Hobart Welding Products OM-945 manual From Hobart to You

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Hobart is registered to the ISO 9001:2000 Quality System Standard.

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with proper maintenance.

And if for some reason the unit needs repair, there’s a Troubleshooting section that will help

you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www.HobartWelders.com.

For Technical Help call 1-800-332-3281.

Hob_Thank 4/05

Working as hard as you do − every power source from Hobart is backed by the best warranty in the business.

Protect Your Investment!

Register your product at:

HobartWelders.com

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Contents OM-945194 047AD 2007−05 ProcessesDescription Stick Smaw WeldingFrom Hobart to You Table of Contents Warranty Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Weld, Power, and Engine Specifications − SpecificationsSymbol Definitions Welding Weld Output Rated Maximum Single-Phase FuelHeight Dimensions, Weights, and Operating AnglesGenerator Power Curve Width100% Duty Cycle at 170 Amperes CC/DC Fuel Consumption All ModelsDuty Cycle 60% Duty Cycle at 210 Amperes CC/DCMaterial Thickness Reference Chart Volt-Ampere Curves− Installation Installing Welding GeneratorOil Engine Prestart Checks Robin-Powered UnitsEngine Prestart Checks Kohler-Powered Units Activating The Dry Charge Battery If Applicable Connecting the BatteryEngine backfire can cause se Installing Exhaust PipeWeld Output Terminals Tools Needed 1/2Connecting To Weld Output Terminals Selecting Weld Cable SizesFront Panel Controls Engine Control Switch− Operating the Welding Generator Infrequently Cold Weather Engine OperationAmperage Selection Table For Stick Smaw Electrodes LoadedTacle RC2 − Operating Auxiliary EquipmentStandard Receptacles Tacle RC3Optional Generator Power Receptacles Gfci Receptacle OptionCurrent Available in Amperes 240 Receptacle− Maintenance ROBIN-POWERED Units Routine Maintenance Robin-Powered UnitsMaintenance Label Robin-Powered Units Servicing Air Cleaner Robin−Powered Units Stop engine and let coolStop engine. Disconnect nega- tive − battery cable Overload Protection Robin-Powered UnitsServicing Optional Spark Arrestor Robin-Powered Units Full Oil Drain Valve 2 ID x 7 in Hose Oil FilterFill crankcase with new oil to full Fuel LineStop engine Adjusting Engine Speed Robin-Powered UnitsIdle Speed Adjustment Recycle engine Fluids Routine Maintenance Kohler-Powered Units= Check = Change ~ = Clean = Replace Hours Weld Cables Slip RingsMaintenance Label Kohler-Powered Units Servicing Air Cleaner Kohler−Powered Units Tools Needed Overload Protection Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units 802 339-G / S-0842 Loosen lock nut. Turn adjustment Adjusting Engine Speed Kohler-Powered UnitsAdjustment Nut Reinstall wrapper Top View Tools Needed 3/8Generator Power − TroubleshootingTroubleshooting WeldingEngine Check fuel levelInstall engine manufacturer’s kit for cold-weather operation Od of time− Electrical Diagram Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Bed liners, shipping skids,Ground generator to system Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090Conditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint Or LessWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Welding Symbols 20 − FIG − Parts List44 − FIG 37 25Main Assembly Panel, Front w/Components Panel, Front w/Components -1Item Generator -1Item Assistance ServiceSupport Contact your Distributor for Hobart Welding Products
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