Hobart Welding Products OM-487 Overload Protection, Troubleshooting, Welding, Trouble Remedy

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7-8. Overload Protection

Tools Needed:

3/8 in

6

5

3

2

4

1

YStop engine.

.If a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent.

1 Circuit Breaker CB6

CB6 protects the 115 volt ac output to Remote 14 receptacle RC1. If CB6 opens, 115 volt ac output to RC1 stops.

2 Circuit Breaker CB5

CB5 protects the 24 volt ac output to Remote 14 receptacle RC1. If CB5 opens, 24 volt ac output to RC1 stops.

Press button to reset breaker. 3 Fuse F5 (See Parts List)

F5 protects the throttle solenoid from overload. If F5 opens, the en- gine will not start at idle speed or re- turn to idle speed.

4 Fuse F6 (See Parts List)

F6 protects the engine wiring sys- tem from overload. If F6 opens, the engine will not crank.

5Fuse F1 (See Parts List)

6Fuse F2 (See Parts List)

Remove side panel.

F1 protects the exciter excitation winding from overload. If F1 opens, weld and auxiliary power output stops.

F2 protects the stator winding from overload. If F2 opens, weld output stops. Auxiliary power is still avail- able.

Replace any open fuses. Reinstall cover before operating unit.

ST-801 962-C / Ref. ST-187 602-A

7-9. Troubleshooting

A. Welding

Trouble	Remedy

No weld output.	Check control settings.

	Check weld connections.

	Disconnect equipment from auxiliary power receptacles during start-up.

	Place Output (Contactor) switch in On position, or move switch to Remote 14 position and connect
	remote contactor to Remote 14 receptacle RC1 (see Section 4-8).

	Check fuses F1 and F2, and replace if necessary (see Section 7-8).

	Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

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Contents OM-487 ProcessesDescription From Hobart to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Battery Explosion can Blind Moving Parts can cause injuryEngine Exhaust Gases can kill Engine Heat can cause firePrincipal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interferenceSignification des symboles Consignes DE SÉ Curité Lire Avant UtilisationUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserPrincipales normes de sé curité Information sur les champs é lectromagné tiquesLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSpecifications Symbol DefinitionsWeld, Power, And Engine Specifications DefinitionsDimensions, Weights, And Operating Angles DimensionsFuel Consumption Auxiliary Power Curve Exceeding duty cycle can damage unit and void warrantyDuty Cycle 100% Duty Cycle at 290 Amperes DCCC/AC Mode CC/DC ModeCV/DC Mode Volt-Ampere CurvesInstallation Installing Welding GeneratorInstalling Exhaust Pipe Do not lift unit from end Airflow Clearance13 mm Full Diesel Coolant Recovery Tank Engine Prestart ChecksFuel Do not use gasoline. Gasoline will damage engine OilConnecting The Battery Connecting To Weld Output TerminalsAdding Coolant To Radiator Connect negativeSelecting Weld Cable Sizes Remote 14 Receptacle InformationAdjusting MIG Weld Puddle Consistency Stop engineTo wet out weld puddle To stiffen weld puddleDo not switch under load Place switch in Run position to operate most Gmaw equipmentOperating Welding Generator Front Panel ControlsRemote Amperage/Voltage Control 1nected to the remote 14 recep- tacle is runningAuxiliary Power Receptacles And Circuit Breakers Auxiliary power decreases as weld current increasesOpen, contact Factory Authorized Service Agent Operating Auxiliary EquipmentOptional Auxiliary Power Receptacles Gfci Receptacle OptionAustralian Receptacle Option Wiring Optional 240 Volt Plug ReceptacleMaintenance and Troubleshooting Maintenance LabelRoutine Maintenance 20 h50 h 75 h200 h 400 h500 h 800 hServicing Air Cleaner Servicing Engine Cooling System Servicing Optional Spark ArrestorStop engine and let cool Servicing Engine Fuel And Lubrication Systems Fuel Lines Replace fuel lines if cracked or wornAdjusting Engine Speed Adjusting Fuel Solenoid PositionStop screw is factory-set and should not be adjusted Checking Fuel SolenoidAdjusting Throttle Solenoid Checking Throttle SolenoidCheck for non-binding Solenoid in relaxedMaking Engine Speed Adjustments Adjusting Idle SpeedAdjusting Weld/Power Speed Troubleshooting Overload ProtectionWelding Trouble RemedyLow weld output Check control settings Check and clean air cleaner as necessary see SectionCheck engine speed, and adjust if necessary see Section See engine manualAuxiliary Power EngineTrouble Remedy Electrical Diagram Circuit Diagram For Welding Generator201 RUN-IN Procedure WetstackingRun-In Procedure Using Load Bank Load BankRun-In Procedure Using Resistance Grid Do not touch hot exhaustBank/grid From flammablesAuxiliary Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesParts List 56- -380- -2 Main Assembly Dia Part Description 124 Panel, Front w/Components Hardware is common Not available unless listedPanel, Front w/Components -1 Item Generator -1 Item Service SupportContact your Distributor for Hobart Welding ProductsCall