Hobart Welding Products OM-474 manual Table of Contents

Page 3

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.

CALIFORNIA

Proposition 65

Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The following terms are used interchangeably throughout this manual:

Stick = SMAW

MIG = GMAW

TIG = GTAW

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

2-1.

Symbols and 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

10

3-4. Duty Cycle And Overheating

11

3-5.

AC Auxiliary Power

11

3-6. Optional AC Power Plant Curves

12

3-7.

Volt-Ampere Curves

13

SECTION 4 – INSTALLATION

14

4-1.

Installing Welding Generator

14

4-2.

Connecting The Battery

14

4-3.

Installing Muffler

15

4-4.

Engine Prestart Checks

15

4-5. Connecting To Weld Output Terminals

16

4-6. Selecting Weld Cable Sizes

16

4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8)

17

4-8. Terminal Strip 3T Connections (Optional)

17

SECTION 5 – OPERATING WELDING GENERATOR

18

5-1. Front Panel Controls (See Section 5-2)

18

5-2. Description Of Front Panel Controls (See Section 5-1)

19

5-3.

Remote Control (Optional)

20

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

21

6-1. 120 Volt Duplex And Optional GFCI Receptacles

21

6-2. 240 Volt Duplex Receptacle (Optional)

22

6-3. Connecting Optional Auxiliary Power Plant

23

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING

24

7-1.

Routine Maintenance

24

7-2.

Maintenance Label

25

7-3.

Servicing Air Cleaner

26

7-4.

Servicing Fuel System

27

7-5.

Adjusting Engine Speed

28

7-6. Changing Engine Oil And Filter

29

7-7.

Overload Protection

30

7-8. Inspecting And Cleaning Optional Spark Arrestor Muffler

31

7-9.

Troubleshooting

31

SECTION 8 – ELECTRICAL DIAGRAMS

35

SECTION 9 – RUN-IN PROCEDURE

38

9-1.

Wetstacking

38

9-2. Run-In Procedure Using Load Bank

39

9-3. Run-In Procedure Using Resistance Grid

40

SECTION 10 – AUXILIARY POWER GUIDELINES

41

SECTION 11 – PARTS LIST

48

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents July OM-474Processes DescriptionFrom 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 Fumées ET LES GAZ peuvent être dangereux Signification des symbolesConsignes DE Sécurité Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures 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 sécuritéInformation sur les champs électromagnétiques LE Soudage À L’ARC risque de provoquer des interférencesDefinitions SpecificationsSymbols And Definitions Weld, Power, And Engine SpecificationsFuel Consumption Dimensions, Weights, And Operating AnglesDimensions WeightMinutes Welding AC Auxiliary PowerDuty Cycle And Overheating 60% Duty Cycle At 350 AmperesOptional AC Power Plant Curves 5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load 100 Ranges 190-Max 110-270 Volt-Ampere CurvesDC Volts CC/DC Standard AC Amperes CV/DC Models with Optional CV-3 ModuleInstallation Installing Welding GeneratorConnecting The Battery Do not use gasoline. Gasoline will damage engine Installing MufflerTemperatures below 0 F -18C 13 mm Full Diesel Valve Open Engine Prestart Checks10 100% Duty Cycle Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 100 ft 30 m Or LessStop engine Remote 14 Receptacle RC3 Information Optional, See SectionTerminal Strip 3T Connections Optional Socket InformationFront Panel Controls See Section Operating Welding GeneratorStop engine and fix trouble if either warning light goes on Ampere Range SwitchDo not switch under load Description Of Front Panel Controls See SectionExample Combination remote amperage control Remote Control OptionalVolt Duplex And Optional Gfci Receptacles Operating Auxiliary EquipmentOpen Contact Volt Duplex Receptacle OptionalConnecting Optional Auxiliary Power Plant Set Engine Control switch to Run when using auxiliary powerFront Maintenance and Troubleshooting Maintenance Label Servicing Air Cleaner To Clean air filterDo not clean housing with air hose To replace fuel filter Servicing Fuel SystemStop engine and let cool To drain water from fuel systemAdjusting Engine Speed Idle Speed AdjustmentEngine Speed No Load Changing Engine Oil And Filter If any fuse or circuit breaker Overload ProtectionTrouble Remedy Inspecting And Cleaning Optional Spark Arrestor MufflerTroubleshooting WeldingAuxiliary Power See engine manual Coolant temperature gets too high see SectionCheck engine control switch, and replace if necessary EngineOM-474 Circuit Diagram For Welding Generator For Standard Models Electrical DiagramsOM-474 193 989-B Wetstacking RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankFrom flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/gridAuxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Use 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 RequirementsProtection is already present Typical Connections To Supply Standby PowerWelding Generator Auxiliary Power output circuit Item 4 is not necessary if circuitCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible101 102 105 104 103 Parts List65 66 Includes Items Dia Part Description Mkgs Quantity PLG9,RC9 PC4 Control Box w/Components Control Box w/Components -4 ItemGenerator Generator -1 Item Panel, Front w/Components Panel, Front w/Components -1 Item Page Support ServiceContact your Distributor for Hobart Welding ProductsCall
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