Hobart Welding Products OM-498 manual Table of Contents

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WARNING

This product, when used for welding or cutting, 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.)

WARNING

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.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The following terms are used interchangeably throughout this manual:

TIG = GTAW

Stick = SMAW

MIG = GMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

2

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

3

1-5.

Principal Safety Standards

4

1-6.

EMF Information

4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2.

Dangers relatifs au soudage à l’arc

5

1-3. Dangers existant en relation avec le moteur

6

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-5. Principales normes de sécurité

8

1-6. Information sur les champs électromagnétiques

8

SECTION 2 – DEFINITIONS

9

SECTION 3 – SPECIFICATIONS

9

3-1. Weld, Power, And Engine Specifications

9

3-2. Dimensions, Weights, And Operating Angles

10

3-3. Fuel Consumption (Kohler-Powered Units)

10

3-4. Fuel Consumption (Honda-Powered Units)

11

3-5.

Duty Cycle

11

3-6.

Auxiliary Power Curve

12

3-7.

Volt-Ampere Curves

12

SECTION 4 – INSTALLATION

13

4-1.

Installing Welding Generator

13

4-2. Grounding Generator To Truck Or Trailer Frame

13

4-3. Grounding Generator When Supplying Building Systems

14

4-4. Engine Prestart Checks (Kohler-Powered Units)

14

4-5. Engine Prestart Checks (Honda-Powered Units)

15

4-6. Connecting The Battery (Honda Electric-Start Models Only)

15

4-7. Connecting To Weld Output Terminals

16

4-8. Selecting Weld Cable Sizes*

16

SECTION 5 – OPERATING THE WELDING GENERATOR

17

5-1.

Controls (Kohler-Powered Units)

17

5-2. Controls (Honda-Powered Units) (See Section 5-3)

18

5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2)

19

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

20

6-1. Auxiliary Power Panel 196 921 (CSA)

20

6-2. Optional Auxiliary Power Panels

21

6-3. Auxiliary Power Panel Ratings

22

6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)

23

SECTION 7 – MAINTENANCE

24

7-1.

Routine Maintenance

24

7-2.

Maintenance Label

25

7-3. Overload Protection (Honda-Powered Units Only)

25

7-4. Adjusting Engine Speed (Kohler-Powered Units)

26

7-5. Adjusting Engine Speed (Honda-Powered Units)

27

SECTION 8 – TROUBLESHOOTING

28

SECTION 9 – ELECTRICAL DIAGRAMS

30

SECTION 10 – AUXILIARY POWER GUIDELINES

34

SECTION 11 – STICK WELDING (SMAW) GUIDELINES

41

SECTION 12 – PARTS LIST

50

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents OM-498 ProcessesDescription 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 SpecificationsWeight Kohler-Powered Units Dimensions, Weights, And Operating AnglesFuel Consumption Kohler-Powered Units Dimensions100% Duty Cycle at 80 Amperes CC/DC Fuel Consumption Honda-Powered UnitsExceeding duty cycle can damage unit and void warranty Duty CycleVolt-Ampere Curves Auxiliary Power CurveInstallation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsConnect negative cable last Engine Prestart Checks Honda-Powered UnitsConnecting The Battery Honda Electric-Start Models Only OilStop engine before Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 mChoke Control Lever Controls Kohler-Powered UnitsOperating the Welding Generator 60 HzRecoil-Start 2Electric-Start Controls Honda-Powered Units See SectionDescription Of Controls Honda-Powered Units See Section Auxiliary Power Panel 196 921 CSA Operating Auxiliary EquipmentCircuit Breakers CB1 and CB2 Auxiliary Power Panel 495 South America Asia Optional Auxiliary Power PanelsAuxiliary Power Panel 495 Australia Europe Auxiliary Power Panel 196It exceeds 3500W Auxiliary Power Panel RatingsOne half of the 240 V receptacle Plug Wired For 120/240Wire Load Plex receptacle shares a load withMaintenance Overload Protection Honda-Powered Units Only Maintenance LabelStop engine. Close fuel valve Top View Adjusting Engine Speed Kohler-Powered UnitsWeld/Power Speed Adjustment Top View Idle Speed AdjustmentTools Needed 3/8 Adjusting Engine Speed Honda-Powered UnitsThrottle Control Lever Adjustment Screw Stop engine. Close fuel valveWelding TroubleshootingTroubleshooting Auxiliary PowerMake starting difficult Check battery voltage Honda electric-start models onlyViscosity oil for operating temperature EngineCircuit Diagram For Welding Generator Electrical DiagramsWiring Diagram For Welding Generator Wiring Diagram For Auxiliary Power Panels 1 Wiring Diagram For Auxiliary Power Panels 2 Selecting Equipment Auxiliary Power GuidelinesRating Data 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 Requirements120 Single-Phase Power Company ServiceObtain and install correct switch Safety practicesCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleStick Welding Procedure Weld current starts when electrode touches work- pieceStick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc Scratch Start TechniqueStriking an Arc Tapping Technique 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting PorosityTroubleshooting Excessive Spatter Weld TestTroubleshooting Incomplete Fusion Troubleshooting Lack Of PenetrationTroubleshooting Excessive Penetration Troubleshooting Burn-Through Troubleshooting Waviness Of BeadTroubleshooting Distortion OM-498 31-Fig Parts ListDia Part Canada South Africa AustraliaEurope America Auxiliary Power Panel 495 290 Europe Auxiliary Power Panel 495 CanadaAuxiliary Power Panel 495 253 South Africa Auxiliary Power Panel 495 289 AustraliaOM-498 Support ServiceContact your Distributor for Hobart Welding ProductsCall