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NOTE - Hobart Welders

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1. aw A ERATOR POWER A If unit does not have GFCI re ceptacles use GFCI 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 A AC Duplex Recep tacle RC2 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 Circuit Breaker CB1 CB1 protects the ac receptacles from overload If CB1 opens the ac receptacles do not work ww Move CB1 toggle switch to On position to reset circuit break er If breaker continues to open contact Factory Authorized Service Agent 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects RC2 and CB3 pro tects RC3 from overload If a circuit breaker opens the receptacle does not work Press button to reset circuit breaker If breaker continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited 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 V x 20 A 240 V x 21 A 10 KVA KW approx 202 069 OM 945 Page 20 7 2 Optional Generator Power Receptacles CR I y A lfunit does not have GFCI
2. O HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional A 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 25 8 4 Overload Protection Robin Powered Units A Stop engine Disconnect nega tive battery cable AP we Tools Needed 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 CBA 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 crank If F6 opens while the engine is running the engine stops Replace fuse if open Reinstall cover before operating F 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 B 8 5 Servicing Optional Spark Arrestor Robin Powered
3. After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm 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 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 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 802 353 B 802 457 OM 945 Page 28 SECTION 9 MAINTENANCE KOHLER POWERED UNITS 9 1 Note gt Routine Maintenance Kohler Powered Units Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period E A Stop engine before maintaining SSC See Engine Manual and Maintenance Label for important start up service and storage informa wre t3 xm engine fl ae tion Serv
4. 1 DES PLG8 177859 Conn Body 5 Terminal 1 E PLG4 116045 Conn Rect Univ 084 6p S 3row Rept Housing Pins amp Skts ps ne EE Service Kit s same means a remet d Be PLG5 066104 Conn Rect Univ 084 9p S 3row Rept Housing Pins amp Skts Farha nes PRA ion Sin EE Service A NEE ees PLG9 130204 Conn Rect Univ 084 3p S 1row Plug Cable Lkg Housing Pins amp EE Skts Service Kit 7 RC2 RC3 141 432 Rept Str Dx Grd 2p3w 20a 125v 5 20r 2 7 GFCI2 GFCI3 151 981 Rept Str Dx Grd 2p3w 15 20a 125v 5 20r GFI 2 Bees CB1 218 591 Circuit Breaker Man Reset 2p 50a 240vac Screw 90 1 9 CB2 CB3 093996 Circuit Breaker Man Reset 1p 20a 250vac Frict 2 AO cgo eu 203 993 Control Push Pull Snap in 36 000 W 1 750 Extension 1 uh der oo e LA s o 207 073 Lever Ignition Switch 1 RE PAR oes 179 734 Link J mper 4s xdi n RERO ER dE A de Gnd 1 a ta uris TT hnius 172661 Block Stud Connection 6 Position 1 o rr POS auus 039 047 Terminal Pwr Output Red 1 15 NEG 039 046 Terminal Pwr Output Black 1 VS SNE 083 030 Stud brs 2p0 20x1cp0 ees 1 VE Lamine
5. 1 A D ELO 114923 Boot solenoid 1 A tthe tee ee 199 062 Kit tune up and filter Onan includes air filter element and wrapper ITEM oil filter fuel filter and spark plugs 1 E cerebri 194 249 Engine Kohler Gas Elec Ch20s ps 64635 consisting of 1 e E 193 856 Muffler Exhaust Engine Kohler 1 A a a a Ke 189 477 Gasket muffler 2 066 698 v44 Filter OW cease YER a NOMA YN SO as Doc ee SE EE 190 248 Pump fuel nee bes aaa d UM E 067 272 Element air cleaner 1 t dede EECH ane Rad vg 215 985 Filter fuel w clamps A palea dedi a Rog bar RR d 067 273 Wrapper air filter d m 067 007 PIU Spark EE cae de a ee LA 2 A ater AEN 199 530 Solenoid idle 1 dr PO Rs OS ts 165 271 Valve Oil Drain 3 8 18 Nptf 1 Sch E aca F6 021 718 Fuse Mintr Gl 30 Amp 32 Volt 1 EE 114923 Boot solenoid 1 EE e 180 096 Kit tune up and filter Kohler includes air filter element and wrapper A PP oil filter fuel filte
6. 197 148 OM 945 Page 11 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 N 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 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 12 SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes Do not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A If unit does not have GFCI re ceptacles use GFCI protected extension
7. o o o ex e N o tc CO Notes Work like a Pro Pros weld and cut oF e dd y v OP gt gt a Y the beginning of this manual OM 945 Page 18 SECTION 6 OPERATING THE WELDING GENERATOR NOTE gt power output 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 and generator If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or generator power load is reduced Front Panel Controls Pio 4 TA CE OCCECCECCNCCN T men TOTAL ALL LOADS 120 V 240 V 10 000 WATTS CB1 GENERATOR POWER Ref 202 069 C 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 engin
8. 7 2 6 Principales normes de s curit 8 2 7 Information sur les champs lectromagn tiques 8 SECTION S DEFINITIONS ele ner eme eee See Ee See ht DE Le 9 SECTION 4 SPECIFICATIONS 444444 usines 9 4 1 Weld Power and Engine Specifications 9 4 2 Dimensions Weights and Operating Angles 10 4 9 Generator Power Cunve cvi etr pese ICA nn ee Qe AM OE pae eS A 10 4 4 Fuel Consumption All Models 11 4 5 B ty Oycle c xcix mines Laden dates nina ie tin amenant uta 11 4 6 Volt Ampere Curves 0 occocccccccc ect hh II nn 12 SECTIONS INSTALLATION amp et a ene enter ied ey 13 5 1 Installing Welding Generator 13 5 2 Engine Prestart Checks Robin Powered Units 14 5 3 Engine Prestart Checks Kohler Powered Units 14 5 4 Activating The Dry Charge Battery If Applicable 15 5 5 Connecting the Battery 16 5 6 Installing Exha stiPIpe i3 ceret retenir a cs 16 5 7 Connecting to Weld Output Termina
9. Check voltage regulator and connections according to engine manual Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check 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 37 SECTION 11 ELECTRICAL DIAGRAM NOILdO ANION3 Y31HOA LU LU LU LH LU OE 938 GION310S 110A 440 1NHS HOLVIS Tana Lei BONNE gt s DECH 3 Gu LOA ZL F ss 3unsssud 8d NYI ZA Iw Mo k new v Vv v y 01 e 914 M ec Mrz os zS ee Lou 9 X Y V IS 09 09 ee
10. o ep o o ou 721 00 4 3 0 9 8 v 189 ES tO Z9 St 4g me LU No HIE 48 y zz Es aot AB OG Z 1049 N 9 ONO x Be E uN Z9 OF G NOILdO SH TOL A 9 Ke Sc Z9 ZE 1949 1949 jun si eones 10 asn QHVZVH NIOHS resu suosiad peyijenb Ajuo are y e 91419373 PeAOLUS S18A09 UU ejejedo jou oq e Dupuies eJojeq euiBua S dois Jo 1amod 1ndui j98UU0981q e 9 sued je2ujoeje eA yono jou og el NINHVM Y NOILdO ONNOYY UNNOYI 3NION3 NIML A NVNO TaNvd 3sv8 o a BEES 4 W y W y La ff e amp E TAN TR mem Hal s M e a a Ns ON Se UJ RN 1S4 s en g Sod nn Lys Es DEI 3 si Don ZI n Z Sch gem a NOI t b p X 73 cs 2 90 TMA L L S q L 0 ON SE E Ae 1 pao ANSSI kk es IO MOT ma 7U W v v v void Y vod V row V y Ala 91d c vx M M vOH Y vou sou Y y PO y PON y oz 9 f 4 s Z 74 Z 7 lt Wm lt zm GE OvZ Z lt 3X Nnu Ge d ell E Se EECH toy 9 X M A YNOH lt is VV Y nu S91d cou oO oz 991d zs T id e E eo 70MINOO OU ze ou DN id Hee ma 22 f d
11. 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 UE 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 47 13 5 Positioning Electrode Holder 10 30 EAT 907 90 a Se d y End View of Work Angle Side View of Electrode Angle GROOVE WELDS o o 10 30 V 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 E 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 NoOverlap 5 Good Penetration into Base Metal S 0052 B OM 945 Page 48 13 8 Conditions That Affect Weld Bead Shape NOTE
12. Eem A det arat EE EN deis ad A 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 57 Item Part No No Description Quantity Figure 14 3 Generator Figure 14 1 Item 20 nl es me ts 220 832 Generator Assy Front consisting of 1 PE HEC 183 419 O ring 1 984 Id X 139 Cs 70 Duro Viton 1 zm Oo Spain 013 367 Label Warning Moving Parts Can Cause Serious Etc 1 X rm 185 148 Housing Generator Rear 1 186 083 Screw 437 14x1 75 Hexwhd 93d Gr8 Pld 4 TE c r 222 130 Rotor Generator consisting of 1 TA GE EE 181 134 Fan Rotor Gen 1 sage WEE 181 143 Bearing Ball Rdl Gol Row 984 X 2 047 X 59 1 Ds Q sated ada tad xa 205 725 Brushholder Assy Generator 1 STO 2d eee emt 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
13. 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 EF 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 B Ref 183 175 A 9 5 Servicing Optional Spark Arrestor Kohler Powered Units EZ r we A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing Tools Needed IZ 1 4 in mmm Ref 801 695 A Ref 802 339 A OM 945 Page 33 9 6 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units ws db 27 LAY S Tools Needed Se u amp tuo RUN IDLE Ae LIRE A Stop engine and let cool 1 Oil Drain Valve 2 1 21Dx7 in Hose 3 Oil Filter Change engine oil and filter accord ing 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 9 2 4 Fuel Filter 5 Fuel Line Replace line if cracked o
14. National Research Council a conclu L accumulation de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectri ques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la recherche il serait souhaitable de r duire l ex position aux champs lectromagn tiques pendant le soudage ou le coupage OM 945 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail respec ter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 Symbol Definitions E Stop Engine Run Weld Power Q da gt nas d j Start Engine A EE A Amperes V Volts RECH Engine Oil Fuel Battery Engine Ox Engine x Engine Choke ee ES Circuit Breaker Temperat
15. OVERHEATING can damage motors e Turn off or unplug equipment before starting or stop ping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face z e Shapetungsten 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 T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 945 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts e Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADIATION can cause interference e High frequency H F can interfere wit
16. uvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance UA e Ey 3 3 D o L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT Laisser l quipement refroidir respecter le facteur de marche nominal 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 2 Vi VA A IN ASS Le e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pieces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut entrainer des blessures e Ultiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant Bes 2 6 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping norme American Welding Society AWS F4 1 de American
17. 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 stick 12 96 ST 151 593 OM 945 Page 46 13 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 250 300 ELECTRODE POSITION PENETRATION DEEP MIN PREP ROUGH DEEP HIGH SPATTER LOW GENERAL SMOOTH EASY MED FAST LOW HYDROGEN LOW STRONG FLAT SMOOTH EASY HORIZ LOW FASTER FILLET NI CL y y A V d y ALL LOW CAST IRON 308L d ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode
18. 252 Baffle engine air Kohler only 1 sec gulis dA adu 193778 Panel Reat ENNEN Ee AA EXE EAR AY RA a 1 Sal NE hs 194 263 Grommet Plastic Snap in Battery Access 1 Thug 219 654 Label Warning Battery Explosion Can Blind 1 E sa sce sese e 209 057 Clamp Muffler 1 625 Dia U Pld 1 LE ee 195 845 Engine Onan Gas Elec Start consisting of 1 shat Ame Sige id 193 845 Muffler Exhaust Engine Onan 1 RAS SUE deeg 065 313 Gasket muffler 2 shah ARE tap LES LAPS ns hea 198 754 Filter NEEN 198 755 Element air cleaner w precleaner A THE 198 96 05 Pump fueli itaua REI ewe ai eevee N PM VEM S5 198757 Switch low oil pressure d VERRE 215 985 Filter fuel wlclamps A TT 198 77 7 PUG SPANK orn bebe ne P ERE RE CERE ELS Sien eet pean debts dene recep b EROR Solenoid w mtg bracket see engine parts list 1 DOMO egal duerech 198 778 Regulator voltage 1 Le KEE 165 271 Valve Oil Drain 3 8 18 Nptf 1 Dada F6 021 718 Fuse Mintr Gl 30 Amp 32 Volt
19. 27 8 7 Adjusting Engine Speed Robin Powered Units 28 TABLE OF CONTENTS SECTION 9 MAINTENANCE KOHLER POWERED UNITS 29 9 1 Routine Maintenance Kohler Powered Units 29 9 2 Maintenance Label Kohler Powered Units 31 9 3 Servicing Air Cleaner Kohler Powered Units 32 9 4 Overload Protection Kohler Powered Units 33 9 5 Servicing Optional Spark Arrestor Kohler Powered Units 33 9 6 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units 34 9 7 Adjusting Engine Speed Kohler Powered Units 35 SECTION 10 TROUBLESHOOTING 4444 nn nnne 36 SECTION 11 ELECTRICAL DIAGRAM ococcoccccccoc casses esse 38 SECTION 12 GENERATOR POWER GUIDELINES 39 SECTION 13 STICK WELDING SMAW GUIDELINES 4 ccuu e 46 SECTION 14 RAISIN eege manne eee et ren den A 54 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom _nd_10 04 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage wi
20. 32 DC Z 205 978 Stabilizer ASSY 1 33 gt SRA ohn te 220 782 Rectifier Si 1ph 400 Amp 400 Piv 60 Duty Cycle 1 OA eee 208 149 Bracket Mtg Rectifier 1 O Ad 193 781 Bracket Mtg Generator 1 EE 193 627 Tank Fuel 10 Gal consisting of 1 DOT as 178632 Fro Stand Pipe 250 X 7 375 Lg 1 Ee e A 124 253 Bushing Tank Fuel 1 39 a Ar 145 976 Hose Sae 250 Id X 500 Od X 4 500 1 AO aaae d 066 113 Filter Fuel Inline 250 included w engine 1 AN a 084 173 Clamp Hose 460 545 Clp Dia Slfttng 3 A ae 193 810 Upright Base EES erate ete a baume 1 AAS ee aa 160 975 Seal Weather Lift Eye 1 VA eh use Figure 14 2 Panel Front w Components 1 A E 180 628 Panel Front Lower 1 46 iia 220 457 Label Need Hein 1 TP NAS E 193 067 Kit Accy 20 Ft 2 W Elec Hldr 15 Ft Grd consisting of 1 EE EE 600 319 Cable Weld Cop Strd No 2 Epdm Jkt order by ft 35ft EE 040 234 Af 2 Holder Electrode 200a
21. 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 en 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 22 SECTION 8 MAINTENANCE ROBIN POWERED UNITS 8 1 Routine Maintenance Robin Powered Units Note gt Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period 2 i gt Y ee A Stop engine before maintaining EI d FF See Engine Manual and Maintenance Label for Recycle important start up service and storage informa SEN tion Service engine more often if used in severe KS conditions To be done by Factory Authorized Service Agent e Every 8h Wipe up sits gt gaue aA 20h Service air E m n Prod E
22. 7 Have Factory Authorized Service Agent check brushes and slip rings B Generator Power Trouble Remedy No output at generator power ac receptacles Reset circuit breakers see Section 7 1 or 7 2 Press optional GFCI receptacle Reset button see Section 7 2 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 36 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 connection
23. Cr Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small p 10 30 Angle Too Large d am S d prag ELECTRODE ANGLE L GE e EE ER Too Short Normal Too Long ARC LENGTH poem o OS Slow Normal Fast TRAVEL SPEED S 0061 13 9 Electrode Movement During Welding N OTE Cr Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 945 Page 49 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 cuttin
24. E cleaner wrapper p l 4 foam element See Section 8 5 See Section 8 3 e Every 50 h Clean and 6 tighten weld s terminals E Oo O Every 100 h Change oil See Section 8 6 and maintenance label Clean cooling system See Engine Manual Service air cleaner element See Section 8 3 Clean and tighten battery connections O Every 200 h uy Change oil filter See Replace fuel a ef Section 8 6 and filter See maintenance label Section 8 6 a ET Check spark plugs Replace _ unreadable labels OM 945 Page 23 O Every 500 h Repair or replace cracked cables O HF Service welding generator e brushes and slip rings Service TS Ze more often in dirty conditions Check valve clearance O Every 1000 h Blow out or A vacuum inside During heavy y OR service clean monthly See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oll Push And Tum CCW TZ Check uum Pull Recommended Oil API Service Classification SG or higher If using LP fuel use synthetic oil Oil Change 100 hours Oil Filter Change 200 hours Oil Filter KOHLER MILLER 066 698 Kohler 1205001 ROBIN MILLER 198 754 Robin 248 65801 00 Oil Capacity w filter change Approximately 1 5 quarts DO NO
25. OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 8 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 HE Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replaceme
26. 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 electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 945 Page 51 13 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead y AN Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before
27. Units A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing HR we Tools Needed IF 1 4 in gt titi Ref 801 682 A Ref 802 353 A OM 945 Page 26 8 6 Changing Engine Oil Oil Filter and Fuel Filter Robin Powered Units A Stop engine and let cool 1 OU Drain Valve 2 1 21Dx7 in Hose 3 Oil Filter Change engine oil and filter ac cording to engine owners manual Ka DW rf lh 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 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 neces sary and wipe up fuel Tools Needed Te uy ma 802 353 B S 0842 OM 945 Page 27 8 7 Adjusting Engine Speed Robin Powered Units ws RP Tools Needed e SB 10mm 3 e 8 mm 3 2200 100 rpm e 3700 50 rpm
28. Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection As sociation P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Cana dian Standards Association Standards Sales 178 boulevard Rexdale LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine Effectuer la maintenance du moteur et du compres seur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication les Services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l
29. ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keepcables close together by twisting or taping them 2 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 Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom_fre 10 04 A Avertissement Prot gez vous et les autres des blessures lisez et suivez ces pr cautions Le Ce groupe de symboles si gnifie Mise en garde lt a Soyez vigilant Il y a des 2 1 Sign
30. avec une bou teille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 2 3 Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu OM 945 Page 6 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 L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le moteur avant de d brancher ou de bra
31. cord Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu Mounting Inadequate support lated copper wire A Do not use flexible mounts 1 Grounding A Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown Electrically bond generator frame to vehicle frame by metal to metal contact install2 11 04 Ref 800 652 Ref 800 477 A 803 274 OM 945 Page 13 5 2 Engine Prestart Checks Robin Powered Units Gasoline 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 CS Follow run in procedure in engine manual CS 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 initial start up fill tank with fresh fuel see ma
32. grounding terminal to bare metal on the vehicle frame as shown A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 945 Page 39 12 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 12 4 How Much Power Does Equipment Require VOLTS 115 AMPS 4 5 Hz 60 6 ow AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax 115 V 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts 1 R
33. installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Rexdale O
34. 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 58 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 the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART 3 31 WARRANTY Effective January 1 2005 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LF 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
35. repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES 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 al
36. respirer les fum es l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager
37. une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme sui vant e Mettre des lunettes de s curit et des gants placer un torchon sur le bou chon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance L
38. 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 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 52 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 Let 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
39. 00 2HP 10550 2850 3HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 945 Page 41 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 10in 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
40. 1 fh SGA A a he LAS 130 750 Clamp Work 300 Amp 1 RE res 600 720 Term Ring Tng 500stud Solistrand 2ga 2 diarios 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 23 3 2 4 OM 945 Page 56 802 344 J 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 ed sence et gata nes ed 198 122 Stand off Support Pc Card 250w Post amp lock 500 6 pa Qi ds a fe pee SEN Om Nameplate order by model amp serial no 1 SC WEE EE Panel Front ts Tuer nie dense Ghee fos hoo erii iaa 1 od s PG1 asain 203 655 Circuit Card Assy Field Current Controller 1 ve db lux CTT us 204 709 Xfmr Current Sensing 1 xg D vides S2 sus 217 680 Switch Ignition 4 Position Without Handle 1 Puce a e WR AN ea Weeds 222 133 Harness Wrg Ignition consisting of
41. 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 42 12 8 Power Required To Start Motor A MOTOR 1 Motor Start Code 2 2 Running Amperage EEE o t 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage x HP 1 4 PHASE 1 To find starting amperage Step 1 Find code and use table to find kVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motors running amperage Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 KVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 A Starting ih t ires 12 2 12 2 amperes 230 arting the motor requires amperes S 0624 12 9 How Much Power Can Generator Supply 1 LimitLoad To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start wi
42. 2 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 If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Gumrent Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 945 Page 45 SECTION 13 STICK WELDING SMAW GUIDELINES H pum ATA A ES ML A ei ES uf E 13 1 Stick Welding Procedure Tools Needed My A Weld current starts when electrode touches work piece A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible
43. 41 Ref S 0756 D 5 6 Installing Exhaust Pipe A Engine backfire can cause se EA 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 Et RUN IDLE RUN v START Tools Needed 801 681 Ref 202 069 A IZ 1 2 in OM 945 Page 16 5 7 Connecting to Weld Output Terminals Va N 1 Negative Weld Output Terminal o 2 Positive Weld Output D Terminal For Direct Current Electrode Posi 60 tive DCEP connect work cable to Negative terminal and electrode e holder cable to Positive terminal For Direct Current Electrode Nega tive DCEN reverse cable connections Tools Needed ot 3 Ain NEGATIVE POSITIVE Ref 202 069 A 5 8 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 100 ft 30 m or Less 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 45 m 60 m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before 10 60 60 100 connectingto weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn dam aged undersized or p
44. 801 209 A OM 945 Page 35 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 speed and adjust if necessary see Section 8 7 or 9
45. IRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectuer la maintenance 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser un illeton de levage pour lever l appareil et les accessoires correctement install s Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications e Nelever 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 assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 945 Page 7 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il y a lieu cd LES TINCELLES VOLANTES ris quent de provoquer des blessures N y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette man
46. OM 945 194 047V Ne AN February 2005 Processes e He Stick SMAW Welding Description WELDER LISS 2 Engine Driven Welding Generator Champion 10 000 DL OWNER S MANUAL Visit our website at www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source i ET Eon A ine you may need to fix the problem Warranty and from Hobart is backed by uality ice i i i the best warranty in the System Standard service information for your particular model y business are also provided 150 9001 2000 QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products
47. 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 53 SECTION 14 PARTS LIST not available unless listed E Hardware is common and q S Le NS F 19 20 FIG 14 3 802 343 M Figure 14 1 Main Assembly Onan Engine Shown OM 945 Page 54 Item Dia Part No Mkgs No Description Quantity Figure 14 1 Main Assembly EE WEE 193 777 sx Wrappet ENNEN NENNEN EEN 1 EE 184791 Label Hobart i aa renier EEN 3 O ne eine ee aa Gets 219 329 Label Use Gasoline Fuel Only 1 Bs ba iss eate Panay eaten 181 881 Grommet Plastic Neck Filler Fuel 1 E eee eee eee 220 711 Cap Tank Screw on w Vent 1 pe Oey eka eee de 222 324 Label Warning General Precautionary Csa 1 TE nn mure 211 527 Pipe Exhaust Elbow 1 dis iO Ne end means 196
48. T OVERFILL KOHLER Keep oil level between L amp F marks on dipstick ROBIN Keep oil level between 2 holes on dipstick Fuel Grade Unleaded 87 Octane min Fuel Filter KOHLER MILLER 215 984 Kohler 2505008 ROBIN MILLER 215 984 Robin 263 65012 A3 Gasoline Air Filter Service 100 hours see Owner s Manual Air Filter EE KOHLER MILLER 067 272 Kohler 4708303 Air Filter Wrapper KOHLER MILLER 067 273 Kohler 2408302 Air Filter ROBIN MILLER 198 755 Robin 263 32610 A1 Includes Air Filter Wrapper 12 Volt Battery Cranking Performance at 0 F Engine Speed 8675 3750 RPM No Load 2200 2300 RPM See Owner s Manual Spark Plug KOHLER MILLER 067 007 Kohler 1213202 Gap 0 030 in Champion RC 12YC ROBIN MILLER 198 777 Robin X65 01407 30 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 180 096 ROBIN MILLER 199 062 215 939 C OM 945 Page 24 8 3 Servicing Air Cleaner Robin Powered Units A Stop engine A Do not run engine without air cleaner or with dirty element 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 803 070 S 0759
49. THN 77 Ses 119 we SIS ve iu GA 222m Ege SE IZ SII r d GM 7 28e le AAA D 9 M A 1314 9NW1O 3H z gt AOL 7z 5 cS 6914 4 S rou 1914 1098 sod V Y Y Ka YIMOd NOLIVLIOX3 AAA m af aiii UR wei f II oS 67 ez LLI a gt ES V OC 4g r ra AAA ER d TF 9 M A AOZL m3 Ge EES YS NNIAHL RA 8 OL GaSO1 X 383 a en m x SS X mus ES os Z6 S x x x nny 2 1S 09 09 S EE ots x T0 nnw ES o Q fP ol EISE CS 4 3 0 5 8 y Ell mU ZS NOWISOd 222129 A For Welding Generator Onan And Kohler Powered Units ircuit Diagram Figure 11 1 Ci OM 945 Page 38 SECTION 12 GENERATOR POWER GUIDELINES NOTE gt The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment A Do not use 2 prong plug un less equipment is double in sulated Be sure equipment has this symbol and or wording gen pwr 11 02 Ref ST 159 730 ST 800 577 EZ Electrically bond generator v frame to vehicle frame by metal to metalcontact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment
50. WS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fiel
51. a zone de soudage pour viter le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes 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 proxi mit DES PARTICULES VOLANTES s f peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PI CES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler
52. ase 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 B OM 945 Page 14 5 4 Activating The Dry Charge Battery If Applicable GO Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 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 6 Battery Charger A Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery EF When electrolyte is low add only distilled water to cells to maintain proper level 5 A For 30 Minutes Tools Needed px rubbergloves E glasses OR TN 30 A For 12 Minutes drybatt1 1 98 S 0886 OM 945 Page 15 5 5 Connecting the Battery Connect negative cable last Tools Needed IZ 1 2 in Ref 202 069 A Ref 802 3
53. books 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 2005 Hobart Welding Products 1 05 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se KA HOBART HS
54. ceed tilt angles or engine could be damaged or unit could tip A Do not move or operate unit where it could tip 4 3 Generator Power Curve AC POWER VOLTS 280 140 The generator power curve shows the generator power in amperes available at the receptacles 240 120 Fp 200 100 r 160 80 f 120 60 r 80 40 r 40 20 L 20 AC 10 AC 40 60 80 POWER AMPERES AT 120V 20 30 40 POWER AMPERES AT 240V 100 50 197 252 OM 945 Page 10 4 4 Fuel Consumption All Models u LITERS HR o IMP GAL HR 4 D 9 U S GAL 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 LL Ed D 1 0 20 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 A 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 O Continuous Welding 100 Duty Cycle at 170 Amperes CC DC nano OB Oxo 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
55. consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 12 4 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 945 Page 44 12 11 Selecting Extension Cord Use Shortest Cord Possible E Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG E 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 6
56. contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 877 Hobart1 AC PAU THO Hob_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Tt Symbol Usage iii rene A A AA 1 1 22 Arc Welding Hazards a a ra aida 1 T 3 Engine Hazards ii ds 2 1 4 Compressed Air Hazards eet e e Re E rh dh er NNN ERAN EN CREE TAFE EE 3 1 5 Additional Symbols For Installation Operation And Maintenance 3 1 6 California Proposition 65 Warnings 4 1 7 Principal Safety Standards 2 4 1 8 EMF Information aa ssaa aA ena ane Ue haat eG RE ot EN an ast ae Re EU FP ends Rol ce n e ride ae 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles oe sees EN x x Ra Er A en ren A UU Ed 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers existant en relation avec le moteur 6 2 4 Dangers li s lair comprim 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance
57. d hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuf fless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes ES e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when wor
58. der manuel lectrode enrob e DC 3 un poste souder ma nuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre risques de danger reli s aux CHOCS LECTRIQUES aux PI CES EN MOUVEMENT et aux PI CES CHAUDES Reportez vous aux symboles et aux directives ci des sous afin de conna tre les mesures prendre pour viter tout danger En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l apparei
59. des fum es toxiques en cas de soudage OM 945 Page 5 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds FRA LE SOUDAGE peut provoquer un in 5 cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut pro
60. ds when welding or cutting OM 945 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electro magnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive 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 levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www
61. e starts EF If the engine does not start let the engine come to a complete stop before attempt ing restart To Stop turn Engine Control switch to Off position 3 Engine Hour Meter 4 Amperage Control Use control to select weld amperage Select amperage according to electrode being used see Section 5 9 Control may be adjusted while welding Control does not affect gener ator power output OM 945 Page 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT NOTE gt power output 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 and generator If the rated output of the unit is exceeded engine speed may vary rapidly until the weld or generator power load is reduced 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 only lamps be powered under these conditions 7 1 Standard Receptacles nw IS i TOTAL ALL LOADS 10 000 WATTS CB1 50A MAN BREAKER 120 V 240 V CB2
62. ed receptacle outlet When making input connections attach proper grounding conductor first double check connections 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 sep arate cable Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or work table 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 i
63. ement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Seservir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n ces saire 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 envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste sou
64. esistive 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 sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment S 0623 OM 945 Page 40 12 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 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 2HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 22
65. g 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 MA 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 strength 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 50 13 13 Weld Test 1 Vise 3 2 Weld Joint 3 Hammer A Strike weld joint in direction shown man e mm Bd EE 1 4 in DP 2 6 4 mm 1 RU UR 2 To3 in 51 76 mm gl ow A good weld bends over but does not break S 0057 B 13 14 Troubleshooting Porosity
66. gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other 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 fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards CA MOVING PARTS can cause injury e Keep away from fans belts and rotors Y e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose c
67. h radio naviga tion safety services computers and communica tions 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 equipment at 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 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 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 Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard A
68. ice engine more often if used in severe conditions Tobe done by Factory Authorized Service Agent e Every 8h Wipe up spills 9 Check fluid levels See Section 5 2 Br e Every 20 h Check and clean optional spark arrestor screen See A Section 9 5 O Every 25 h Service air cleaner wrapper foam element See Section 9 3 O Every 50 h Clean and tighten weld terminals 4 O Every 100 h Change oil See Section 9 6 and maintenance label Check air cleaner element See Section 9 3 Clean cooling system See Engine Manual Clean and tighten battery connections OM 945 Page 29 e Every 200 h gt Change oil filter See Section Replace fuel filter See gt BS 9 6 and maintenance label Section 9 6 A Check spark plugs Z Replace unreadable labels e Every 500 h e a Repair or replace cracked P Rh ae ae Sedo cables XN ZAO more often in dirty conditions Every 1000 h Blow out or vacuum inside Pd During heavy service clean e OR monthly O HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional Au trade Square East Troy Ohio 45373 OWEF 80 000 trained since 1930 Welding Career Now 1 800 332 9448 www welding org OM 945 Page 30 9 2 Ma
69. ification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 2 6 Veuillez lire et respecter toutes ces normes de s curit A L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rement les enfants ra x UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le log
70. intenance Label Kohler Powered Units KOHLER CH20 ROBIN EH64 EH65 GAS ENGINES YY See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oil Check Push And Tum CCW Daily 4 CH m Pull Recommended Oil API Service Classification SG or higher Oil Change If using LP fuel use synthetic oil 100 hours Oil Filter Change 200 hours Oil Filter 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 Gasoline ROBIN Keep oil level between 2 holes on dipstick Fuel Grade Unleaded 87 Octane min Fuel Filter KOHLER MILLER 215 984 Kohler 2505008 ROBIN MILLER 215 984 Robin 263 65012 A3 Air Filter Service 100 hours see Owner s Manual Air Filter KOHLER MILLER 067 272 Kohler 4708303 Air Filter Wrapper KOHLER MILLER 067 273 Kohler 2408302 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 430 Amps min Engine Speed High Speed 3675 3750 RPM No Load 2200 2300 RPM Miller Legend See Owner s Manual Spark Plug KOHLER MILLER 067 007 Kohler 1213202 Gap 0 030 in Champion RC 12YC ROBIN MILLER 198 777 Robin X65 01407 30 NGK BPR4EY Use on
71. intenance 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 Full mark on the oil level dipstick The fuel pump may operate erratically if crankcase is overfilled After fueling check oil with unit on level 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 D Gasoline 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 EF 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 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 Do not exceed the Full mark on the oil level dipstick The fuel pump may operate erratically if crankc
72. king on a battery e Stop engine before disconnecting or connecting bat tery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stopengine and let it cool off before checking or add ing 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 OM 945 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e e e Do not touch hot engine parts or just welded parts e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since
73. l hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un cable distinct ne pas utiliser le connecteur de pi ce ou le cable de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine 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 Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots 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 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 Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas
74. lothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator compo nents 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 pres ent on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no overflow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap ENGINE EXHAUST GASES can kill e Use equipment outside in open well ventilated ar eas e fused in a closed area vent engine exhaust outside and away from any building air intakes 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 TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury A pot e Release air pressure from tool
75. low limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province HOBART 3 hobart_warr 2 05 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 Hand
76. ls 17 5 8 Selecting Weld Cable Sizes 17 5 9 Amperage Selection Table For Stick SMAW Electrodes 18 SECTION 6 OPERATING THE WELDING GENERATOR eeeeee III nnn 19 6 1 Front Pariel Goritr ls ose teas eating eee ant date Ee m ba RA rx bay de cR AE HR 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT 00 0 cece cece eee e eee e eee eee Hh 20 7 1 Standard Receptacles s hassan see Rp emn REP cha waar awards m A td 20 7 2 Optional Generator Power Receptacles 21 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P 22 SECTION 8 MAINTENANCE ROBIN POWERED UNITS 23 8 1 Routine Maintenance Robin Powered Units 23 8 2 Maintenance Label Robin Powered Units 24 8 3 Servicing Air Cleaner Robin Powered Units 25 8 4 Overload Protection Robin Powered Units 26 8 5 Servicing Optional Spark Arrestor Robin Powered Units 26 8 6 Changing Engine Oil Oil Filter and Fuel Filter Robin Powered Units
77. ly resistor spark plugs and wires Tune up and Filter Kit Includes Air Oil and Fuel Filters and 2 Spark Plugs KOHLER MILLER 180 096 ROBIN MILLER 199 062 215 939 C OM 945 Page 31 9 3 Servicing Air Cleaner Kohler Powered Units A Stop engine A Do not run engine without air cleaner or with dirty element w amp Eto RUN IDLE Ae V a 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 S 0759 OM 945 Page 32 9 4 Overload Protection Kohler Powered Units EN gt we ar Tools Needed EE A Stop engine EF 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 opens there will be no low weld and generator power output Press button to reset breaker 2 Fuse F6 See Parts List
78. ncher les c bles de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hi cules de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge N DES ORGANES MOBILES peuvent provoquer des blessures a e Ne pas approcher les mains des ventilateurs cour roles et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil e Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d en tretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les t
79. nfined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material wool and leather and foot protection OM 945 Page 1 AWE 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 Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks an
80. nput capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer 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 watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate co
81. nt Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear 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
82. ntario Canada M9W 1R3 t l phone 800 463 6727 ou To ronto 416 747 4044 site Web www csa international org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 7 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn tiques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lectro magn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pen dant une p riode de recherche de 17 ans un comit de sp cialistes du
83. oorly spliced cables 100 4 20 4 20 4 20 3 30 2 85 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 70 2x70 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 70 2x95 2x95 2 ea 2 0 2 ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 40 120 ox 2x25 2x05 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 40 120 x7 2x25 2x120 2x120 2 ea 2 0 2 ea 3 0 2 ea 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 For distances longer than those shown in this guide call a factory applications representative at 1 800 332 3281 OM 945 Page 17 5 9 Amperage Selection Table For Stick SMAW Electrodes lect correct amperage for the Use table on front panel to se electrode being used
84. r and spark plugs 1 fe LGE EEN 196 778 Hose Vinyl Clear 500 Id X 625 Od X 7 000 oil drain 1 TOPIC TT 167 788 Nut 375 16 56hex 84h Stl Pld Sem Cone Wshr 88d 3 ATi d Meg cua was 151 542 Washer Flat 438idx1 0000dx 125t Stl Pld 3 ease ded cd E 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 3 i520 gags Figure 14 3 Generator 1 e ag es siens 193782 Cover Tank Fuel ict erbei aer da E 1 EE 217 848 Cable Bat Neg 15 000 No 4 Awg W Clamp amp 343 Rng 1 aa Pd the ege EE 168 037 Battery Stor 12v 430 Crk 75 Rsv Gp 58 Dry 1 E Sy Peta ae 219811 Cable Bat Pos 25 000 No 4 Awg W Clamp 8 312 Rng 1 O ne a Potens 172 669 Cable Bat Neg 11 000 6ga W 250 Rng 8 375 Rng 1 Ado NN detent tence Bee 182 935 Hold Down Battery 1 A A a 193 780 Bracket Mtg Engine 1 DEE 193 783 Base eee vad unk eat Echt 1 5429 ah hero At 215 939 Label Engine Maintenance 1 e WEE 197 930 Label warning do not weld on base 2 OM 945 Page 55 Item Dia Part No Mkgs No Description Quantity Figure 14 1 Main Assembly Continued docu adressant 181 057 is COVER EENEG 2
85. r worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe up fuel 802 339 B S 0842 OM 945 Page 34 9 7 Adjusting Engine Speed Kohler Powered Units ESP r a 2200 50 rpm e 3700 50 rpm Tools Needed H oe 1 4 3 8 in Top View After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm 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 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 802 339 B
86. ravaux d entretien d brancher le c ble n gatif de batterie de la borne 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 coupa ge gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures 4 4 e Relacher la pression d air de l outillage ou du sys teme 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 e Ne pas approcher les mains cheveux v tements l ches et outils des orga nes mobiles e Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le mo teur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroidissement
87. re ceptacles use GFCI d protected extension cord Combined output of all receptacles limited to 10 kVA kW rating of the generator GFCI Receptacle Option V 1 120 V 20 AAC GFCI Recep TOTAL ALL LOADS 1290v 240V Ce Ca 0 CBS ven GFCI2 and GFCI3 10 000 WATTS NE A GFCI2 and GFCI3 supply 60 Hz 1 single phase power at weld power speed Maximum output from GFCI2 or GFCI3 is 2 4 kVA kW Cir E J cuit breaker protection is the same N E as standard receptacles If a ground fault is detected the Y Y GFCI Reset button pops out and NN ON A A the circuit opens to disconnect the faulty equipment Check for damaged tools cords plugs etc OFF connected to the receptacle Press button to reset receptacle and c c resume operation CB1 A L AN L AN J x At least once a month run engine at weld power speed 50A MAIN and press Test button to verify FCI is working properly BREAKER GFC ENERATOR POWER O HA Start Your Professional Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 945 Page 21 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14
88. s and system before servicing adding or changing attachments or open ing compressor oil drain or oil fill cap BATTERY ACID can BURN SKIN and EYES e Donottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flam mables EXHAUST SPARKS can cause fire e Donotlet engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Lei system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servicing unit e Stop engine and release air pressure before servicing 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit and properly installed acces Sories only 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 P
89. s and tighten if necessary Check plug PLG4 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine will not start Check fuel level Check battery voltage Check battery connections and tighten if necessary Check oil level see Section 5 2 or 5 3 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 2 or 5 3 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
90. sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact
91. te 010 915 Washer flat Drs zanta e a ae AA ad aba 3 AB WEE 601 836 Nut 250 20 BS nett eet n eens 3 19 RC1 182 954 Ropt Str 3p4w 50a 125 250v Flush Mtg 14 50 1 p MP 188 039 Cover Receptacle W Gasket 1 A AATE a 159 921 rn Bozal mersis ost ER ae Mia haere EE 1 iA a wes x LAE DES Deleted WEE EC 1 28 CB4 161 078 Circuit Breaker Man Reset 1p 7a 250vac Fri 1 va DA nier BER ten 207 077 Knob Pointer 1 625 Dia Push On 1 E 072 590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 100 uses HM 145 247 Meter Hour 12 24vdc 1 25 X 2 12 Rect 1 OT uus RT 201 486 Potentiometer w leads 1 En TIR 202 631 Cover Circuit Breaker 1 22x20 EG 202 630 Brkt Mtg Ckt Breaker Cover 1 P690 ss uid um 602 207 Washer Lock 255idx0 4890dx 062t Stl Pld Split 250 1 be GA SA wat ooh st 163 167 Washer Lock 254idx0 4890dx 062t Sst Split 250 1 da RZ vsus 035 704 Rectifier Integ Bridge 40 Amp 800 V 1 93 LEM 191 941 Transducer Current 1 RE ET eae 220 632 Harness Wrg Feedback consisting of 1 NI A Se E 220 629 1 Cable
92. th this procedure The possible hazards are shown in Means Warning Watch Out There are possible hazards A the adjoining symbols Marks a special safety message EF Means Note not safety related 1 A A A 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and re pair this unit During operation keep everybody especially children away Zi e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big eno
93. thin 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 43 12 10 Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner s Manual and national state and local codes 1 2 3 4 Utility D Fused Welding H S isconnect Electrical Transfer Switch s Switch de Generator Service If Required Output 5 Essential Loads A Have only qualified persons perform these connections according to all applicable codes and safety practic es A Properly install and ground this equipment according to its Owner s Manual and national state and local codes Customersupplied equipment is re quired if generator will supply 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 Trans fer load back to electric utility when service is restored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be
94. ugh to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electri cally 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 unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 ground
95. ure Positive Negative NU ee oo CG Output h Hours S Seconds e Time D eun Fi of Welding Arc de CG Stick SMAW Lr Fuse Electrode SECTION 4 SPECIFICATIONS 4 1 Weld Power and Engine Specifications Notez This unit uses either an Robin or a Kohler engine Differences between models are noted throughout this manual i Rated Maximum f rens EA Welding Open Circuit SE Rating Dee Engine Output Voltage 230 25 V Robin 30 Duty Peak 10 kVA kW Air Cooled Two Cylinder Cycle 8442A Four Cycle 20 5 HP 210 A 25 V 120 240 V AC T Gasoline Engine CC DC 50 230A 60 Duty 73 60 Hz or Cycle 38 L Tank do ohler CH 170 A 25 V aues Ms dor KW Air Cooled Two Cylinder 10096 Duty 9 Four Cycle 20 HP Cycle Gasoline Engine OM 945 Page 9 4 2 Dimensions Weights and Operating Angles Dimensions Height 33 1 2 in 851 mm Width 18 1 2 in 470 mm Depth 38 in 965 mm O 73 UJ 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 Oln m ooo 13 32 in 10 mm Dia Weight Robin Powered Unit 445 Ib 202 kg Kohler Powered Unit 444 Ib 201 kg Lifting Eye Weight Rating O4 1280 Ib 580 kg Engine End AN La SC 802 855 A Do not ex
96. voquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de l

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