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section 1 - Hobart Welders

1. One ANNOY TANVd 3SV8 0 leo a LU LU y FERE y MS 291 Es e e E yyyy i 2 Z GIONa10S 440 1NHS o AN a o and aN AL Z en y gt go SOd nn s as YALAVIS A a OA LYS LOA ZI EE LZ 109 a 4 a NS recat 7Z ss z 90 LYA ai LS ga A 4 0 ON o z ve wf CH mo nig zu 8 v sota Y ed Ki vod Y vod Vi pn Y e s 9 z tyy wy y TOM y VOY y TH y 08 oz E 9 ba 4 2 DE Z 7 lt Nu lt ES 37 Aovz a 17 Yan g a 01 Lou 2 X M A YNOH lt avis DINA Vv Y wa s914 08 se oz 8914 ZS ya 19 e ZS 0e _e sung Ou ES 8 oe lod Z9 Ze e 22 Le gt 6 gt THK 09 a 2 2 rb gt gt 22M Y Y Y zao zej H LC 991 BL SR eC a uz EZ Se ZLA E SEN EZ SE SE AAA GF a M OO ONIATOARY z gt NOZI Ve fia ES 6914 75 1S FH L91d 194 sou Y V VY Ze HIMOd NOLLWLI9X3 AAA J de d E BR EN E e az LI tz 00 if a ba AAA a FF 9 M A AOCL HE AR A RKL 8 oL OSO x Ba yao a 2 GOS ce X wis ES os ze es x x x Na 2 IS 09 09 S als x aonn g Oo QP O O OL SIElP IS ge dao y SIb Zs NOLLISOd 222129 B And Kohler Powered Units in For Welding Generator Rob ircuit Diagram Figure 11 1 C OM 945 Page 41 SECTION 12 GENERATOR POWER GUIDELINES E The views in this section are intended to be representative
2. Welding Symbols Finish Symbol Groove Angle Included Angle of Ki Countersink for Plug Weld SCH en Root Opening Depth of Filling y d Fillet Groove Weld Size for Plug Welds Size of Weld A Field Weld Symbol Ke e R Weld All J Around i Symbol Sg Une J Groove LP Tail L Line Weld Symbol Length of Weld S E Arrow Side Other Side Pitch Center to Center Spacing V Groove U Groove lt lt Ref AWS ANSI A2 4 T Square Groove OM 945 Page 57 SECTION 14 PARTS LIST 5 Hardware is common and not available unless listed Ref 802 343 R Figure 14 1 Main Assembly Robin Engine Shown OM 945 Page 58 Item Dia Part No Mkgs No Description Quantity Figure 14 1 Main Assembly So E NOS LL osc WAPP eege ee Ee EE Eeer 1 Sate ee Macatee T A 227 725 Label Use Gasoline Fuel Only 1 fee EE 211 398 Grommet Plastic Neck Filler Fuel 1 iP WEEN 220711 Cap Tank Screw on w Vent 1 pal WEEN 233 639 Label Warning General Precautionary 1 Me EE EA 220 457 Label Need Hein 1 e EE 211527 Pipe Exhaust Elbow 1 E EE 196 252 Baffle engine air Kohler only
3. 9 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 9 2 6 Proposition californienne 65 Avertissements 11 2 7 Principales normes de s curit 11 2 8 Information EME RER M RES SE AE wank dun el it sted Ear ee a EE 11 SECTION 3 DEFINITIONS Ze ocho casas A Bees wetted 12 SECTION 4 SPECIFICATIONS eege ae een eng bev Ped ee NEEN de 12 4 1 Weld Power and Engine Specifications 12 4 2 Dimensions Weights and Operating Angles 13 4 3 Generator Power Curve 44444 13 4 4 Fuel Consumption All Models 14 4 5 DUTY Cy Cle nn seen she A Ee btn Sots oo era as 14 4 6 Volt Amp re C rves Lin near en rer ee eee nda ee ene 15 SECTION 5 INSTALLATION ee te dat ses cas eda ted el ee GE Eeer 16 5 1 Installing Welding Generator 16 5 3 Rating Label Location eris tiina nen ee etd e a dit gis dE Ee A mn e 17 5 4 Engine Prestart Checks Subaru Robin Powered Units 18 5 5 Engine Prestart Checks Kohler Powered Units 18 5 6 Activating The Dry Charge Battery If Applicable
4. 1 D EE 226 448 Panel Rear she EENS AEN AER EEN Ee aa 1 at A a a 194 263 Grommet Plastic Snap in Battery Access 1 De KN 227 913 Label Warning Battery Explosion Can Blind 1 LR o 209 057 Clamp Muffler 1 625 Dia U Pld 1 LC OTTEET 224 134 Engine Robin Gas Elec Start consisting of 1 EE ee ee eee ee 228 678 Muffler Exhaust Engine Robin 1 CR oP debates SL AA 2 GASKET MUC eet a ma Mad a a gh des e BEE TEE A EE Ol Ed age As ed EE Ee ee aac A Steet eeh dE EE 198 755 Element air cleaner w precleaner 1 dant Brand aut gh Sadan rt 198796 2004 Pump Tel se ao Aa Re a et A na a ane d EE S5 198757 Switch low oil pressure 1 AE EEN wae 215 985 Filter fuel w clamps 1 Ee Se EC 198 777 a Plug Spark ass arte tn a De EECH Solenoid w mtg bracket see engine parts list 1 oily DURE Geet ENN AIR ak 198 778 Regulator voltage 7 ja VOS EE 165 271 Valve Oil Drain 3 8 18 Nptf 1 ar F6 021 718 Fuse Mintr Gl 30 Amp 32 Volt 1 tee 114923 Boot solenoid
5. aka 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 4 Motor Voltage SE AS MOTOR 2 To find starting amperage 1 VOLTS 230 AMPS 25477 Bee 3 x CODE M z 60 Step 1 Find code and use table to SE find kVA HP If code is not listed HP 1 4 PHASE 1 multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule H motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 945 Page 46 12 10 Typical Connections To Supply Standby Power Utility Electrical Service Transfer Switch Essent
6. 19 5 7 Connecting the Battery eiiie ua EEE E eee 19 5 8 Installing ExhatistiPipe ss ae ie aieea Ea EE sds eee Gig ele hg o UEU es 20 5 9 Weld Output Gruef EE 20 5 10 Connecting To Weld Output Terminals 21 5 11 Selecting Weld Cable Gizeen noc 21 SECTION 6 OPERATING THE WELDING GENERATOR 22 GE Front PanelGontrolsies 2 heat date bytes ae dates de Ud Large ead Deh E 22 6 2 Cold Weather Engine Operation 23 6 3 Amperage Selection Table For Stick SMAW Electrodes 23 SECTION 7 OPERATING AUXILIARY EQUIPMENT 0 00 cece cece cece ee ee eee eeee 24 7 1 Standard Receptacles l ipen p seco ce Sew Lehi ay Lee eed EE ona dE degre oak 24 7 2 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P 25 SECTION 8 MAINTENANCE SUBARU ROBIN POWERED UNITS 26 8 1 Routine Maintenance Subaru Robin Powered Units 26 8 2 Maintenance Label Subaru Robin Powered Units 27 8 3 Servicing Air Cleaner Subaru Robin Powered Units 28 8 4 Overload Protection Subaru Robin Powered Units 29 8 5 Servicing Optional Spark Arrestor Subaru Robin Powered Units 29 8 6 Changing Engine Oil Oil Filter and Fuel Filter Subaru
7. 1 eee 183 419 O ring 1 984 Id X 139 Cs 70 Duro Viton 1 se EE 227 724 Label Warning Moving Parts Can Cause Serious Etc 1 cle A eee see 185 148 Housing Generator Rear 1 E isa bs A 186 083 Screw 437 14x1 75 Hexwhd 93d Gr8 Pld 4 wie O rss ok gaa nd 222 130 Rotor Generator consisting of 1 e E EAE 181 134 Fan Rotor Gen 1 sie SE 181 143 Bearing Ball Rdl Gol Row 984 X 2 047 X 59 1 win Og hee ae eee 8 eae wae 205 725 Brushholder Assy Generator 1 a AO Get a Ee 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 4 802 345 B Figure 14 3 Generator When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 945 Page 62 Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of t
8. 13 5 Positioning Electrode Holder 10 30 Val WN 907 90 a ge d y End View of Work Angle Side View of Electrode Angle GROOVE WELDS o o 10 30 WN ga End View of Work Angle Side View of Electrode Angle FILLET WELDS S 0060 13 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration OO BR ND A S 0053 A 13 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 945 Page 51 13 8 Conditions That Affect Weld Bead Shape gt 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 a E panna EA d Drag ELECTRODE ANGLE L poe A ee eres Too Short Normal Too Long ARC LENGTH SSS hs Se Slow Normal Fast TRAVEL SPEED S 0061 13 9 Electrode Movement During Welding CS 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
9. gt This unit has a low oil pressure shutdown switch However some conditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Fuel Gasoline To help prime the fuel system at initial start up fill tank with fresh fuel see maintenance label for specifications Always leave filler neck empty to allow room for expansion see fuel tank window on base Check fuel level on a cold engine before use each day Oil EF Do not exceed the Fu mark on the oil level dipstick The fuel pump may operate erratically if crankcase is overfilled After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label To improve cold weather starting Keep battery in good condition Store bat tery in warm area Use correct grade oil for cold weather 802 353 G Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil pressure gets too low E Follow run in procedure in engine manual gt This unit has a low oil pressure shutdown switch However some conditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Fuel To help prime the fuel system at ini
10. e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection 2 LE SOUDAGE peut provoquer un ER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables a une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e N
11. ALLER ELECTRIC MFG CO APPLETON M USA or More of the Following US Patents si s Ms anger pete 3 620 620 5 607 608 6 469 276 6 472 635 AMPERAGE RANGE ELECTRODE 0 o 150 o AMPERAGE ADJUST 1 Engine Control Switch Use switch to start engine select speed and stop engine In Run Idle position engine runs at idle speed at no load and weld power speed under load In Run position engine runs at weld power speed 2 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Con trol switch to Start position Release switch and slowly push choke in when engine starts CS If the engine does not start let the engine come to a complete stop before attempt ing restart CS During cold weather some gasoline en gines encounter difficulties that are easily remedied See Section 6 2 and 10 1 230 RUN IDLE e e A ENGINE S di START 10 000 WATTS NZ JN ON s LD OFF ZS 3 CB1 50A MAIN YS BREAKER Sy A Se amsn O Champ l on 10 000 RACCORDE AU B TI GND PE 3 MADE IN E D 10 000 WATT GENERATOR e 230 AMP DC CC WELDER wee Ref 226 427 A To Stop turn Engine Control switch to Off position 3 Engine Hour Meter 4 Amperage Control Use control to select weld amperage Select amperage ac
12. stick 2007 04 ST 151 593 OM 945 Page 49 13 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 250 300 ELECTRODE POSITION PENETRATION DEEP DEEP MIN PREP ROUGH HIGH SPATTER LOW GENERAL MED SMOOTH EASY FAST LOW LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL Y Y Y Y d Y ALL LOW CAST IRON 308L d ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it S 0049 13 4 Striking an Arc Tapping Technique L Z 2 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0050 OM 945 Page 50
13. Term Ring Tng 500stud Solistrand 2ga 2 EE 034 377 Term Ring Tng 312stud Solistrand 2ga 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor F LS Si OM 945 Page 60 802 344 K Figure 14 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 14 2 Panel Front w Components Figure 14 1 Item 47 Dt EE 198 122 Gtand oft Support Pc Card 250w Post amp lock 500 6 E EE Nameplate order by model amp serial no 1 D EE 226 447 Panel Front 1 A cias POL sais 203 655 Circuit Card Assy Field Current Controller 1 Died chee CTT geng 204 709 Xfmr Current Sensing 1 Onain EE 217 680 Switch Ignition 4 Position Without Handle 1 EEN 222 133 Harness Wrg Ignition consisting of 1 MR TIT PLOS 177 859 Conn Body 5 Terminal 1 RE PLG4 116045 Conn Rect Univ 084 6p S 3row Rept Housing Pins amp Skts EE Service Kit corn Ee ER antenne rene
14. 1 E 199 062 Kit tune up and filter Robin includes air filter element and wrapper Eeer oil filter fuel filter and spark plugs 1 ce KEE 238 298 Engine Kohler Gas Elec Start consisting of 1 a E 228 679 Muffler Exhaust Engine Kohler 1 eege E Arr dn 189 477 va Gasket Muffler erer meae NEE ed dE a a ar dE A EE 066 698 Filter Ol aii A EE 190 248 PUMP fael 2 a e e iaa A EE 230016 Element air cleaner 1 e 215 985 Filter fuel w clamps 1 RC RE EPL Eos 230 017 Wrapper air filter 1 E RS TROT ETA 067007 A Plug Spark u At Ha A tanga d dd Rye uch S AE PARE a 199 530 01 SONO De EENG Ee KEE 165 271 Valve Oil Drain 3 8 18 Nptf 1 EES F6 021 718 Fuse Mintr GI 30 Amp 32 Volt 1 EE 114923 Boot solenoid 1 SANTER al sois aient A 230 015 Kit tune up and filter Kohler includes air filter element and wrapper Et DAA SA WRN Roe kena eee ees oil filter fuel filter and spark plugs 1 VO tiv cet ha EAA 196 778 Hose Vinyl Clear 500 Id X 625 Od X 7 000 oil drain 1 AUT Lai EE 167 788 Nut 375 16 56hex 34h Stl Pld Sem Con
15. 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 945 Page 15 SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Do not move or operate unit where it could tip A Do not lift unit from end A Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes Do not install unit where air flow is re stricted or engine may overheat See Section 4 2 for lifting eye rat ing Mounting A Do not mount unit by support ing the base only at the four mounting holes Do not use flexible mounts Use cross supports to adequately sup port unit and prevent damage to base 6 Cross Supports Mount unit on flat surface or use cross supports to support base 460 mm Mounting install2 2008 01 Ref 800 652 Ref 800 477 A 803 274 A 804 712 OM 945 Page 16 5 2 Grounding Generator To Truck Or Trailer Frame A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators
16. A Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to aD bare metal on the vehicle GND PE frame as shown O A If unit does not have GFCI re ceptacles use GFCI pro H tected extension cord ea 1 Equipment Grounding 3 TD Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator frame to vehicle frame by met al to metal contact rot_grnd 2008 01 800 652 D 5 3 Rating Label Location 4 Rating Label Typical Locate rating label on unit Label pro vides information such as weld output DC DC DC DC AC ratings generator ratings and engine CV CC CV cc cc e information zh gt RATED WELD OUTPUT AMPS DUTY CYCLE HD Q GENERATOR OUTPUT VOLTS Kohler MAX KW AMPS 120 240 Robin MAX KW AMPS CONT KW PHASE 1 HERTZ 60 rot_label2 2008 02 804 712 OM 945 Page 17 5 4 Engine Prestart Checks Subaru Robin Powered Units Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil Engine stops if oil pressure gets too low gt Follow run in procedure in engine manual
17. l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES EECH SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES FUMEES ET LES GAZ peu vent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions 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 portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit D
18. 2 0 70 3 0 95 4 0 120 4 0 120 A Stop engine before connecting to weld 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 eg S o output terminals donot use worn dem 300 1 50 1060 2 0 70 3 0 95 4 0 120 222 20 26a 3 0 2 2a 3 0 aged undersized or E Get Ge DE 2x70 2x95 2x95 poorly spliced cables 5 Sal eg Lo Jo 2 SS ea ea ea ea 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 2 ea 2 0 2ea 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 40 120 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheating occurs 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 F OM 945 Page 21 SECTION 6 OPERATING THE WELDING GENERATOR weld generator power output 6 1 on Panel Controls CS If the unit is extremely overloaded weld and generator power will stop Turn unit off and restart to reset the generator protection circuit and restore CS If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or generator load is reduced SWAN e
19. Do not block or filter airflow to unit P9 STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling So e boards or parts Use proper static proof bags and boxes to store move or ship PC boards Use tongue jack or blocks to support weight Properly install welding generator onto trailer y i TILTING OF TRAILER can cause injury Oo according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals 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 If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings A Welding or
20. Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 945 Page 40 SECTION 11 ELECTRICAL DIAGRAM NOILdO 3NION3 Y31HOA LU yy LU Kei LU Gi 1938 038 ESCH TOA 440 1NHS MOLVIS Tan Lei YOLVNY3LTV gt s ee 2 Lei Ek YILAVLS 2 ES OA ZL ss F ON 77 8a 7 NYI ESCH ZH 70 MOT k Dj 487 Vv Ki 91d V d 974 Y u wld s 9 z ce Mtz os zs ee rou X Re e IS 09 09 G cr oqpooon il TA TON 4 3 4 9 8 y E 180 SL E E E aig LU No H x uN Te Zao 27 AT ie sos 21949 No NO Le af ag uN Tag aw Se NOILdO Sy 319V1d3938 A 9 5 D Z9 oF 1949 1049 gun si aoindas Jo een AYVZVH NIOHS resu suosiad peyenb Ajuo axe y e 91419373 POEAOLUG S18A09 YIM ejejedo zou oq e Buines auojaq suiBus x4 dos Jo 1emod yndul j98UU0981Q e CR sped 1891119819 an yono jou og el HNINHYWM Y NOLLdO 3NI9N3 AHO NIgOY
21. and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart_warr 2008 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA O 2008 Hobart Welding Products 2008 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 4
22. s 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under
23. AC MA Gasoline Engine CC DC 50 230A 60 Duty 73 60 Hz Sc or ee SE Kohler CH 23 ohler CH 170 A 25 V Continuous 9 5 kVA kW Air Cooled Two Cylinder 100 Duty while not welding Four Cycle 23 HP Cycle Gasoline Engine OM 945 Page 12 4 2 Dimensions Weights and Operating Angles Dimensions Height 33 1 2 in 851 mm A Width 18 1 2 in 470 mm Depth 38 in 965 mm O F wW A Do not move or operate unit IL G where it could tip W 4 HOLES A Do not exceed tilt angles or engine could be damaged or W A 18 in 457 mm 16 9 16 in 421 mm 23 32 in 18 mm 3 in 76 mm 31 1 2 in 800 mm 37 1 2 in 953 mm O1 M 0 O OD 13 32 in 10 mm Dia Weight Subaru Robin Powered Unit 445 Ib 202 kg Kohler Powered Unit 440 Ib 200 kg Lio 4 Lifting Eye Weight Rating 1280 Ib 580 kg Engine End 50285 4 3 Generator Power Curve The generator power curve shows the generator power in amperes available at the receptacles 280 140 240 120 F 200 100 160 80 tr 120 60 f 80 40 f AC POWER VOLTS 40 20 L 0 0 L 1 1 1 0 20 40 60 80 100 AC POWER AMPERES AT 120V 0 10 20 30 40 50 AC POWER AMPERES AT 240V 197 252 OM 945 Page 13 4 4 Fuel Consumption All Models
24. 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 945 Page 55 13 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 13 20 Troubleshooting Waviness Of Bead Le wm Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 13 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 945 Page 56 Notes
25. at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein
26. cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 749 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 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 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency El
27. group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks 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 e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work
28. la maintenance e N utiliser que les pi ces de rechange recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou a proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que Pali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service MIC LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l illeton voir les sp cifications e Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 945 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommagerle moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteu
29. machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 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 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2
30. o IMP GAL HR N D o U S GAL HR u LITERS HR AC POWER DC WELD 4 73 1 04 1 25 3 78 0 84 1 00 2 84 0 63 0 75 1 89 0 42 0 50 IDLE 2200 RPM 0 95 0 21 0 25 0 25 50 75 100 125 150 175 200 225 250 275 WELD AMPERES AT 100 DUTY CYCLE LEE Ed D 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 POWER KVA AT 100 DUTY CYCLE 197 254 4 5 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 230 210 WELDING AMPERES 170 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE Oe Continuous Welding 100 Duty Cycle at 170 Amperes CC DC A gt OB BA 6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting 60 Duty Cycle at 210 Amperes CC DC 30 Duty Cycle at 230 Amperes CC DC 197 148 OM 945 Page 14 4 6 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 80 70 RANGES MAX RHEO 60 50 RHEO un MIN RHEO 50 O gt 40 O A 30 20 10 0 0 50 100 150 200 250 300 350 400 DC AMPERES 197 253 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge
31. se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi op rer com me suivant Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 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 cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit a
32. your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection AA 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 945 Page 2 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 Do not weld where the atmosphere may contain flammable dust gas or l
33. 00 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 945 Page 48 SECTION 13 STICK WELDING SMAW GUIDELINES INS 4 aa E 13 1 Stick Welding Procedure Tools Needed Mt A Weld current starts when electrode touches work piece Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass
34. 01 00 Oil Capacity w filter change Approximately 1 5 quarts DO NOT OVERFILL KOHLER Keep oil level between L amp F marks on dipstick ROBIN Keep oil level between 2 holes on dipstick NO SOBRELLENE KOHLER Mantenga el nivel del aceite entre las marcas L y F del medidor ROBIN Vantenga el nivel del aceite entre los dos huecos del medidor Fuel Grade Unleaded 87 Octane min Fuel Filter KOHLER MILLER 215 984 Kohler 2505022 KOHLER MILLER 215 984 Robin 263 65012 A3 Gasoline Air Filter Service 100 hours see Owner s Manual Air Filter KOHLER MILLER 230 016 Kohler 2408303 S Air Filter Wrapper KOHLER MILLER 230 017 Kohler 2408305 S Air Filter ROBIN MILLER 198 755 Robin 263 32610 A1 Includes Air Filter Wrapper 12 Volt Battery BCI Group 58 Cranking Performance at 0 F 18 C 430 Amps min Engine Speed High Speed 3675 3750 RPM No Load 2200 2300 RPM Spark Plug KOHLER MILLER 067 007 Kohler 1213202 Gap 0 030 in Champion RC 12YC Spark Plug ROBIN MILLER 198 777 Robin X65 01407 30 Gap 0 025 in NGK BPR4EY Use only resistor spark plugs and wires Tune up and Filter Kit Includes Air Oil and Fuel Filters and 2 Spark Plugs KOHLER MILLER 230 015 ROBIN MILLER 199 062 238296 A OM 945 Page 27 8 3 Servicing Air Cleaner Subaru Robin Powered Units A Stop engine and let cool NOTICE Do not run engine with out air cleaner or with dirty element CRE
35. 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs compos
36. 4 2444 and Subaru Robin 1 800 277 6246 offer kits for cold weather operation The user can install these kits Both kits pull heated air from the muffler surface into the carburetor and shut the cold air off This increases engine temperature during operation in both idle and high speed EF When the ambient temperatures become warmer above 45 F the air flow will have to be returned to normal Ref 226 427 A 6 3 Amperage Selection Table For Stick SMAW Electrodes EF Use table on front panel to se lect correct amperage for the AMPERAGE electrode being used RANGE ELECTRODE o LO a soto LT a A 13 amp 6011 3 32 6013 18 5 32 Laef ee 3 32 KE 7014 18 5 32 FA 3 32 7018 7024 Ni Cl 308L Ref 202 069 A OM 945 Page 23 SECTION 7 OPERATING AUXILIARY EQUIPMENT CS If the unit is extremely overloaded weld and generator power will stop Turn unit off and restart to reset the generator protection circuit and restore weld generator power output CF If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or generator load is reduced CS The welding generator provides power while welding and with the Amperage control in any position However under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations It is recommended that on
37. 5373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se KA HOBART tHe
38. Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 945 Page 5 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom_2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 2 1 Signification des symboles l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A DANGER Indique une situation dangereuse qui si on peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A Indique une situation dangereuse qui si on l vite pas NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel
39. H generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 12 4 OM 945 Page 47 12 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads e A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Curren Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads e A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 8
40. N 9 MAINTENANCE KOHLER POWERED UNITS D Routine Maintenance Kohler Powered Units GO Y Chi Y LAY ee Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label fluids for important start up service and storage information Service engine more often if used in severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 5 8 Hours GH Fuel Level Y Oil Level Q Oil Fuel Spills Every Section 9 5 Si G Hours 1Q Spark Arrestor Screen Every Section 9 3 25 Hours Q Air Cleaner Wrapper Every 50 e Hours A 2 Q Weld Terminals Every Engine 100 Manual Hours Section 9 3 9 6 Q Battery Terminals Q Cooling System x Air Cleaner Element Every o pan E gt Engine 200 y PES gt LD Manual Hours E aaa Section 9 6 i Unreadable Labels Y Spark Plug Gap Oil Filter Fuel Filter Every Engine 500 Manual Hours G 1 5 Weld Cables OQ Slip Rings Mi Brushes OM 945 Page 32 9 2 Maintenance Label Kohler Powered Units KOHLER CH23 ROBIN EH64 EH65 GAS ENGINES See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oil Push And Turn CCW D Check Es Recommended Oil API Service C
41. OM 945 194 047AE Ne ZN El 2008 04 Processes e He Stick SMAW Welding Description WELDER LISS E Engine Driven Welding Generator Champion 10 000 www HobartWelders com gt From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular model are also provided 150 9001 2000 QUALITY SYSTEM Hobart is registered to the ISO 9001 2000 Quality System Standard Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets To locate your nearest d
42. PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 945 Page 44 12 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10in 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 945 Page 45 12 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0
43. RTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 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 e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flus
44. RUN IDLE START Incorrect Installation A Stop engine A Failure to properly connect weld cables may cause ex cessive heat and start a fire or damage your machine 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against cop per bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean Tools Needed IF 3 4 in 803 778 A Ref 226 427 A 5 11 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding For distances longer than those shown in this guide call a factory applications representative at 1 800 332 3281 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30m orLess 45m 60m 70m 80m 105 m 120 m a 10 60 60 100 Weld Output Welding E Duty Duty 10 100 Duty Cycle Terminals Amperes Cycle Cycle 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
45. Robin Powered Units 30 8 7 Adjusting Engine Speed Subaru Robin Powered Units 31 TABLE OF CONTENTS SECTION 9 MAINTENANCE KOHLER POWERED UNITS 32 9 1 Routine Maintenance Kohler Powered Units 32 9 2 Maintenance Label Kohler Powered Units 33 9 3 Servicing Air Cleaner Kohler Powered Units 34 9 4 Overload Protection Kohler Powered Units 35 9 5 Servicing Optional Spark Arrestor Kohler Powered Units 35 9 6 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units 36 9 7 Adjusting Engine Speed Kohler Powered Units 37 SECTION 10 TROUBLESHOOTING 0c cece cece eee eee eee eee eee eee eee eee 38 SECTION 11 ELECTRICAL DIAGRAM 000 c cece eee eee eee eee eee eee eee eee eee ai SECTION 12 GENERATOR POWER GUIDELINES 42 SECTION 13 STICK WELDING SMAW GUIDELINES 49 SECTION 14 PARTS LIST iris AA A 58 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom_2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in deat
46. ants sont reconnus par l tat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation L4W 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin pos
47. cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns 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 FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 945 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer
48. cessary Check plug PLG4 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine will not start Check fuel level Check battery voltage Check battery connections and tighten if necessary Check oil level see Section 5 4 or 5 5 Check low oil pressure shutdown switch see Parts List for location Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 Engine starts but stops when Engine Control switch returns to Run position Check oil level Check and refill crankcase with proper viscosity oil for operating temperature if necessary Check low oil pressure shutdown switch see Parts List for location Engine stopped during normal operation Check fuel level Check oil level see Section 5 4 or 5 5 Check fuse F6 and replace if open see Section 8 4 or 9 4 Check low oil pressure shutdown switch see Parts List for location Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 Battery Discharges between uses Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltag
49. cket Mtg Generator 1 A 193 627 Tank Fuel 10 Gal consisting of 1 Sf Osean ene 178 632 Fro Stand Pipe 250 X 7 375 Lg 1 DO cei win cee 124 253 Bushing Tank Fuel 1 BO hihi e 145 976 Hose Sae 250 Id X 500 Od X 4 500 1 AO oppna aa i 066 113 Filter Fuel Inline 250 included w engine 1 dl ses meer 084 173 Clamp Hose 460 545 Clp Dia Slfttng 3 AD a 193 810 Upright Base 1 CC WEE 160975 Seal Weather Lift Eye 1 ier AA EEN Figure 14 2 Panel Front w Components 1 E EEN 180 628 Panel Front Lower 1 AG 354 Ses E 233 088 Label Danger Using A Generator Indoors bh RAY ha aa veh aaa RE ech Can Kill You In Minutes Unit 1 SE 193 067 Kit Accy 20 Ft 2 W Elec Hldr 15 Ft Grd consisting of 1 E onal ter eave ve a 600 319 Cable Weld Cop Strd No 2 Epdm Jkt order by ft 35ft aT ge ier eae sae 040 234 Af 2 Holder Electrode 200a 1 SASS bo do aL A 130 750 Clamp Work 300 Amp 1 idad 600 720
50. cording to electrode being used see Section 6 3 Control may be adjusted while welding Control does not affect gener ator power output OM 945 Page 22 6 2 Cold Weather Engine Operation 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall This condition occurs when the temperature is near freezing and the rela 1 Infrequently tive humidity is high Ice forms on the throttle plate and inner bore of the carbu Loaded retor The engine typically restarts without problems but soon stalls again Y D RUN IDLE Ki START e Treat gasoline with a fuel de icer product isopropyl alcohol e Place the Engine Control switch in the Run position Run engine only when expecting to frequently load it Breather Icing Oil breather pulse line icing occurs in severe cold continuously below 0 F Moisture accumulates in the oil from piston ring blow by if the engine is exten sively idled This may cause vacuum line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to above freezing Frequently Load engine and reduce idle times to prevent engine shutdowns Loaded oad engine al e p g e Use an electric fuel pump to avoid pulse line freezing gt RUN IDLE e Install engine cold weather kit Both Kohler 1 800 54
51. cted extension cord 800 652 D OM 945 Page 42 12 3 Grounding When Supplying Building Systems IN 1 Equipment Grounding 1 2 Terminal GND PE 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 12 4 How Much Power Does Equipment Require ES 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re 3 sistive load and requires approxi 2 ee SE mately six times more power while H Se starting the motor than when running l see Section 12 8 SS 3 Rating Data 60W Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts 3 Example 1 If a drill uses 4 5 am F q peres at 115 volts calculate its run ning power requirement in watts 4 5 A x 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 Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load appli
52. e Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 945 Page 54 13 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead y ba Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 13 18 Troubleshooting Excessive Penetration
53. e Se 207 077 Knob Pointer 1 625 Dia Push On 1 LOT whee Wena 072 590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 26 HM 223 164 Meter Hour 12 60vdc 2 00 Dia 1 27 ENEE 201 486 Potentiometer W leadS 1 28 EE 202 631 Cover Circuit Breaker 1 OO vais pais care ae Ae 202 630 Brkt Mtg Ckt Breaker Cover 1 BO EL a Sen 602 207 Washer Lock 255idx0 4890dx 062t Stl Pld Split 250 1 dass 163167 Washer Lock 254idx0 4890dx 062t Sst Split 250 1 32 SR2 035 704 Rectifier Integ Bridge 40 Amp 800 V 1 33 LEM 191 941 Transducer Current 1 a va RA a 220 632 Harness Wrg Feedback consisting of 1 EEN 220 629 E A O ECKE 135 134 Conn Rect Univ 084 9p S 3row Plug Cable Lkg 1 Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 945 Page 61 Item Part No No Description Quantity Figure 14 3 Generator Figure 14 1 Item 20 DE PR E EN 220 832 Generator Assy Front consisting of
54. e Section 8 2 A Fuel Filter 5 Fuel Une Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connections as necessary and wipe up fuel 802 339 G S 0842 OM 945 Page 36 9 7 Adjusting Engine Speed Kohler Powered Units After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows GO r 2200 50 rpm Start engine and run until warm Remove wrapper to access speed 3700 50 rpm adjustments dt Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Weld Power Speed Adjustment Nut 5 Lock Nut Loosen lock nut Turn adjustment nut until engine runs at weld power speed Tighten lock nut A Stop engine Reinstall wrapper Top View Tools N
55. e Wshr 88d 3 2h E e inetd ee he 151542 Washer Flat 438idx1 0000dx 125t Stl Pld 3 sis EE 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 3 AO aan Figure 14 3 Generator 1 DT nasal in 193 782 Cover Tank Fuel NNN 1 le ege 217 848 Cable Bat Neg 15 000 No 4 Awg W Clamp amp 343 Rng 1 se QT nus AE EAR 234 299 Battery Stor 12v 480 Crk 75 Rsv Gp 58 Dry 1 EE 219 811 Cable Bat Pos 25 000 No 4 Awg W Clamp 8 312 Rng 1 EEN 172 669 Cable Bat Neg 11 000 6ga W 250 Rng 8 375 Rng 1 Be AO shanks Asch Bea 182 935 Hold Down Battery 1 O be 193 780 Bracket Mtg Engine 1 28 ET bean 226 446 5 Base EEN e a he Pe eee 1 ME WER 238 296 Label Engine Maintenance 1 SEC WE 229 134 Label warning do not weld on base 2 OM 945 Page 59 Item Dia Part No Mkgs No Description Quantity Figure 14 1 Main Assembly Continued exible O ah ook 181 057 Cover Base cria ia e ada dae Pa does a oa dada 2 82 DC Z 205 978 Stabilizer ASSY 1 33 SR1 228 056 Rectifier Si 1ph 250 Amp 400 Piv 100 Duty Cycle 1 E ET 208 149 Bracket Mtg Rectifier 1 EE 193 781 Bra
56. e pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en
57. e regulator and connections according to engine manual Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check field control board PC1 and current transformer CT1 Engine speed varies rapidly under heavy generator power load Reduce generator power load at ac receptacles Unstable or sluggish engine speeds Readjust throttle linkage if necessary Check throttle solenoid TS1 for smooth operation Check oil level Oil level should not exceed Full mark on dipstick Fuel pump will operate erratically if crankcase is overfilled Tune up engine according to engine manual Engine does not return to idle speed Remove weld and generator power loads Check throttle linkage for smooth non binding operation Have Factory Authorized Service Agent check current transformer CT1 Engine Control switch S2 throttle solenoid TS1 and field control board PC1 OM 945 Page 39 Trouble Remedy During operation in near freezing tem Treat fuel with isopropyl alcohol de icer product peratures engine starts and goes to idle but stalls after a few minutes Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath Install engine manufacturer s kit for cold weather operation er engine starts and goes to idle but stalls after a few minutes
58. ec le moteur e Seules des personnes qualifi es sont autoris es enlever les por L EXPLOSION DE LA BATTERIE tes panneaux recouvrements ou dispositifs de protection pour peut RENDRE AVEUGLE effectuer s il y a lieu des travaux d entretien et de d pannage e Toujours porter une protection faciale des gants e Pour emp cher tout d marrage accidentel pendant les travaux en caoutchouc et v tements de protection lors d entretien d brancher le c ble n gatif de batterie de la borne d une intervention sur la batterie e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles e Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire e Eviter de provoquer des tincelles avec les outils en travaillant sur d marrer le moteur la batterie e Avant d intervenir d poser les bougies ou injecteurs pour viter la e Ne pas utiliser le poste de soudage pour charger les batteries ou mise en route accidentelle du moteur des v hicules de d marrage rapide e Bloquer le volant moteur pour viter sa rotation lors d une interven e Observer la polarit correcte et sur les batteries tion sur le g n rateur e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer
59. ectric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding
60. ed and adjust if necessary see Section 8 7 or 9 7 Have Factory Authorized Service Agent check brushes and slip rings B Generator Power Trouble Remedy No output at generator power ac receptacles Reset supplementary protectors see Section 7 1 Reset circuit breaker CB4 see Section 8 4 or 9 4 Unit overloaded Stop unit and reduce load Restart unit to reset generator protection circuit and resume operation Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings integrated rectifier SR2 and field control board PC1 High power output at generator power ac receptacles Check engine speed and adjust if necessary see Section 8 7 or 9 7 Low power output at generator power ac receptacles Reset circuit breaker CB4 see Section 8 4 or 9 4 Check engine speed and adjust if necessary see Section 8 7 or 9 7 OM 945 Page 38 Trouble Remedy Erratic power output at generator pow er ac receptacles Check fuel level Check engine speed and adjust if necessary see Section 8 7 or 9 7 Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes and slip rings C Engine Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 4 or 9 4 Check battery voltage Check battery connections and tighten if ne
61. ed by the three flood lamps and drill is 1120 watts S 0623 OM 945 Page 43 12 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 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 12 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550
62. ee insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e 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 Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid 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 EF Indicates special instructions AEN This
63. eeded oS H Ie 1 4 3 8 in 802 339 G 801 209 A OM 945 Page 37 SECTION 10 TROUBLESHOOTING 10 1 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Check weld connections Reset circuit breaker CB4 see Section 8 4 or 9 4 Unit overloaded Stop unit and reduce load Restart unit to reset generator protection circuit and resume operation Be sure all equipment is disconnected from receptacles when starting unit Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings integrated rectifier SR2 and field control board PC1 Low weld output Reset circuit breaker CB4 see Section 8 4 or 9 4 Check control settings Check engine speed and adjust if necessary see Section 8 7 or 9 7 Service air cleaner according to engine manual Have Factory Authorized Service Agent check brushes and slip rings and field control board PC1 High weld output Check control settings Check engine speed and adjust if necessary see Section 8 7 or 9 7 Erratic weld output Check control settings Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine spe
64. en connections as necessary and wipe up fuel 802 353 G S 0842 OM 945 Page 30 8 7 Adjusting Engine Speed Subaru Robin Powered Units Y After tuning engine check engine aw U speeds with a tachometer see G i table If necessary adjust speeds as follows 2 2200 100 rpm Start engine and run until warm 3700 50 rpm Remove wrapper to access speed adjustments Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw J Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Jam Nut 5 Lock Nut 6 Weld Power Speed Adjustment Screw 0000 Loosen jam nut and lock nut Turn adjustment screw until engine runs at weld power speed Tighten jam nut and then tighten lock nut A Stop engine Reinstall wrapper Tools Needed aS Bo 10mmU 22 8 mm a 802 353 G 802 457 OM 945 Page 31 SECTIO
65. er les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s 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 composants DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler
66. es et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe 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 filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reco
67. es fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort 4 e Fermer alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage
68. g Air Cleaner Kohler Powered Units w OFF Y RUN IDLE A Stop engine and let cool NOTICE Do not run engine with out air cleaner or with dirty element 1 Wrapper Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 S 0759 O HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional 400 Trade Square East Troy Ohio 45373 Welding Career Now 1 800 332 9448 www welding org OM 945 Page 34 Over 80 000 trained since 1930 9 4 Overload Protection Kohler Powered Units EN gt we ap Tools Needed a gt gt H ZE 3 8in RUN IDLE A START A Stop engine If the unit is extremely over loaded weld and generator pow er will stop Turn unit off and re start to reset the generator protection circuit and restore weld and generator power out put If the rated output of the unit is ex ceeded engine speed may vary rapidly until the weld or generator power load is reduced 1 Circuit Breaker CB4 See Parts List CB4 protects the generator excitation circuit If CB4 ope
69. ge plasma ou de chauf fage par induction e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Si des BOUTEILLES sont endomma g es elles pourront exploser e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la Des bouteilles de gaz protecteur contiennent du gaz bouteille sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Maintenirle chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Prot ger les bouteilles de gaz comprim d une chaleur excessive e Lire et suivre les instructions sur les bouteilles de gaz comprim des chocs m caniques des dommages physiques du laitier des l quipement connexe et le d pliant P 1 de la CGA Compressed Gas flammes ouvertes des tincelles et des arcs Association mentionn dans les principales normes de s curit 2 3 Dangers existant en relation av
70. h eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes a TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 945 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion Lh e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this un
71. h or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away FX e ELECTRIC SHOCK can kill gt 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 equip mentis a hazard e Do not touch live electrical parts e Wear dry hole fr
72. he distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART 2 WELDERS HOBART 5 3 11 WARRANTY Effective January 1 2008 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of LJ or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equi
73. heed d EE PLG5 066104 Conn Rect Univ 084 9p S 3row Rept Housing Pins amp Skts EE Service Ki ia EE EE ENN Set PLG9 180 204 Conn Rect Univ 084 3p S 1row Plug Cable Lkg Housing Pins amp ENEE Skts Service Kit 7 RC2 RC3 141 432 Rept Str Dx Grd 2p3w 20a 125v 5 20r 2 EEN CB1 233 039 Supplementary Protector Man Reset 2p 50a 240vac 1 9 CB2 CB3 093 996 Supplementary Pro Man Reset 1p 20a 250vac Frict 2 DEE 203 993 Control Push Pull Snap in 36 000 W 1 750 Extension 1 A Vals aaa dtc 207 073 Lever Ignition Switch 1 TDF ck na eege Bie ker ER ee JUMPER de oie dd eae GL Eee ta Rede Soe dat 1 i ke EE RI B SCH 172 661 Block Stud Connection 6 Position 1 VE EE 099 255 Terminal Pwr Output Neutral 2 ER Re eS Deller A RE 083 030 Stud brs 250 20 x 1 750 1 Ee 010915 Washer flat brs 3 EE 601 836 N t 250 200 coc Ate d AS eg ile deng foe Ae 3 19 RC1 182 954 Rept Str 3p4w 50a 125 250v Flush Mtg 14 50 1 20 serres 188 039 Cover Receptacle W Gasket 1 SiO acne char ieee tue tbat EN 159921 0 BEZE E 1 A Sonate de Ba es RIED 1 23 CB4 161 078 Circuit Breaker Man Reset 1p 7a 250vac Fri 1 NO RO a
74. ial Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch 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 wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises
75. iquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear 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 After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby A NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres s
76. istributor or service agency call 1 877 Hobartl or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob_Thank 4 05 5 3 11 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com Ga NUI HO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ti Symbol Uleies A Pte neds Sarna deta bebo we 1 1 2 Are Welding Hazards 2 isn geed eae dd Sek 1 1 93 Engine H ardS EEN 3 1 54 Compressed Air Hazards io Konrat AE Net M he da ede hie ee las 3 1 5 Additional Symbols For Installation Operation And Maintenance 4 1 6 California Proposition 65 Warnings 5 1 7 Principal Safety Standards 5 1 8 EMF Information 4213 NEEN dnc tes hase ea ta de te ENER pee eee dene ne wana aces 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 6 2 1 Signification des symboles 6 2 2 Dangers relatifs au soudage l arc 6 2 3 Dangers existant en relation avec le moteur 8 2 4 Dangers li s l air comprim
77. it FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable UN FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 945 Page 4 WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body pn K other people or any metal when threading welding wire OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again
78. ited to 10 kVA kW rating of the generator EXAMPLE If 20 A is drawn from each 120 V duplex receptacle only 21 A is available at the 240V receptacle 2 x 120 Vx 20 A 240 V x 21 A 10 KVA KW approx Ref 226 427 A OM 945 Page 24 7 2 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P Her Current Available in Amperes 240 V Each 120 V Duplex Receptacle Receptacle 0 20 5 20 10 20 15 20 20 20 25 15 30 10 35 5 40 0 V x A Watts One 240 V load or two 120 V loads 240 V AC gt Lee The plug can be wired for a 240 V 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Amperes Available using 120 240 V Plug NO P Co Tools Needed plug1 11 03 120 813 D OM 945 Page 25 SECTION 8 MAINTENANCE SUBARU ROBIN POWERED UNITS 8 1 Routine Maintenance Subaru Robin Powered Units AE A hi ws A G Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label for important s
79. k If F6 opens while the engine is running the engine stops Replace fuse if open Reinstall cover before operating E If a fuse or circuit breaker opens it usually indicates a more serious problem exists Contact a Factory Authorized Service Agent 802 342 Ref 802 353 G 8 5 Servicing Optional Spark Arrestor Subaru Robin Powered Units La fe A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing SIS Y RUN IDLE a lt y START Tools Needed IF 1 4 in tt Ref 801 682 A Ref 802 353 A OM 945 Page 29 8 6 Changing Engine Oil Oil Filter and Fuel Filter Subaru Robin Powered Units Ka Gol Tools Needed Ss UN gt I gt Y RUN IDLE LKE A v 4 A Stop engine and let cool 1 Oil Drain Valve 2 1 21Dx7in Hose 3 Oil Filter Change engine oil and filter ac cording to engine owner s manual A Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tight
80. lassification SG or higher If using LP fuel use synthetic oil 100 hours 200 hours KOHLER MILLER 066 698 Kohler 1205001 ROBIN MILLER 198 754 Robin 248 65801 00 Oil Capacity w filter change Approximately 1 5 quarts DO NOT OVERFILL KOHLER Keep oil level between L amp F marks on dipstick ROBIN Keep oil level between 2 holes on dipstick NO SOBRELLENE KOHLER Mantenga el nivel del aceite entre las marcas L y F del medidor ROBIN Vantenga el nivel del aceite entre los dos huecos del medidor Fuel Grade Unleaded 87 Octane min Fuel Filter KOHLER MILLER 215 984 Kohler 2505022 KOHLER MILLER 215 984 Robin 263 65012 A3 Gasoline Air Filter Service 100 hours see Owner s Manual Air Filter KOHLER MILLER 230 016 Kohler 2408303 S Air Filter Wrapper KOHLER MILLER 230 017 Kohler 2408305 S Air Filter ROBIN MILLER 198 755 Robin 263 32610 A1 Includes Air Filter Wrapper 12 Volt Battery BCI Group 58 Cranking Performance at 0 F 18 C 430 Amps min Engine Speed High Speed 3675 3750 RPM No Load 2200 2300 RPM Spark Plug KOHLER MILLER 067 007 Kohler 1213202 Gap 0 030 in Champion RC 12YC Spark Plug ROBIN MILLER 198 777 Robin X65 01407 30 Gap 0 025 in NGK BPR4EY Use only resistor spark plugs and wires Tune up and Filter Kit Includes Air Oil and Fuel Filters and 2 Spark Plugs KOHLER MILLER 230 015 ROBIN MILLER 199 062 238296 A OM 945 Page 33 9 3 Servicin
81. lt gt RUN IDLE 1 Wrapper Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 803 070 S 0759 OBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional Au Trade Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 945 Page 28 8 4 Overload Protection Subaru Robin Powered Units ry y Tools Needed A Stop engine Disconnect nega O SS tive battery cable Y RUN IDLE LE y If the unit is extremely over loaded weld and generator pow er will stop Turn unit off and re start to reset the generator protection circuit and restore weld and generator power output If the rated output of the unit is ex ceeded engine speed may vary rapidly until the weld or generator power load is reduced 1 Circuit Breaker CB4 See Parts List CB4 protects the generator excitation circuit If CB4 opens there is no low weld and generator power output Press button to reset breaker 2 Fuse F6 See Parts List F6 protects the engine wiring system If F6 opens the engine does not cran
82. ly lamps be powered under these conditions 7 1 Standard Receptacles LE y A If unit does not have GFCI re ceptacles use GFCI d protected extension cord 1 120 240 V 50 A AC Recep tacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maxi mum output is 10 kVA kW 2 120 V 20 AAC Duplex Recep tacle RC2 3 120 V 20 A AC Duplex Recep tacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 KVA KW 4 Supplementary Protector CB1 TOTAL ALL LOADS 120V 240 VU 10 000 WATTS CB1 protects the ac receptacles from overload If CB1 opens the ac receptacles do not work PEN Move CB1 toggle switch to On ON position to reset If supplemen tary protector continues to open contact Factory OFF Authorized Service Agent 5 Supplementary Protector CB2 CB1 6 Supplementary Protector CB3 CB2 protects RC2 and CB3 pro 50A MAIN tects RC3 from overload If a sup BREAKE plementary protector opens the re ceptacle does not work GENERATOR POWER E EF Press button to reset If supple mentary protector continues to open contact Factory Authorized Service Agent Combined output of all receptacles lim
83. mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev OM 945 Page 7 e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser LES CHAMPS MAGNETIQUES peuvent affecter des implants m dicaux e Tenir les bouteilles loign es des circuits de soudage ou autres e Porteur de simulateur cardiaque ou autre im CES circuits lectriques plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin e Ne jamais placer une torche de soudage sur une bouteille gaz avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupa
84. multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 1 2 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode 3 Z UC YM a S 0054 A OM 945 Page 52 13 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 13 11 Lap Joint 30 o 30 Or Less Or Less eh S o 2 3 Single Layer Fillet Weld Multi Layer Fillet Weld 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum s
85. nna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada
86. ns there will be no low weld and generator power output Press button to reset breaker 2 Fuse F6 See Parts List F6 protects the engine wiring harness If F6 opens the engine does not crank If F6 opens while the engine is running the engine stops Replace fuse if open Reinstall panel before operating unit E If a fuse or circuit breaker opens it usually indicates a more seri ous problem exists Contact a Factory Authorized Service Agent Ref 801 221 B Ref 802 353 G 9 5 Servicing Optional Spark Arrestor Kohler Powered Units aw fe y Tools Needed IZ 1 4 in My gt Y RUN IDLE te A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing Ref 801 695 A Ref 802 339 A OM 945 Page 35 9 6 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units d lt gt Y RUN IDLE LKE AN Tools Needed Se Un A Stop engine and let cool 1 Oil Drain Valve 2 1 2 1D x7 in Hose 3 Oil Filter Change engine oil and filter ac cording to engine owner s manual A Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick se
87. of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment NS 120 q 1 GI gt 1 Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment EF Be sure equipment has double A insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen_pwr 2008 01 ST 800 577 1 GND PE ox 1 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator A frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro te
88. our stocker d placer ou exp dier des cartes de circuits imprimes OM 945 Page 10 entra ner des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable y g UNE REMORQUE QUI BASCULE peut 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 quipe ments de radio navigation et de communica tion 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 instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les port
89. pment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes 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 HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings dri
90. 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 curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants UN CHOC ELECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants s
91. pprouv 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 e Relacher la pression d air de l outillage ou du syst 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 LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES ETINCELLES A L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de pro duits 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 rel cher la pression avant d effectuer
92. r de 50 ou de 60 Hz la prise de 100 Hz D LES ETINCELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage et les yeux e Aff ter lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette ma noeuvre est ex cuter dans un endroit s r lors que l on porte l quipement homologu de pro tection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance inflammable DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage 3 H L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste 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 p
93. s and install battery When electrolyte is low add only distilled water to cells to maintain proper level drybatti 2008 01 S 0886 RUN IDLE te y Tools Needed 20 1 2 in A Connect negative cable last Ref 226 427 A Ref 802 341 Ref S 0756 D OM 945 Page 19 5 8 Installing Exhaust Pipe GO Bac 4 e y START Tools Needed IZ 1 2 in A Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet Point exhaust pipe in desired di rection but always away from front panel and direction of travel 801 681 Ref 226 427 A 5 9 Weld Output Terminals NEGATIVE POSITIVE 1 Negative Weld Output Terminal 2 Positive Weld Output Terminal For Direct Current Electrode Posi tive DCEP connect work cable to Negative terminal and electrode holder cable to Positive terminal For Direct Current Electrode Nega tive DCEN reverse cable connections Tools Needed LT 3 Ain 802 353 G Ref 226 427 A OM 945 Page 20 5 10 Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar lt gt y Correct Installation
94. sible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 945 Page 11 SECTION 3 DEFINITIONS 3 1 Symbol Definitions Fast Fast Slow E Stop Engine Run Weld Power lt gt Run idie ei gt Slow Idle Read Operator s A V d Start Engine FA Manual Amperes Volts QA Engine Oil Fuel Battery Engine Ox Engine x Engine Choke Check Valve S Circuit Protector Temperature Clearance Positive Negative NU Alternating Current CG Output AC h Hours e Seconds O Time D Ds Welding Arc JT Fuse os Electrode FR BiCK SMAW E 4 1 Weld Power and Engine Specifications This unit uses either a Subaru Robin or a Kohler engine Differences between models are noted throughout this manual Rated Maximum E Welding Weld Output x ARE Single Phase Fuel 7 Welding Open Circuit gt A Engine Mode Range Output Voltage Generator Power Rating Capacity ee V Subaru Robin E 65 o Duty y Air Cooled Two Cylinder Cycle Wope SE kW Four Cycle 22 HP 210 25 V 120 240 V
95. sion vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der 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 une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectro cution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enroul
96. tart up service and storage 1 Weld Cables Q Slip Rings Lk Brushes Valve Clearance fluids E h information Service engine more often if used in severe conditions Y Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 4 P j Y Hours 1 Fuel Level Y Oil Level Q Oil Fuel Spills Every Section 8 5 Se G Hours Q Spark Arrestor Screen Every Section 8 3 25 e Qn Hours Q Air Cleaner Wrapper Every 50 A A Hours M 2 Q Weld Terminals Every Engine 100 Manual Hours Section 8 6 8 3 Q Battery Terminals Q Cooling System x Air Cleaner Element Every WARNY gt Engine 200 Ki G gt A Manual Hours Do Section 8 6 il Unreadable Labels Y Spark Plug Gap Oil Filter Fuel Filter Every Engine 500 Manual Hours G OM 945 Page 26 8 2 Maintenance Label Subaru Robin Powered Units KOHLER CH23 ROBIN EH64 EH65 GAS ENGINES See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oil Push And Turn CCW SIE Check Daily Recommended Oil API Service Classification SG or higher If using LP fuel use synthetic oil Oil Change 100 hours Oil Filter Change 200 hours KOHLER MILLER 066 698 Kohler 1205001 ROBIN MILLER 198 754 Robin 248 658
97. tial start up fill tank with fresh fuel see maintenance label for specifications Always leave filler neck empty to allow room for expansion see fuel tank window on base Check fuel level on a cold engine before use each day Oil Do not exceed the Eu mark on the oil level dipstick The fuel pump may operate erratically if crankcase is overfilled After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label To improve cold weather starting Keep battery in good condition Store bat tery in warm area Use correct grade oil for cold weather 802 339 G OM 945 Page 18 5 6 Activating The Dry Charge Battery If Applicable Tools Needed Se Bi A Always wear a face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 1 Vent Caps 2 Sulfuric Acid Electrolyte 1 265 Specific Gravity 3 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger A Read and follow all instruc tions supplied with battery charger 5 5 Amperes For 30 Minutes Charge Time 6 30 Amperes For 12 Minutes Charge Time Charge battery Disconnect charg ing cable
98. trength S 0063 S 0064 13 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 13 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 945 Page 53 13 13 Weld Test 1 Vise 3 2 Weld Joint 3 Hammer A Strike weld joint in direction shown man lle mm ES AA 1 4 in a 2 6 4 mm 1 SER ZU 2To3 in t 51 76 mm a w A good weld bends over but does not break S 0057 B 13 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrod
99. uffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder OM 945 Page 6 F Indique des instructions sp cifiques AEN Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger manuel AC avec ten
100. un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincel les ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage DES ORGANES MOBILES peuvent provoquer des blessures courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil OM 945 Page 8 e Ne pas approcher les mains des ventilateurs DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de
101. ure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct 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 Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing batter
102. ve rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Millers option of repair or replacement will be F O B Factory
103. y Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand 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 e Keep away from fans belts and rotors e Keep all doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit e Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while working on generator components HOT PA

section 1 - Hobart Welders

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