Hobart Welding Products OM-498 manual Dia Part

Page 55

Item

Dia.

 

Part

 

 

 

 

No.

 

Mkgs.

No.

Description

 

Quantity

 

 

 

 

 

 

Figure 12-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

 

. . .

1

. . .

. . . . . . .

. .

. . +495 247

. . TOP, control box (specify color)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

2

. . .

. . . . . . .

. .

. . . 495 096

. . LABEL, precautionary

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

3

. . CR1, CR2

. . . 200 759

. . RECTIFIER, silicon

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2

. . .

4

. . .

. . . . . . .

. .

. . . 134 201

. . STAND-OFF, support

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4

. . .

5

. . .

. . . . . . .

. .

. . . 495 236

. . BASE, control box

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

6

. . . . . L3 .

. .

. . . 495 200

. . REACTOR, stabilizing

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

7

. . .

. . . . . . .

. .

. . . 204 140

. . LABEL, moving parts

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 8

. . .

. . . . . . .

. .

. . . 493 509

. . BRUSHHOLDER, assembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

9

. . .

. . . . . . .

. .

. . . 204 138

. . LABEL, warning fuel (also supplied with engine)

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +195 557

. . ENGINE, gas Kohler 8.5HP (recoil start)

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 952

. . FILTER, air Kohler cs 8.5 & 12

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 954

. . FILTER, air pre Kohler cs 8.5 & 12 . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 955

. . CAP, fuel Kohler cs 8.5 & 12

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 956

. . TANK, fuel Kohler cs 8.5 & 12

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 957

. . STRAINER, fuel Kohler cs 8.5 & 12 . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 958

. . MUFFLER, exhaust engine Kohler cs 8.5 & 12

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 959

. . GASKET, muffler Kohler cs 8.5 & 12 .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . .

. . . . . . .

. .

. . *203 960

. . SPARK PLUG, Kohler cs 8.5 & 12 . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +184 556

. . ENGINE, Honda 9HP (recoil start) . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 10

. . .

. . . . . . .

. .

. . +184 555

. . ENGINE, Honda 9HP (electric start) .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 11

. . .

. . . . . . .

. .

. . . 494 606

. . ADAPTER, engine

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 12

. . .

. . . . . . .

. .

. . . 494 629

. . GUARD, generator

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 13

. . .

. . . . . . .

. .

. . . 194 509

. . FAN, generator (Kohler)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 13

. . .

. . . . . . .

. .

. . . 493 868

. . FAN, generator (Honda)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 14

. . .

. . . . . . .

. .

. . . 495 213

. . GENERATOR, w/stator assembly . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 15

. . .

. L1-D

. .

. . . 494 574

. . ROTOR, assembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 16

. . .

. . . . . . .

. .

. . . 495 349

. . SCREW, 1/4-20 HWH

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4

. . . 17

. . .

. . . . . . .

. .

. . . 494 587

. . CARRIER, bearing

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 18

. . .

. . . . . . .

. .

. . . 495 348

. . SCREW, 5/16-24 HWH

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 19

. . .

. . . . . . .

. .

. . +494 628

. . PANEL, end generator

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 20

. . .

. . . . . . .

. .

. . . 495 113

. . LEAD, bonding

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 21

. . .

. . . . . . .

. .

. . . 495 257

. . MOUNT, shock w/bushing

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2

. . . 22

. . .

. . . . . . .

. .

. . . 495 256

. . MOUNT, shock generator

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 23

. . .

. . . . . . .

. .

. . . 194 504

. . FRAME, mtg assembly (Kohler)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 23

. . .

. . . . . . .

. .

. . . 495 132

. . FRAME, mtg assembly (Honda)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 24

. . .

. PC1

. . . . . 148 608

. . BOARD, PC filter (CSA only)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 25

. . .

. . . . . . .

. .

. . . 494 613

. . TERMINAL, output

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2

. . . 26

. . .

. . R1 .

. .

. . . 494 618

. . RHEOSTAT, 35 ohm 100W

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 27

. . .

. . . . . . .

. .

. . . 495 214

. . SEAL, air duct

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 28

. . .

. . . . . . .

. .

. . . 495 255

. . DUCT, air

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 29

. . .

. . . . . . .

. .

. . . 097 924

. . KNOB, pointer

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 30

. . .

. . . . . . .

. .

. . . . . . . . . . . .

. . NAMEPLATE, overlay (order by model and serial number)

. . . 1

. . . 31

. . .

. . . . . . .

. .

Figure 12-2

. . PANEL, aux power assembly (CSA) . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 32

. . .

. . 1T .

. .

. . . 172 661

. . BLOCK, terminal

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 33

. . .

. . . . . . .

. .

. . . 495 193

. . BRACKET, mtg terminal block

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 34

. . .

. . L2 .

. .

. . . 495 202

. . REACTOR, weld assembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 35

. . .

R2/VR1 .

. . . 046 819

. . SUPPRESSOR, assembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 36

. . .

. CR3

. . . . . 495 188

. . RECTIFIER, assembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 37

. . .

. . . . . . .

. .

. . . 201 223

. . LABEL, warning electric shock power still present

. . . 1

. . . 38

. . .

. . . . . . .

. .

. . . 494 976

. . LABEL, current selection

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 39

. . .

. . . . . . .

. .

. . . 495 112

. . LEAD, battery neg (electric start)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 40

. . .

. . . . . . .

. .

. . . . . . . . . . . .

. . BATTERY, 12V (electric start)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 41

. . .

. . . . . . .

. .

. . . 494 604

. . BOLT, hold down (electric start)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 42

. . .

. . . . . . .

. .

. . . 493 057

. . CLAMP, battery (electric start)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 43

. . .

. . . . . . .

. .

. . . 495 111

. . LEAD, battery pos (electric start)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 44

. . .

. . . . . . .

. .

. . . 494 039

. . COVER, battery cable (electric start) .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

+When ordering a part displaying a precautionary label, order label also.

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-498 Page 51

Page 54 Page 56
Image 55
Page 54 Page 56
Contents Processes OM-498Description 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 CurveInstalling Welding Generator InstallationGrounding 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 Operating Auxiliary Equipment Auxiliary Power Panel 196 921 CSACircuit 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 PossibleWeld current starts when electrode touches work- piece Stick Welding ProcedureStick Welding Smaw Guidelines Striking an Arc Scratch Start Technique Electrode and Amperage Selection ChartStriking 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 Lack Of Penetration Troubleshooting Incomplete FusionTroubleshooting Excessive Penetration Troubleshooting Waviness Of Bead Troubleshooting Burn-ThroughTroubleshooting Distortion OM-498 31-Fig Parts ListDia Part South Africa Australia CanadaEurope 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 ServiceHobart Welding Products Contact your Distributor forCall
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