at Run weld power speed Start engine and operate at Run weld power speed Set front panel amperage controls at Max to achieve full generator power see Section 6 1 Press the GFCI Test button The GFCI Re set button should pop out Press the GFCI Reset button Have GFCI replaced by a Factory Au thorized Service Agent if any of the fol lowing occur GFCI does not trip when tested LED blinks GFCI does not reset OM 266 040 Page 28 A complete Parts List is available at www HobartWelders com 7 3 Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Full kVA Receptacle 240 V Full kVA Receptacle Amperes Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 11 000 92 46 7 4 Wiring Optional 120 240 Volt Plug 2 The plug can be wired for a 240 V gt gt ar 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V mo 7 3 Wire Load Current Available in Amperes When wired for 120 V loads each duplex receptacle shares a load 240
95. ssive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz comprim r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers existant en relation avec le moteur L EXPLOSION D
96. sur faces of the weld cable termi nal and copper bar are clean 1 Correct Weld Cable Installation 2 Incorrect Weld Cable Installation 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld out put terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar 7 Negative Output Terminal 8 Positive Output Terminal For Direct Current Electrode Positive DCEP connect work cable to Neg E ative terminal and electrode hold er cable to Positive terminal For Direct Current Electrode Negat ive DCEN reverse cable connec tions See Sections 6 3 for typical pro cess connections and control settings 120 240V V o Oo CBI i 50A MAIN BREAKER 1208 AWA 4 on is Horr MAIN BREAKER MAIN BREAKER Tools Needed IZ gin 244 029 A 265 985 266 064 OM 266 040 Page 22 A complete Parts List is available at www HobartWelders com 5 7 Selecting Weld Cable Sizes NOTICE The Total Cable Length in Weld Circuit see table below is the combined length of both weld cables For example if the power source is 100 ft 30 m from the workpiece the total cabl
97. tely by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment 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 Miller s 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
98. the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If 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 OM 266 040 Page 5 1 6 California Proposition 65 Warnings A Welding or cutting equipment 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 A 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
99. ting must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 12 4 OM 266 040 Page 46 12 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads A Use GFCI protection when operating auxiliary equipment If unit does not have GFCI receptacles use GFCI protected exten sion cord Do not use GFCI receptacles to power life support equipment Maximum Allowable Cord Length in ft m for Conductor Size AWG Rages Load Watts 4 6 8 10 12 14 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
100. tive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5Ax115V 2 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 266 040 Page 42 12 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 12 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running W
101. tside welding generator Check engine speed and adjust if necessary see Section 8 5 Have Factory Authorized Service Agent check brushes slip rings and integrated rectifiers SR2 SR3 9 2 Generator Power Troubleshooting Trouble Remedy No or low generator power output at ac receptacles weld output okay Reset supplementary protectors see Section 7 1 For models with GFCI receptacles also press receptacle reset button see Section 7 2 Check fuse F2 and replace if open see Section 8 6 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings and integrated rectifier SR3 OM 266 040 Page 36 FF A complete Parts List is available at www HobartWelders com Trouble Remedy No generator power or weld output Be sure all equipment is disconnected from receptacles when starting unit Check fuses F1 and F2 and replace if open see Section 8 6 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 Low power output at ac receptacles Check fuse F2 and replace if open see Section 8 6 Increase Fine control R1 setting to max High power output at ac receptacles Check engine speed and adjust if necessary see Section 8 5 Erratic power output at ac receptacles Check fue
102. ttes e Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction Le bruit des processus et des quipements peut Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz comprim protecteur contien nent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur exce
103. ur 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 apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants 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 galementsous tension ce moment l En souda ge semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement 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 compor tant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pou
104. ute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds LE SURCHAUFFEMENT peut endommager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz S il y a lieu LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette ma noeuvre est ex cuter dans un endroit sir lors que l on porte l quipement homologu de pro tection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance inflammable N Les PIECES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande 3 OM 266 040 Page 11 LA SORTIE DE RECHARGE et L EXP LOSION DE LA BATTERIE peuvent provoquer des blessures La recharge de batterie n existe pas sur tous les mod les Toujours porter une protection f
105. vertance e D tendre la pression avant de d brancher ou de brancher des canalisations d air e Avant d utiliser l appareil contr ler les composants du circuit d air comprim les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure Ne pas diriger un jet d air vers soi m me ou vers autrui e Pourintervenir sur un circuit d air comprim porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser de l eau savonneuse ou un d tecteur ultrasons jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil e En cas d injection d air dans la peau ou le corps demander imm diatementune assistance m dicale L INHALATION D AIR COMPRIM risque de provoquer des blessures ou m me la mort Ne pas inhaler d air comprim Utiliser l air comprim uniquement pour d couper ou gouger ainsi que pour l outillage pneumatique Une PRESSION D AIR R SIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures e D tendre la pression pneumatique des outils et circuits avant d entretenir ajouter ou changer des accessoires et avant d ouvrir le
106. y 1 A A A 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away 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 automat ic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process

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