Hobart Welding Products OM-945 manual Engine Hazards, Compressed Air Hazards

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1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

DAlways wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop 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.

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or adding fuel.

DDo not add fuel while smoking or if unit is near any sparks or open flames.

DDo not overfill tank — allow room for fuel to expand.

DDo not spill fuel. If fuel is spilled, clean up before starting engine.

DDispose of rags in a fireproof container.

DAlways keep nozzle in contact with tank when fueling.

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 doors, panels, covers, or guards for maintenance 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 doors, panels, covers, or guards 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.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

D Allow cooling period before working on equip- ment.

DTo handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

STEAM AND HOT COOLANT can burn.

DIf possible, check coolant level when engine is cold to avoid scalding.

D Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

DIf the engine is warm, checking is needed, and there is no over- flow tank, follow the next two statements.

DWear safety glasses and gloves and put a rag over radiator cap.

DTurn cap slightly and let pressure escape slowly before completely removing cap.

Using a generator indoors CAN KILL YOU IN MINUTES.

D Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

DNEVER use inside a home or garage, EVEN IF doors and windows are open.

DOnly use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

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

DKeep exhaust and exhaust pipes way from flammables.

EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire.

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

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

DDo not use compressed air for breathing.

DUse only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

DWear approved safety goggles.

DDo not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

DRelease air pressure from tools and system be- fore servicing, adding or changing attach- ments, or opening compressor oil drain or oil fill cap.

OM-945 Page 3

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Contents Stick Smaw Welding ProcessesDescription OM-945194 047AD 2007−05From Hobart to You Table of Contents Warranty HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF Welding Weld Output Rated Maximum Single-Phase Fuel − SpecificationsSymbol Definitions Weld, Power, and Engine SpecificationsWidth Dimensions, Weights, and Operating AnglesGenerator Power Curve Height60% Duty Cycle at 210 Amperes CC/DC Fuel Consumption All ModelsDuty Cycle 100% Duty Cycle at 170 Amperes CC/DCVolt-Ampere Curves Material Thickness Reference ChartInstalling Welding Generator − InstallationEngine Prestart Checks Kohler-Powered Units Engine Prestart Checks Robin-Powered UnitsOil Connecting the Battery Activating The Dry Charge Battery If ApplicableTools Needed 1/2 Installing Exhaust PipeWeld Output Terminals Engine backfire can cause seSelecting Weld Cable Sizes Connecting To Weld Output Terminals− Operating the Welding Generator Engine Control SwitchFront Panel Controls Loaded Cold Weather Engine OperationAmperage Selection Table For Stick Smaw Electrodes InfrequentlyTacle RC3 − Operating Auxiliary EquipmentStandard Receptacles Tacle RC2Gfci Receptacle Option Optional Generator Power ReceptaclesReceptacle Current Available in Amperes 240Routine Maintenance Robin-Powered Units − Maintenance ROBIN-POWERED UnitsMaintenance Label Robin-Powered Units Stop engine and let cool Servicing Air Cleaner Robin−Powered UnitsServicing Optional Spark Arrestor Robin-Powered Units Overload Protection Robin-Powered UnitsStop engine. Disconnect nega- tive − battery cable Fuel Line Oil Drain Valve 2 ID x 7 in Hose Oil FilterFill crankcase with new oil to full FullIdle Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsStop engine Hours Weld Cables Slip Rings Routine Maintenance Kohler-Powered Units= Check = Change ~ = Clean = Replace Recycle engine FluidsMaintenance Label Kohler-Powered Units Servicing Air Cleaner Kohler−Powered Units Servicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsTools Needed 802 339-G / S-0842 Reinstall wrapper Top View Tools Needed 3/8 Adjusting Engine Speed Kohler-Powered UnitsAdjustment Nut Loosen lock nut. Turn adjustmentWelding − TroubleshootingTroubleshooting Generator PowerCheck fuel level EngineOd of time Install engine manufacturer’s kit for cold-weather operation− Electrical Diagram Bed liners, shipping skids, − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Ground generator to systemFarm/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 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes− Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique 10-30 9090 Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead ShapeOr Less Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Welding Symbols 37 25 − Parts List44 − FIG 20 − FIGMain Assembly Panel, Front w/Components Panel, Front w/Components -1Item Generator -1Item Support ServiceAssistance Hobart Welding Products Contact your Distributor for
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