Hobart Welding Products OM-487 manual Moving Parts can cause injury, Battery Explosion can Blind

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MOVING PARTS can cause injury.

D Keep away from fans, belts, and rotors.

D Keep all doors, panels, covers, and guards closed and securely in place.

DStop engine before installing or connecting unit.

DHave only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

DTo prevent accidental starting during servicing, disconnect negative (–) battery cable from battery.

DKeep hands, hair, loose clothing, and tools away from moving parts.

DReinstall panels or guards and close doors when servicing is finished and before starting engine.

DBefore working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

DBlock flywheel so that it will not turn while working on generator components.

BATTERY EXPLOSION can BLIND.

DAlways wear a face shield, rubber gloves, and

protective clothing when working on a battery.

DStop engine before disconnecting or connect- ing battery cables or servicing battery.

DDo not allow tools to cause sparks when working on a battery.

DDo not use welder to charge batteries or jump start vehicles.

DObserve correct polarity (+ and –) on batteries.

DDisconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

DUse equipment outside in open, well-ventilated areas.

DIf used in a closed area, vent engine exhaust outside and away from any building air intakes.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flammables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories.

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEAT- ING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stopping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer according to instructions supplied with trailer.

READ INSTRUCTIONS.

DUse only genuine MILLER replacement parts.

DPerform engine maintenance and service according to this manual and the engine manual.

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Contents Processes OM-487Description From Hobart to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsDimensions Dimensions, Weights, And Operating AnglesFuel Consumption 100% Duty Cycle at 290 Amperes DC Auxiliary Power CurveExceeding duty cycle can damage unit and void warranty Duty CycleVolt-Ampere Curves CC/AC ModeCC/DC Mode CV/DC ModeDo not lift unit from end Airflow Clearance InstallationInstalling Welding Generator Installing Exhaust PipeOil 13 mm Full Diesel Coolant Recovery TankEngine Prestart Checks Fuel Do not use gasoline. Gasoline will damage engineConnect negative Connecting The BatteryConnecting To Weld Output Terminals Adding Coolant To RadiatorRemote 14 Receptacle Information Selecting Weld Cable SizesTo stiffen weld puddle Adjusting MIG Weld Puddle ConsistencyStop engine To wet out weld puddleFront Panel Controls Do not switch under loadPlace switch in Run position to operate most Gmaw equipment Operating Welding Generator1nected to the remote 14 recep- tacle is running Remote Amperage/Voltage ControlOperating Auxiliary Equipment Auxiliary Power Receptacles And Circuit BreakersAuxiliary power decreases as weld current increases Open, contact Factory Authorized Service AgentGfci Receptacle Option Optional Auxiliary Power ReceptaclesAustralian Receptacle Option Receptacle Wiring Optional 240 Volt PlugMaintenance Label Maintenance and Troubleshooting75 h Routine Maintenance20 h 50 h800 h 200 h400 h 500 hServicing Air Cleaner Servicing Optional Spark Arrestor Servicing Engine Cooling SystemStop engine and let cool Fuel Lines Replace fuel lines if cracked or worn Servicing Engine Fuel And Lubrication SystemsChecking Fuel Solenoid Adjusting Engine SpeedAdjusting Fuel Solenoid Position Stop screw is factory-set and should not be adjustedSolenoid in relaxed Adjusting Throttle SolenoidChecking Throttle Solenoid Check for non-bindingAdjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Trouble Remedy TroubleshootingOverload Protection WeldingSee engine manual Low weld output Check control settingsCheck and clean air cleaner as necessary see Section Check engine speed, and adjust if necessary see SectionEngine Auxiliary PowerTrouble Remedy Circuit Diagram For Welding Generator Electrical Diagram201 Wetstacking RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankFrom flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/gridGrounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible56- -3 Parts List80- -2 Main Assembly Dia Part Description 124 Hardware is common Not available unless listed Panel, Front w/ComponentsPanel, Front w/Components -1 Item Generator -1 Item Support ServiceHobart Welding Products Contact your Distributor forCall