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Hobart Welding Products CHAMP 2060 Welding System User Manual

Contents

1. Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 28 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 If unit does not have GFCI receptacles use GFCI protected extension Maximum Allowable Cord Length in ft m for Conductor Size AWG Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800
2. Move lever to Run far right posi tion To increase speed turn screw gt ences out counterclockwise while lightly ZH pushing lever to the right To de crease speed turn screw in clock wise Idle Speed Adjustment 3 Adjustment Screw Move lever to idle far left position To increase idle speed turn screw in clockwise To decrease idle speed turn screw out counter clockwise A Stop engine Close fuel valve Top View 802 511 A Kohler Dwg OM 499 Page 26 7 5 Adjusting Engine Speed Honda Powered Units pes e After tuning engine check engine ug id speeds See table for proper no load speeds If necessary adjust speeds as follows 1400 150 rpm Start engine and run until warm 3720 50 rpm 60 Hz Speed 3250 50 rpm 50 Hz 4 Throttle Control Lever 2 Adjustment Screw Move lever to Run 60 Hz position Turn screw and move lever until en gine runs at weld power speed Idle Speed Adjustment 3 Pilot Screw 4 Throttle Stop Screw Move lever to idle position Turn pi lot screw until engine runs at high est idle speed Turn stop screw until engine runs at rated idle speed normally about 2 1 4 turns out A Stop engine Close fuel valve Tools Needed C EE gt 1 4 3 8 in 802 097 A OM 499 Page 27 SECTION 8 TROUBLESHOOTING 8 1 Troubleshooting A Welding Trouble Remedy
3. 1 a 495 256 MOUNT shock generator 1 o prc LECT 194 504 FRAME mtg assembly Kohler 1 pid ato idea s ati aiia 495 132 FRAME mtg assembly Honda 1 o E 495255 Ca 1 495 2147 SEAL UL 1 EC EEEN ay n 207083 POTENTIOMETER esc tocar R ad a San Wa ea ane K peu cana 1 e PCIE 207072 gt KNOB DOL Sa RH red ne Sede Ba bake 1 ECT oe E NAMEPLATE overlay order by model serial number 1 asd HM 17678697 METER M eame datis dan ane 1 Figure 12 2 PANEL gen power assembly 1 PE MMC 405230 BASE CONMOLDOX 23 ceto dx PR aa ie ae a waned 1 OM 499 Page 51 No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued N MERE Te 1726601 1BLOGK dka or d ht Gdn ar Dr d 1 495 193 BRACKET mtg terminal block 1 43 R2 VR1 046819 SUPPRESSOR assembly 1 44 SR2 495 189 RECTIFIER assembly w mtg hardware 1 wale OL 197 795 RESISTOR ASSEMBLY Kohler 1 46 176007 GAPAGITOR Seo wees
4. 1 5 PERPE 494 629 GUARD generator 1 VO 194 509 FAN generator Kohler 1 le ere 493 868 FAN generator Honda 1 bill ee ee eee 204 469 GENERATOR w stator assembly 1 o lO ick EET S 495197 lt ROTOR assembly 2 kad 1 495154 BEARING Seya aye ku ne Gb Se ee eh wees hera eae eee as dar 1 495 349 SCREW 1 4 20 HWH 4 NU ins ne 494 587 CARRIER bearing 1 ele disais 495 348 SCREW 5 16 24 HWH 1 D PH 494 628 PANEL end generator 1 C MERE 495 257 MOUNT shock w bushing 2 edo 495 113 22 EEAD aud p a Rees 1 RCM PM PRESS 494 039 COVER battery cable 1 495 111 LEAD pattern DOS 122 4934 293 9 3 9 0 1 403 057 sa xak eon OA denis med 1 a a Nek W stet 494 0041 BOLT d ll a kak are dak arik es er E 1 Le NE r 1 POT 495 112 LEAD battery neg
5. 21 6 1 Generator Power Panel 495 218 USA 21 6 2 Optional Generator Power Panels 22 6 3 Generator Power Panel Ratings 23 6 4 Wiring Instructions For Optional 120 240 Volt Twistlock Plug NEMA L14 30P 24 SECTION 7 MAINTENANGE ar us x o c Sw FIO nets vada nd dd CERO d he 24 Fele Maintenance Labels Ec soia rectae dead dca a do n d 24 722 Roine MAINTENANCE ud edente Oden dtu RO nan Iu TR Odd etam n qp RR 25 7 3 Overload Protection Honda Powered Units 26 7 4 Adjusting Engine Speed Kohler Powered Units 26 7 5 Adjusting Engine Speed Honda Powered Units 27 SECTION 8 TROUBLESHOOTING lt J 4 un Rx kk kak kak ka kk ak a kk kk kak ka kk kk kk kk ka 28 SECTION 9 ELECTRICAL DIAGRAMS 30 SECTION 10 GENERATOR POWER GUIDELINES 35 SECTION 11 STICK WELDING SMAW GUIDELINES 42 SECTION I2 PARTS LIST iius wi Sin E ad Gitar Ehd y ualet did En d d IR d un dia 50 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom nd 10 02 A Warning Protect yourse
6. Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection AL WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cove
7. Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le cable n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des orga nes mobiles Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur o f LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de verifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi op rer comme sui vant Mettre des lunettes de s curit et des gants placer un torchon sur le bou chon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon LA CHALEUR DU MOTEUR peut pro voquer un incendie e pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distan
8. ENGINE EXHAUST GASES can kill e Use equipment outside in open well ventilated areas e If used in a closed area vent engine exhaust outside and away from any building air intakes BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Stop engine and release air pressure before servicing 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long eno
9. Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty LEN all grease oil moisture rust paint coatings slag and dirt from work surface before welding 11 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 499 Page 47 11 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 11 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base
10. HO aay 4 914 H3 1lIS PASS 8 91d ALIHM 2 0 5 3 1 li dol zpior 5 S3 V6 6 9 v6 98 S 0HJVB 8 L S89M VLL L vrOM VA 9 G9M V91 9 9u v9 S G 9M VGL S3 v S 0HJVE 02 693 L 2 L 499 Page 32 WARNING Do not touch live electrical parts Disconnect input power stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit AUXILIARY PANEL 196914 2 120V DX 240V TWLK CSA AUXILIARY PANEL 495219 2 120V DX 240V TWLK AUXILIARY PANEL 495253 S AFRICA l 55A RC1 Y AUXILIARY PANEL 196921 2 120V 240V TWLK CSA ERIGI DIDI ACA L E B D E F R CE 5 i 55A CB2 J 201 026 A Figure 9 4 Wiring Diagram For Auxiliary Power Panels 1 Of 2 OM 499 Page 33 WARNING e Do not touch live electrical parts De 20 e Disconnect input power or stop jN engine
11. 1 Prasa AGA co siya 129 067 RECEPTACLE tw Ik grd 3P4W 30A 125 250V 1 PEER A y eee MANEV 088 898 PLUG tw Ik grd 3P4W 30A 125 250V 21 RC2 RC3 141432 RECEPTACLE str dx grd 2P3W 20 125V 2 Hania htc ar W SOINS 073 690 PLUG str grd armd 2P3W 15A 125V Generator Power Panel 495 290 Europe Eo on 495 282 PANEL generator power assembly 1 CB1 CB2 495245 CIRCUIT BREAKER 15A ie Li he ea eed ore ed EE 2 Generator Power Panel 495 288 S America Si ZE VD TT LR 495 287 PANEL generator power assembly 1 250 an OBI 495 245 22 CIRGUIT BREAKER 15 iio Loue kan Oe bed ee 4 Generator Power Panel 495 283 S E Asia ye etl 495 282 Panel generator power assembly 1 CB2 495245 CIRCUIT BREAKER T5A terere tens 2 Generator Power Panel 495 298 USA gt rv 495 220 PANEL generator power assembly 1 29 uu 495 183 gt GIRGUIT BREAKER he breed aed 1 30 CB2 495 246 CIRCUIT BREAKER 20 2 31 RCI 22 007 467 RECEPTACLE tw Ik grd 2P3W 30A 125V 1 dite ae 605 797 PLUG tw Ik 3P3W 20 125V 32 RC2 141 432 RECEPTACLE st
12. Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille e Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Main
13. e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e 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 e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire
14. L 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 rement les enfants ER e UN CHOC LECTRIQUE peut tuer ne Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique c
15. MACHINE OPTION ONLY SEE AUXILIARY PANEL SCHEMATIC D E 77 PLG4 40 9 8 7 PLG5 RC4 WELD WINDING NEGATIVE 17 78 o a PLGS S BLACK RCS PLG5 2 1 2 N N ENGINE lt CW Cai lt CURRENT CONTROL 77 74 75 76 ENGINE LAMP 12VAC COIL 197 857 E Figure 9 1 Circuit Diagram For Welding Generator 1 Of 2 OM 499 Page 30 WARNING engine before servicing Do not touch live electrical parts Disconnect input power or stop Do not operate with covers removed Have only qualified persons install 57 use or service this unit 1T A 1T B 1T C 1T E 57 RC 240V RC2 120V RC3 120V 1T B 1T C 1T E RC1 240V 55 RC2 120V o5 77 3 x RC 120V 56 77 RC2 120V B G 23 57 17 RC3 120V AUXILIARY PANEL 495218 USA cd RC1 240V 26 RC2 120V RC3 120V AUXILIARY PANEL 495219 USA 1T A 1T B 1T C 1T D 1T E o ___ 57 B G cB1 _ Las 24 RC1 230V 57 p CB2 22 44 RC2 2300 AUXILIARY PANEL 495283 S E ASIA AUXILIARY PANEL 495253 S AFRICA AUXILIARY PANEL 495290 EUROPEAN 1T A 1T B 1T C 1T D 1T E 5 E 1 57 B G W cB1 CB2 55 77 56 27 54 B G W CB3 CB4 57 77 o8 RC1 230V RC2 230V AUXILIARY PANEL 495289 AUSTRALIA 77 1T A 1T B 1T C 1T D 1T E
16. CSA only 1 des 198 472 REACTOR stabilizing 1 pO Aa ions A a bA 204 140 LABEL MOVING parts 4 1 bu 493 509 BRUSHHOLDER assembly 1 ara We mk Kay ane 204 138 LABEL warning fuel also supplied with engine 1 Wo 195 771 ENGINE Kohler 12HP electric start 1 sf teste 203 952 FILTER air Kohler cs 8 5 amp 12 1 se AN ee ANS re eee 203 954 FILTER air pre Kohler cs 8 5 amp 12 1 EET 203 955 CAP fuel Kohler cs 8 5 amp 12 203 956 TANK fuel Kohler cs 8 5 amp 12 1 SETTE nA d 203 957 STRAINER fuel Kohler cs 8 5 amp 12 d No Ghee 203 958 MUFFLER exhaust engine Kohler cs 8 5 amp 12 1 Le day donk 203 959 GASKET muffler Kohler cs 8 5 amp 12 1 DEHN 203 960 SPARK PLUG Kohler cs 8 5 amp 12 1 a SENTE 495 055 ENGINE Honda 13HP recoil start 1 nee a 495 053 ENGINE Honda 13HP electric start 1 Ww o 494 606 ADAPTER engine
17. Fill fuel tank up to 1 2 in 13 mm from top to allow room for ex pansion Check fuel level on a cold en gine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dip stick add oil see maintenance label Closed r5 To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather 802 511 A OM 499 Page 15 4 5 Engine Prestart Checks Honda Powered Units Tools Needed JT 3 8 1 2 in OM 499 Page 16 F Gasoline Connect negative cable last Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil level gets too low jr Follow run in procedure in en gine manual 1 Fuel Valve Open valve gt Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label 7 To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold
18. Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors Rotors Stators and Brushes 2 Years Parts and Labor Drive Systems PC Boards Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries a
19. No weld output Check Amperage control setting Check weld connections Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Be sure all equipment is disconnected from receptacles when starting unit Have Factory Authorized Service Agent check brushes slip rings capacitor C1 integrated rectifiers SR1 and 582 resistor R3 Kohler only and circuit board PC1 Low weld output Check Amperage control and throttle lever settings Check engine speed and adjust if necessary see Section 7 4 or 7 5 Service air cleaner according to engine manual Check weld cable size and length Have Factory Authorized Service Agent check brushes slip rings capacitor C1 integrated rectifiers SR1 and SR2 resistor R3 Kohler only and circuit board PC1 High weld output Check Amperage control setting Check engine speed and adjust if necessary see Section 7 4 or 7 5 Have Factory Authorized Service Agent check brushes slip rings capacitor C1 integrated rectifiers SR1 SR2 suppressor VR1 R2 resistor R3 Kohler only and circuit board PC1 Erratic weld output Check Amperage control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside wel
20. Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motors running amperage Motor Start rmn p KVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 1 4 Using Table Code M results in 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 230 122A Starting the motor requires 12 2 amperes 10 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 499 Page 39 10 10 Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner s Manual and national state and local codes Utility Electrical Service Have only qualified persons perform these connections according to all applicable codes and safety practic es Properly install and ground this equipment according to its Owner s Manual and national state and local codes r Customer supplied equipment is re quired if generator will supply standby power during emergencies or power out ages 1 Utility Electrica
21. close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area levard Rexdale Ontario Canada M9W 183 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Kee
22. see Section 5 1 or 5 2 Erratic power output at generator power ac receptacles Check fuel level Check receptacle wiring and connections Check throttle governor linkage for smooth non binding operation Service air cleaner according to engine manual Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Have Factory Authorized Service Agent check brushes slip rings resistor R3 Kohler only and circuit board PC1 C Engine Trouble Remedy Engine will not crank electric start models only Reset ignition circuit breaker see Section 7 3 Check battery voltage Check battery connections and tighten if necessary Have Factory Authorized Service Agent check engine ignition circuit Engine will not start Check fuel level see Section 4 4 or 4 5 Move choke lever to correct position see Section 5 1 or 5 2 Open fuel valve see Section 4 4 or 4 5 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check battery voltage electric start models only Check battery connections and tighten if necessary electric start models only Check oil level see Section 4 4 or 4 5 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil level shutdow
23. 120 160 E 7014 70 90 120 145 145 gt lt ELECTRODE m m m m m 802 094 A 802 095 495 187 OM 499 Page 19 5 3 Description Of Controls ee Powered Units See Section 5 2 r Weld and generator power output stops if generator overheats or engine speed is too low 1 Engine Switch On models with recoil start use switch to open ignition circuit and to stop engine On models with electric start use switch to open ignition circuit and to start and stop en gine 2 Throttle Control Lever Use lever to select engine speed Use 50 Hz or 60 Hz position for generator power Use 60 Hz position for maximum weld output 3 Choke Control Lever Use lever to change engine air fuel mix Move lever to left if starting a cold engine Move le ver to right if starting a warm engine 4 Starter Handle Recoil Start Models Only Notes OM 499 Page 20 To Start Recoil open fuel valve turn engine switch to On move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Start Electric open fuel valve move throttle lever to Idle set choke and turn en gine switch to Start position Open choke as engine warms A If engine does not start let engine come to a complete stop before at tempting restart To Stop turn engine switch to Off gt Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and m
24. 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 499 Page 41 SECTION 11 STICK WELDING SMAW GUIDELINES 11 1 Stick Welding Procedure A Weld current starts when electrode touches work piece A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode W A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 11 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass Tools Needed 499 42 stick 12 96 ST 151 593 11 2 Electrode and Amperage Selection Chart AMPERAGE RANGE 50 100 150 250 DEEP MIN PREP ROUGH HIGH SPATTER GENERAL EASY E V A FAR 7014 P EN DES FAST LOW HYDROGEN 7024 EPEN HORIZ m SM EE FILLET EP AL
25. 27 54 w B CB2 ies Le m RC1 230V Ww G B 54 CB3 CB4 57 77 RC2 230V AUXILIARY PANEL 495288 S AMERICA Figure 9 2 Circuit Diagram For Welding Generator 2 Of 2 OM 499 Page 31 197 857 E quvzvH ywJOHS 21919913 JUN siu 821M8 10 esn pesu Ajuo e 5 YUM eje1edo JOU OG e dois 10 18mod Indu 158uu09S1Q e syed 9NINHVM P AYOM Ng uv ae OUION3 IOS MN3LNHVIS AYA LIVE N Q e T T N 6 AN LISOd J 0l A 285 10 ANNHS HOVIE HO 34 NOlLdO 3NION3 33 1HO I 1 J 197 858 C zu QU 19 ZADE JIE TU 3NION3 SNION3 Z 831HOM Ws Di GOO LL OOO Ti tows LI A 914 RHS OVIG NO 435 4 Wr Figure 9 3 Wiring Diagram For Welding Generator ai dor O INnHS sar C C e peg aj 6
26. ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu OM 499 Page 6 Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 518 pour les travaux chaud et avoir de la surveillance et un extincteur proxi mit DES PARTICULES VOLANTES 2 peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PIECES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques
27. OK It exceeds 5500W OM 499 Page 23 6 4 Wiring Instructions For Optional 120 240 Volt Twistlock Plug NEMA L14 30P 1 Plug Wired For 120 240 V 3 Wire Load When wired for 120 V loads each du plex receptacle shares a load with one half of the 240 V receptacle Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Cord Grip Strip cord jacket back enough to sep arate conductors Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not overtighten plug3 11 99 802 527 Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period 7 1 Maintenance Label ENGINE MAINTENANCE 1 1 1 2 US at 1 94 Imp at Unleaded 86 Octane 6 5 1 7 US Gal 11 4 Imp pt 0 7 0 8 mm 0 028 0 031 in Ref S 175 679 A OM 499 Page 24 7 2 Routine Maintenance Stop engine before maintaining Recycle gt See Engine Manual and Maintenance Label Ser engine vice more often if used in severe conditions fluids To be done by Factory Authorized Service Agent 20h Check fluid Check and clean levels See qi Wipe up spills spark arrestor screen Tem Section 4 4 See engine manual N or 4 5 50h Service air cleaner LA Clean and element S
28. Page 37 10 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 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 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 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 499 Page 38 10 8 Power Required To Start Motor Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage AC MOTOR 60 PHASE 1 Step 1 Find code and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example
29. West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 HOBART WELDERS
30. avn de 1 na 494 915 CLAMP capacitor iesu e edd eet o Oe les KK KK KK de 1 paca EO acd 201 223 LABEL warning electric shock power still present 1 PNE oC 495 187 LABEL current selection 1 aco de Em 188 039 COVER receptacle w gasket 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 499 Page 52 Hardware is common and not available unless listed Generator Power Panel 495 218 USA 12 W 30 Generator Power Panel 495 298 USA Generator Power Panel 495 278 Canada CSA Figure 12 2 Generator Power Panels OM 499 Page 53 Dia Part Mkgs No Description Quantity Figure 12 2 Generator Power Panels Figure 12 1 Item 39 Generator Power Panel 495 218 USA UE utat 495 220 PANEL generator power assembly 1 495216 si OVERLAY ans ds saa e a wie Bh iaceo d ed bebes 1 3 CBI 2s 495183 gt CIRCUM BREAKER 30A a K ku k n 1 a pm 007 467 RECEPTACLE twistlock grd 2P3W 3
31. before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit pum 201 026 Figure 9 5 Wiring Diagram For Auxiliary Power Panels 2 Of 2 OM 499 Page 34 SECTION 10 GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 10 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Do not use 2 prong plug un less equipment is double in sulated Be sure equipment has this symbol and or wording gen pwr 11 02 Ref ST 159 730 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame GND PE Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire If unit does not have re ceptacles use GFCl pro tected extension cord Electrically bond generator CS frame to vehicle frame by metal to metalcontact Bed liners shipping skids an some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generato
32. electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards FUEL can cause fire or explosion Stop engine and let it cool off before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury Keep away from fans belts and rotors gt Ny Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negati
33. for generator power 1 120 V AC Twistlock Receptacle RC1 Generator Power Panel 495 218 USA RC2 120V N RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 3 5 kVA kW 2 120V 20 A AC Duplex Receptacle RC2 120 V 20 A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or is 2 4 KVA KW r Each receptacle of the duplex can pro vide 15A 1800W Do not parallel the two 120V duplex receptacles 4 Circuit Breaker CB1 protects RC1 from overload If CB1 opens RC1 does not work 495 218 5 Circuit Breakers CB2 And CB2 protects RC2 and protects RC3 from overload If a circuit breaker opens the receptacle does not work r Press button to reset circuit breaker If breaker continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 6 kVA kW rating of the generator See Section 10 Generator Power Guide lines EXAMPLE If 10 A is drawn from each 120 volt duplex receptacle only 9 A is available from the 120 V twistlock receptacle 2 x 120 V x 10 A 240 V x 9 A 3 5 kVA KW OM 499 Page 21 6 2 Optional Generator Power Panels e Generator Power Panel 495 315 Generator Power Panel 495 219 USA USA Ji e iH Generator Power Panel 495 278 Generator Power Panel 495 253 G
34. is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAG
35. niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvani s plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 499 Page 5 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur cas de non utilisation e Veiller toujours a bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage 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 mun
36. une prise correctement mise la terre Ce groupe de symboles si gnifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci des sous afin de conna tre les mesures prendre pour viter tout danger e effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e 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 Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les pann
37. weather 802 094 A Engine Switch to electric start models only 802 524 Ref S 0756 D 4 7 Connecting To Weld Output Terminals Positive Weld Output Terminal Negative Weld Output Terminal For Direct Current Electrode Posi tive DCEP connect work cable to Negative terminal and electrode holder to Positive terminal For Direct Current Electrode nega tive DCEN reverse cable con nections Tools Needed gt 3 4 in 196 914 495 178 4 8 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200 ft 250ft 300ft 350 400 ft 100 ft 30 or Less 45m 60m 70 90 m 105 m 120 m Weld Output Terminals A Stop engine before 10 60 60 100 connecting to weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Do use worn dam aged undersized poorly spliced cables 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 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 2 0 2ea 2 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 This chart is a general guideline and suit all a
38. 0A 125 V 1 gite Ain a GM E s 408 898 RECEPTACLE duplex 115 V 20 2 CB2 495246 CIRCUIT BREAKER 20 2 eds Power Panel 495 315 USA Nr or 495 314 PANEL generator power assembly 1 CB1 CB2 495245 CIRCUIT BREAKER 15 2 UE 404 089 RECEPTACLE Duplex 230 V S American 1 495246 CIRCUIT BREAKER 20A 2 o 408 898 RECEPTACLE Duplex scc atv DX Y PEE EE 2 Generator Power Panel 495 253 South Africa 2 495 252 PANEL generator power assembly 1 gt CB1 GB2 lt 4 495 245 CIRCUIT BREAKER 15A wi a a eek aya ke CER 2 Generator Power Panel 495 289 Australia AL P SA We ae ee Te 495 254 PANEL generator power assembly 1 lt 15 CB1 GB4 495 245 2 CIRCUIT BREAKER 15A sez RR lala beta bed ee 4 Generator Power Panel 495 219 USA NUM EE EET 495 220 PANEL generator power assembly 1 17 CBI CB 495 182 CIRGUIT BREAKER 25A ix ened i DIS a bk du b dila D SEP ELE 2 18 495 246 CIRCUIT BREAKER 20 2 495217 a OVERLAY
39. 308 EP lt ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY EP 6013 PE O r in PENETRATION xL 601 IN j9 9 Ie co 5 5 lt 5 l 55 03 S105 d DIAMETER N lo R lo N N N 69 IN KS lo SK Po RO C8 RO RR gH JO N x ES bas IS j2T_ End 23 a 03 o 65 Fo B lo INIS INIS N r E e 2 6 D ELECTRODE Ref 5 087 985 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it 5 0049 1 Electrode 2 Workpiece 3 Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it OM 499 Page 43 11 5 Positioning Electrode Holder End View of Work Angle Side View of Electrode Angle GROOVE WELDS End View of Work Angle Side View of Electrode Angle FILLET WELDS 11 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S 0053 A 11 7 Good Weld Bead Characteristics
40. 3600W 15A Duplex CBI See 3600W Note 2 240 V 15A Duplex eH 3600W 230 V 1 15 15 15 Single 3600W 3600W 3600W 230 V CB2 15A 15A 15A Single 3600W 3600W 3600W 230 V 15A Single Cele 3600W 230 V 15A Single ORS 3600W 120 V 304 Twist Lock uo 3500W 30A 120 V CB1 3 3600W Duplex CB2 4 See Note 1 120 V 20A Duplex 2400W 20A 20A 120 V 20 2400W 2400W Duplex 2400W See see Note 3 Note 3 20A 20A 120 V CB4 2400W 2400W Duplex See See Note 3 Note 3 Total Power NOT 5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W to exceed Notes 1 Each receptacle of the duplex can provide 15A 1800W Do not parallel the two 120V duplex receptacles 2 Do not parallel the two 120V circuits 3 Do not parallel the two duplex outlets Calculating total power provided by generator For example for the 495 218 Generator Power Panel See Section 10 Generator Power Guidelines 120V 3000W heater 3000W Each receptacle can provide the watts or amps as shown 120V 10A chain saw 1200W above However the total power can not exceed 5500W 120V 500W halogen lamp 500W The rating plate on electrical apparatus will contain the watts Tela DODA nis doading Ie OF consumed or the rated input amps Watts may be calculated by multiplying the rated voltage by the rated input amps 120V 3000W heater 3000W 120V 10A chain saw 1200W watts volts x amps 120V 5A router 600W 120V 1000W halogen lamp 1000W Total 5800W This loading is not
41. 9 Page 11 3 6 Generator Power Curves The generator power curves show the ac power available in amperes at the receptacles 60 Hz Model 250 225 200 175 150 125 LOAD VOLTS 100 75 50 25 10 15 20 25 30 35 LOAD AMPS 50 Hz Model 250 225 200 175 150 125 LOAD VOLTS 100 75 50 25 10 15 20 25 30 35 LOAD AMPS 198 570 499 12 3 7 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all A 60 Hz Model other settings fall between the LOAD VOLTS curves shown 80 7 70 60 50 40 MID ai MIN 10 100 125 150 175 200 225 250 LOAD AMPS N B 50 Hz Model LOAD VOLTS 80 70 60 50 40 30 MAX MID 2p MIN 100 125 150 175 200 225 250 LOAD AMPS N 198 570 499 13 SECTION 4 INSTALLATION 4 1 Installing Welding Generator amp EA L H A Always securely fasten welding EM generator onto transport vehicle EJ or trailer and comply with all DOT and other applicable codes Movement Airflow Clearance install1 10 00 802 524 A Ref 151 556 158 936 A S 0854 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Gener
42. E exists in inverters after stopping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health e Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases e f ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 499 Page 1
43. Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 499 Page 44 11 8 Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 4 10 30 Angle Too Large ELECTRODE ANGLE 7 poi MS cma Too Short Normal Too Long ARC LENGTH c A on Normal TRAVEL SPEED 11 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better Stringer Bead Steady Movement Along Seam Weave Bead Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 499 Page 45 11 10 Butt Joints 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld 30 Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy 1 6 mm acety
44. OM 499 197 850G June 2003 Processes Stick SMAW Welding Description K o Da Engine Driven Welding Generator WELDERS CHAMP 2060 L OWNER S MANUAL Visit our website at www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years REGISTERED QUALITY SYSTEM of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered to the you may need to fix the problem Warranty and A from Hobart is backed by a Quality System Service information for your particular model the best warranty in the business are also provided Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Hobart Welders manufactures a full line of welde
45. Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 10 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De lcer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 499
46. ake starting difficult Engine Hour Meter Welding Range Label Use label to determine correct weld amper age based on electrode size type and mate rial thickness 7 Current Control Use control to select weld amperage Control may be adjusted while welding To Set Current Control Use label to deter mine correct size electrode for material thick ness Select electrode type and set current control to corresponding amperage range on nameplate Adjust control within selected range to obtain desired weld performance EXAMPLE Material Thickness 1 8 to 1 4 in Electrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A SECTION 6 OPERATING AUXILIARY EQUIPMENT The welding generator provides power while welding and with the Current control in any position However under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations It is recommended that only lamps be powered under these conditions 6 1 A lf unit does not have recep tacles use GFCI protected exten sion cord Power is still present at the 240 volt receptacle when only one circuit breaker trips Unplug power cord before attempt ing to service accessories or tools gt Generator power decreases as weld current increases Set Amperage control at max for full generator power r Place throttle lever in Run position far right
47. anuals 1 6 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 7 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council conclude
48. ator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does have re ceptacles use GFCI protected extension cord Electrically bond generator frame to vehicle frame by metal to metal con tact install 10 00 Ref 151 556 S 0854 OM 499 Page 14 4 3 Grounding Generator When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Ground generator to sys tem earth ground if supply Use ground device as Ing power to a premises home shop farm wiring stated in electrical codes 800 576 r Follow run in procedure in engine manual Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil 1 2 in 13 mm Engine stops if oil level gets too low r This unit has a low oil level shut Gasoline down switch However some con ditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil level shutdown system to monitor oil level 1 Fuel Valve Open valve by turning lever to vertical position Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications
49. ce de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes 1 3 Engine Hazards LES
50. ce les produits inflammables de l chappement LES TINCELLES A peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et relacher la pression avant d effectuer la maintenance 1 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires Utiliser un quipement de levage de capacit suffisante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c
51. coil open fuel valve see Sec tion 4 4 move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Stop turn engine switch to Off r Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 3732 50 80 75 130 0 70 0 85 70 90 120 145 75 100 90 150 08L 16 55 80 55 115 85 14 DIAMETER i 5 3 7 10 16 20 16 30 15 45 MA 15 MA 18 T EP lt lt gt gt lt gt lt gt lt 150 150 95 495187 gt lt NEGATIVE v 802 511 A 802 0511 495 178 5 Engine Hour Meter 6 Welding Range Label Use label to determine correct weld amper age based on electrode size type and mate rial thickness 7 Current Control Use control to select weld amperage Control may be adjusted while welding To Set Current Control Use label to deter mine correct size electrode for material thick ness Select electrode type and set current control to corresponding amperage range Adjust control to obtain desired weld performance EXAMPLE Material Thickness 1 8 to 1 4 in Electrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A 5 2 Controls Honda Powered Units See Section 5 3 Recoil Start S 1 Electric Start WELDING RANGE CHART
52. d that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting OM 499 Page 4 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce possible interference keep weld cables as short as possible
53. de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 metres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e cas d interf rences apres avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou To ronto 416 747 4044 site Web www csa international org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Superintenden
54. ding generator Check engine speed and adjust if necessary see Section 7 4 or 7 5 Check throttle governor linkage for smooth non binding operation Have Factory Authorized Service Agent check brushes slip rings capacitor C1 integrated rectifiers SR1 and SR2 resistor R3 Kohler only and circuit board PC1 B Generator Power Trouble Remedy No output at generator power ac receptacles Reset circuit breakers see Sections 6 1 and 6 2 Check receptacle wiring and connections Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Have Factory Authorized Service Agent check brushes slip rings capacitor C1 integrated rectifiers SR1 and SR2 resistor R3 Kohler only and circuit board PC1 High power output at generator power ac receptacles Check engine speed and adjust if necessary see Section 7 4 or 7 5 Move throttle lever to 50 Hz position for 50 Hz equipment see Section 5 1 or 5 2 Have Factory Authorized Service Agent check capacitor C1 resistor R3 Kohler only and circuit board PC1 OM 499 Page 28 Trouble Remedy Low power output at generator power ac receptacles Check Amperage control setting Check engine speed and adjust if necessary see Section 7 4 or 7 5 Output stops if engine speed is too low Move throttle lever to 60 Hz position for 60 Hz equipment
55. e RE eed a eee on ERE EN ERN RR uti qe s 11 3 0 Generator Power Curv s EX p k H S E Via primes PER Ve l re EX 12 9 7 MOlbE Ampere a Xu en ONES Eb oett qe Ima ede Oe EE 13 SECTION 4 INSTALLATION si cis e rna ea ane eds Ava a a eee 14 4 1 Installing Welding Generator vases id Rp oe ead eec b ear ee at K KIR KI rca o c a KK ei 14 4 2 Grounding Generator To Truck Or Trailer Frame 14 4 3 Grounding Generator When Supplying Building Systems 15 4 4 Engine Prestart Checks Kohler Powered Units 15 4 5 Engine Prestart Checks Honda Powered Units 16 4 6 Connecting The Battery Electric Start Models 16 4 7 Connecting Weld Output Terminals 17 4 8 Selecting Weld Cable Sizes 17 SECTION 5 OPERATING THE WELDING GENERATOR 18 5 1 Controls Kohler Powered Units 18 5 2 Controls Honda Powered Units See Section 5 3 19 5 3 Description Of Controls Honda Powered Units See Section 5 2 20 SECTION 6 OPERATING AUXILIARY EQUIPMENT
56. eaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e soler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apres avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le
57. ee engine lt tighten weld manual terminals 100h Change oil See Check engine manual and spark maintenance label plugs Clean and tighten battery connections Electric Start models only Clean Fuel sediment cup Q 200 h Clean fuel Replace tank and unreadable strainer labels Check valve clearance 500 n Repair or Service welding generator replace cracked brushes and slip rings Service cables more often in dirty conditions 1000 h Blow out or vacuum inside During heavy service clean monthly OM 499 Page 25 7 3 Overload Protection Honda Powered Units 1 Ignition Circuit Breaker Electric Start Models Only The circuit breaker protects the en gine battery charging circuit A short circuit or a battery connected in reverse polarity will trip the circuit breaker Press button to reset breaker gt If a switch or breaker opens it usually indicates a more seri ous problem exists Contact a Factory Authorized Service Agent Ref 802 094 A 7 4 Adjusting Engine Speed Kohler Powered Units After tuning engine check engine up speeds See table for proper no load speeds If necessary adjust speeds as follows 2000 150 rpm Start engine and run until warm Weld Power Speed 3720 50 rpm 60 Hz Adjustment 3250 50 rom 50 Hz 1 Throttle Control Lever 2 Adjustment Screw
58. enerator Power Panel 495 288 Canada CSA South Africa South America Generator Power Panel 495 289 Generator Power Panel 495 290 Generator Power Panel 495 283 Australia Europe S E Asia Ref ST 802 124 H 495 290 H 495 283 495 277 A If unit does not have recep gt Generator power decreases as weld Circuit breakers protect the generator from tacles use GFCl protected exten Het erences sion cord EB A Power may still be present at a re Set Amperage control at max for full zd LA iliac ceptacle when a circuit breaker trips Alan ON Factory Authorized Service Agent Unplug power cord before attempt r Place throttle lever in Run position far ing to service accessories or tools right for generator power OM 499 Page 22 6 3 Generator Power Panel Ratings Unless otherwise stated the rating of duplex outlets is the combined load of all receptacles Total power from generator NOT to exceed 5500 Watts 60 Hz or 5000 Watts 50 Hz Panel Panel Panel Panel Panel Panel Panel Panel Panel Receptacle MORT 495218 495315 495219 Canada 495253 South 495289 495290 495283 y USA USA USA CSA S Africa America Australia Europe S E Asia 60 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 25A 25A 240 V CB1 2 5500W 5500W Twist Lock i See See Note 2 Note 2 15A 240 V
59. hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way WELDERS HOBART 3 31 WARRANTY Effective January 1 2002 5 3 11 WARRANTY applies to all Handler 135 and 175 models Airforce 250 250A 375 models and Champion 10 000 models This warranty also applies to the Beta Mig 1800 Champ 1435 2060 8500 models Ironman 250 Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial No KK200262 and newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship
60. i d un cran de filtre appropri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds LE SOUDAGE peut provoquer un in FSS cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distan
61. imes UNE REMORQUE QUI BASCULE peut entrainer des blessures B e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indique dans le manuel sy rapportant 1 6 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection As sociation P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 telephone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la dian Standards Association Standards Sales 178 boulevard Rexdale LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effectuer la maintenance du moteur et du com
62. ing that forces base metal to move I Base metal moves inthe direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 499 Page 49 SECTION 12 PARTS LIST gt Hardware is common not available unless listed 802 509 A Figure 12 1 Main Assembly OM 499 Page 50 Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly a 495 247 TOP control box specify color 1 495 096 LABEL precautionary 1 Eo SR1 200 759 s REGTIFIER SIICOD exse bio ada d otc tetas da eot doa 1 1294 525 SHUNT 2 64028 747 s SHUNT metet soi soca eio dre Pee Ris dor Pet ees 1 5 POT us 198 449 BOARD PC 1 E ID cr 134201 2 STANDOFF SUDDOM RR Rete o es 4 E EH 494 613 TERMINAL output 250V 2 Aaron P 129 525 TERMINAL output Dinse 50 70 series European models 2 ETE 129 527 PLUG weld cable European models 2 8 POZ urei 148 608 BOARD PC filter
63. l Service 2 Transfer Switch Double Throw Notes Transfer Switch Fused Disconnect Switch If Required Essential Loads Switch transfers the electrical load from electric utility service to the generator Trans fer load back to electric utility when service is restored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Welding Generator Output Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 10 4 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 499 Page 40 10 11 Selecting Extension Cord Use Shortest Cord Possible n
64. lation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart retail 6 02 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Contact your Distributor for Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2003 Hobart Welding Products 1 03 Hobart Welding Products An Illinois Tool Works Company 600
65. lene or plasma cutting equip sp ment Remove scale from material after cutting A grinder can also be used to prepare bevels 1 16 in Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm 11 11 Lap Joint 30 1 Electrode Or Less 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass b Weld both sides of joint for maxi gt mum strength Single Layer Fillet Weld Multi Layer Fillet Weld S 0063 S 0064 11 12 Tee Joint 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 11 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 499 Page 46 11 13 Weld Test 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not break 2 To 3 in 51 76 mm 5 0057 8 11 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal
66. lf and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols r Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 6 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection
67. loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Symbol Definitions Battery Engine Read Operator s Engine Choke Manual Engine Oil Engine Protective Earth Ground SECTION 3 SPECIFICATIONS Circuit Breaker This unit uses either a Kohler or a Honda engine Differences between models are noted throughout this manual 3 1 Weld Power And Engine Specifications Rated Maximum dos Welding Open Circuit died a Fuel Capacity Engine Output Voltage Kohler CS12STG Air Cooled u One Cylinder C dle y Single Phase Four Cycle 40 180 A y 80 6 kVA kW Peak Kohler 12 HP 360 CC 60 Hz 130 A 25 V 60 Hz 5 5 kVA kW 1 8 gal 6 9 L Tank Gasoline Engine CC DC 60 Duty Continuous OR Un A Cycle 70 50 25 A Honda Honda GX390 50 Hz RU DEN 50 Hz 410 220 V AC 50 Hz 1 7 gal 6 4 L Tank Air Cooled 100 Duty 120 240 V AC 60 Hz One Cylinder Cycle Four Cycle 13 HP 390 CC Gasoline Engine OM 499 Page 9 3 2 Dimensions Weights And Operating Angles Dimensions Height 20 3 4 in 527 mm Wid
68. metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 11 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed OM 499 Page 48 11 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 11 20 Troubleshooting Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 11 21 Troubleshooting Distortion Distortion contraction of weld met al during weld
69. n switch Engine stopped during normal operation Check fuel level see Section 4 4 or 4 5 Open fuel valve see Section 4 4 or 4 5 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check oil level see Section 4 4 or 4 5 Engine stops if oil level is too low Have Factory Authorized Service Agent check low oil level shutdown switch Check unit operating angle Low oil level shutdown switch may stop engine if unit is tilted Battery discharges between uses elec tric start models only Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Unstable or sluggish engine speeds Check engine speed and adjust if necessary See Section 7 4 or 7 5 Check throttle governor linkage for smooth non binding operation Tune up engine according to engine manual OM 499 Page 29 SECTION 9 ELECTRICAL DIAGRAMS 4 WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit IGNITION UNIT OIL IGNITION A STOP SU LL OW SWITCH
70. nd tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 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 goods a
71. on e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge DES ORGANES MOBILES peuvent provoquer des blessures K E e Ne pas approcher les mains des ventilateurs cour roies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements pour effectuer s il y a lieu des travaux d en tretien et de d pannage 1 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le coupa ge gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures 9 4 e Relacher la pression d air de l outillage ou du sys t me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile
72. ourant lectrique s av re n ces saire 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 envi ronnements 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 ma nuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der 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 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
73. p cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom 10 O2fre A Avertissement Prot gez vous et les autres des blessures lisez et suivez ces precautions 1 1 Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit
74. pplications If cable overheating occurs normally you can smell it use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 E For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 499 Page 17 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 r Weld and generator power output stops if generator overheats or engine speed is too low 1 Engine Switch Use switch to open ignition circuit and to stop engine 2 Throttle Control Lever Use lever to select engine speed Use 50 Hz or 60 Hz position for 50 or 60 Hz generator power Use 60 Hz position for maximum weld output 3 Choke Control Lever Use lever to change engine air fuel mix Move lever to right if starting a cold engine Move le ver to left if starting a warm engine OM 499 Page 18 WELDING RANGE CHART 6010 6011 6013 01 amp 018 ELECTRODE rm To Start Electric open fuel valve see Sec tion 4 4 move throttle lever to Idle set choke and turn engine switch to Start position Open choke as engine warms If engine does not crank use recoil starting procedure following to start engine A If engine does not start let engine come to a complete stop before at tempting restart 4 Starter Handle To Start Re
75. pres seur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r gulierement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables
76. r dx grd 2P3W 20 125V 2 ees wea ae 073 690 PLUG str grd armd 2P3W 15A 125V Generator Power Panel 495 278 Canada CSA Ja BO obi iad tat 495 277 PANEL generator power assembly 1 34 CBI sassi 203 095 CIRCUIT BREAKER maon 1 PA PE EN E E 202 631 COVER circuit breaker be SOR OD a ev k akan L EET 202 630 BRACKET mtg circuit breaker cover 1 35 CB2 495246 CIRCUIT BREAKER 20A 2 O0 ce ek AOI awazi 129 067 RECEPTACLE tw Ik grd 3P4W 30A 125 250V 1 e A b De 088 898 PLUG tw Ik grd 3P4W 30A 125 250V roles 2 141 432 RECEPTACLE str dx grd 2P3W 20A 125V 1 073 690 PLUG str grd 2P3W 15 125V NOTE Replacement receptacles not listed can be found at your local hardware or electrical supply store To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 499 Page 54 Warranty Questions Call 1 877 11 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24
77. r equipment grounding terminal to bare metal on the vehicle frame as shown OM 499 Page 35 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device GND PE Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 1 Resistive Load A light bulb is a resistive load and VOLTS 115 AMPS 45 requires a constant amount of power 60 2 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 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment AMPERES x VOLTS z WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirement in watts 4 5Ax 115 V 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts OM 499 Page 36 10 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating
78. r them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards 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 oil free protective garments 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 Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge bat
79. ration And Maintenance 3 1 o Principal Salelyolandalds 533 um k bel stint E One DR RD Ek 4 126 EMF ANOMAN co etam y Mel Dau sae Seu eased eds kec Se e leases 4 SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 1 1 Signification des symboles e ht arden bie ha bet he x KK KK KK KK KK KK kK kk ke 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers existant en relation avec le moteur 6 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement ella maintenance nese a pee e a eae bose ee eens seta DAE ET 7 1o P uncipales normes de S QUT cru satan nad br ERR ee eat 8 1 6 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS 2 lt 5x cak k daka k UE c ia arana Edo E era ORE ERRARE WA EAR 9 SECTION 3 SPECIFICATIONS ca RAM LA Ld a E EAE REA RC EM ERRARE ERU AR 9 3 1 Weld Power And Engine Specifications 9 3 2 Dimensions Weights And Operating Angles 10 3 3 Fuel Consumption Kohler Powered Units naaa aa nananana aana 10 3 4 Fuel Consumption Honda Powered Units 11 9 95 DUTY CY CIO Sees ducta
80. rs and welding related equipment distributor Your distributor For information on other quality Hobart products contact your local Hobart can also supply you with distributor to receive the latest full line catalo individual log sh Re Ya g or nd v dual catalog sheets such as SMAW GTAW To locate your nearest distributor or service agency call 1 877 Hobart1 GMAW and GMAW F WELDING PRODUCTS 44 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 44 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 44 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The following terms are used interchangeably throughout this manual TIG GTAW Stick SMAW MIG GMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 11s USAGE TP 1 152 At Welding Hazards teet art oe Oy en be 1 1234 Engine RSS 2 1 4 Additional Symbols For Installation Ope
81. t oppos de l appareil OM 499 Page 7 LE SURCHAUFFEMENT peut endom mager le moteur electrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles e pas brancher de moteur de 50 ou 60 Hz la prise de 100 Hz s il y a LES ETINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance inflammable L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Laisser l quipement refroidir respecter le facteur de marche nominal e R duire le courant ou le facteur de marche avant poursuivre le soudage e pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits impr
82. t of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 1 7 Information sur les champs electromagnetiques Donn es sur le soudage lectrique et les effets des champs magn tiques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lectro magn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pen dant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumulation de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectri ques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la recherche il serait souhaitable de r duire l ex position aux champs lectromagn tiques pendant le soudage ou le coupage OM 499 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail respec ter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus
83. t customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at 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 WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY 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 legis
84. tenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants caoutchouc et v tements de protection lors d une in tervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher les cables de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hi cules de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le cable n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansi
85. teries or jump start vehicles e Observe correct polarity and on batteries e Disconnect negative cable first and connect it last OM 499 Page 2 FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet HOT PARTS can cause severe burns e Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other
86. th 22 3 4 in 577 mm Depth 31 1 4 in 793 mm Do not exceed tilt angles or engine could be damaged or unit could tip A 31 1 4 in 7 93 mm not move or operate unit where 10 1 2 in 268 mm could tip 13 45 64 in 848 mm 22 3 4 in 577 mm 1 3 4 in 44 mm 19 1 2 in 495 mm 13 32 in 10 mm Dia Weight Kohler 265 Ib 120 kg On molol Honda Electric Start Model 278 10 126 kg Honda Recoil Start Model Engine End 253 10 114 kg 802 096 802 524 A 3 3 Fuel Consumption Kohler Powered Units r Fuel consumption at low idle 2000 rom 0 2 U S gal hr o on IMP GAL HR Q O N 60 HZ WELD EN N 60 HZ_AUX pet 50 HZ AUX 50 HZ WELD HIGH IDLE 50 75 100 125 150 175 200 DC WELD AMPERES AT 100 DUTY CYCLE 1 2 3 4 5 6 POWER KVA AT 100 DUTY CYCLE 198 575 OM 499 Page 10 3 4 Fuel Consumption Honda Powered Units I 3 Q 1 67 1 50 1 33 60 HZ AUX 50 HZ AUX 50 HZ WELD IDLE RPM 50 75 100 125 150 175 200 DC WELD AMPERES AT 100 DUTY CYCLE TT 1 2 3 4 5 6 POWER KVA AT 100 DUTY CYCLE 3 5 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit void warranty Continuous Welding 100 Duty Cycle at 100 Amperes CC DC A 2 lt gt DUTY CYCLE OM 49
87. ugh to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable OM 499 Page 3 gt FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away 2 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling LS boards or parts e Use proper static proof bags and boxes to store move or ship PC boards n e Use tongue jack or blocks to support weight Properly install welding generator onto trailer according to instructions supplied with trailer TILTING OF TRAILER can cause injury READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts Perform engine and air compressor if applica ble maintenance and service according to this manual and the engine air compressor if appli cable m
88. ve battery cable from battery Keep hands hair loose clothing and tools away from moving parts e Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator components e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e If the engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap cap slightly and let pressure escape slowly before completely removing cap 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury Wear approved safety goggles e Do not direct air stream toward self or others TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury Release air pressure from tools and system before servicing adding or changing attach ments or opening compressor oil drain or oil fill cap STEAM AND HOT COOLANT can burn

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