OM-4418

February 2003

210 597A

Processes
Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Champion 4500

Visit our website at

www.HobartWelders.com

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 dont have time to do it any other way. This Owners 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. Weve 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, theres 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 Hobart is registered to the you may need to fix the problem. Warranty and ISO 9001:2000 Quality service information for your particular model System Standard. 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 catalog sheets. To locate your nearest distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-6. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Dangers lis lair comprim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Amperage Selection Table For Stick (SMAW) Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Generator Power Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 2 3 3 4 4 5 5 5 6 7 7 8 8 9 9 9 9 10 10 11 11 12 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 20 22 23 30 38

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: Stick = SMAW

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING

rom _nd_10/02

Y Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

. Means Note; not safety related. 1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-6. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owners Manual and national, state, and local codes. D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conductor first double-check connections. D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.

D Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-4418 Page 1

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

HOT PARTS can cause severe burns.

D Allow cooling period before maintaining. D Wear protective gloves and clothing when working on a hot engine. D Do not touch hot engine parts or just-welded parts bare-handed.

D D D D

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connecting battery cables or servicing battery. D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles. D Observe correct polarity (+ and ) on batteries. D Disconnect negative () cable first and connect it last. OM-4418 Page 2 D D D D

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or adding fuel. D Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. Always 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. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. D To prevent accidental starting during servicing, disconnect negative () battery cable from battery. D Keep hands, hair, loose clothing, and tools away from moving parts. D Reinstall panels or guards and close doors when servicing is finished and before starting engine. D Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. D Block flywheel so that it will not turn while working on generator components.

ENGINE EXHAUST GASES can kill.

D Use equipment outside in open, well-ventilated areas. D If used in a closed area, vent engine exhaust outside and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

D Do not tip battery. D Replace damaged battery. D Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

D Do not locate unit on, over, or near combustible surfaces or flammables. D Keep exhaust and exhaust pipes way from flammables.

STEAM AND HOT COOLANT can burn.

D If 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). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. D Wear safety glasses and gloves and put a rag over radiator cap. D Turn cap slightly and let pressure escape slowly before completely removing cap.

EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire. D Use 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.
D Do not use compressed air for breathing. D Use only for cutting, gouging, and tools.

HOT METAL from air arc cutting and gouging can cause fire or explosion.
D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury.

D Wear approved safety goggles. D Do not direct air stream toward self or others.

HOT PARTS can cause burns and injury.

D Do not touch hot compressor or air system parts. D Let system cool down before touching or servicing.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

D Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.

READ INSTRUCTIONS.
D Read Owners Manual before using or servicing unit. D Stop engine and release air pressure before servicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

D Turn off or unplug equipment before starting or stopping engine. D Do not let low voltage and frequency caused by low engine speed damage electric motors. D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable. OM-4418 Page 3

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. D Sparks can cause fires keep flammables away. D D D D

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

TILTING OF TRAILER can cause injury.

D Use tongue jack or blocks to support weight. D Properly install welding generator onto trailer according to instructions supplied with trailer.

D D D D

READ INSTRUCTIONS.
D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals.

1-6. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 100368002 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-7. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. OM-4418 Page 4 To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

rom_10_02fre

Y Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdure prsente des risques de danger ! Ceux-ci sont identifis par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit. 1-2. Dangers relatifs au soudage larc
Y Les symboles prsents ci-aprs sont utiliss tout au long du prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnes afin dviter tout danger. Les consignes de scurit prsentes ci-aprs ne font que rsumer linformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes ces normes de scurit. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.

D D D D D D D D D D D D

En effectuant les raccordements dentre fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est endommag un cble dnud peut provoquer une lectrocution. Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct ne pas utiliser le connecteur de pice ou le cble de retour. Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel. Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique.

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peut provoquer une lectrocution ou des blessures graves. Llectrode et le circuit de soudage sont sous tension ds que lappareil est sur ON. Le circuit dentre et les circuits internes de lappareil sont galement sous tension ce moment-l. En soudage semi-automatique ou automatique, le fil, le dvidoir, le logement des galets dentranement et les pices mtalliques en contact avec le fil de soudage sont sous tension. Des matriels mal installs ou mal mis la terre prsentent un danger. D D D Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel avec la pice ou la terre. Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. ronnements risque comme: les endroits humides ou lorsque lon porte des vtements mouills; sur des structures mtalliques au sol, grillages et chafaudages; dans des positions assises, genoux et allonges; ou quand il y a un risque important de contact accidentel avec la pice ou le sol. Dans ces cas utiliser les appareils suivants dans lordre de prfrence: 1) un poste souder DC semiautomatique de type CV (MIG/MAG), 2) un poste souder manuel (lectrode enrobe) DC, 3) un poste souder manuel AC avec tension vide rduite. Dans la plupart des cas, un poste courant continu de type CV est recommand. Et, ne pas travailler seul! D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. D D D D D

Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
D Couper lalimentation du poste et dcharger les condensateurs dentre comme indiqu dans la Section Maintenance avant de toucher des composants.

LES FUMES ET LES GAZ peuvent tre dangereux.

Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereux pour votre sant. Eloigner votre tte des fumes. Ne pas respirer les fumes. linterieur, ventiler la zone et/ou utiliser un chappement au niveau de larc pour lvacuation des fumes et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur alimentation dair homologu. Lire les spcifications de scurit des matriaux (MSDSs) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger. Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien ventil, et si ncessaire, en portant un respirateur alimentation dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques en cas de soudage.

D D D

D Des prcautions de scurit supplmentaires sont requises dans des envi-

D D

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LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.

Fermer lalimentation du gaz protecteur en cas de non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu. D

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B

pour les travaux chaud et avoir de la surveillance et un extincteur proximit.

DES PARTICULES VOLANTES peuvent blesser les yeux.

D Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrent des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage. D D D D Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). Porter des protections approuvs pour les oreilles si le niveau sondre est trop lev. Utiliser des crans ou des barrires pour protger des tiers de lclair et de lblouissement; demander aux autres personnes de ne pas regarder larc. Porter des vtements de protection constitu dans une matire durable, rsistant au feu (laine ou cuir) et une protection des pieds.

DES PICES CHAUDES peuvent provoquer des brlures graves.

Prvoir une priode de refroidissement avant deffectuer des travaux dentretien. D Porter des gants et des vtements de protection pour travailler sur un moteur chaud. Ne pas toucher mains nues les parties chaudes du moteur ni les pices rcemment soudes. D

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecter loue. D Porter des protections approuvs pour les oreilles si le niveau sondre est trop lev.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectu sur des conteneurs ferms tels que des rservoirs, tambours ou des conduites peut provoquer leur clatement. Des tincelles peuvent tre projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peut provoquer des incendies et des brlures. Le contact accidentel de llectrode avec des objets mtalliques peut provoquer des tincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vrifier et sassurer que lendroit ne prsente pas de danger. D D D D D D D D Se protger et dautres personnes de la projection dtincelles et de mtal chaud. Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables. Dplacer toutes les substances inflammables une distance de 10,7 m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus. Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et des ouvertures. Surveiller tout dclenchement dincendie et tenir un extincteur proximit. Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de scurit). Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution et dincendie. Ne pas utiliser le poste de soudage pour dgeler des conduites geles. En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact. Porter des vtements de protection dpourvus dhuile tels que des gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes. D D D D D D D D D D

LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.

D D Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

Si des BOUTEILLES sont endommages, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec prcaution. Protger les bouteilles de gaz comprim dune chaleur excessive, des chocs mcaniques, du laitier, des flammes ouvertes, des tincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de se renverser. Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords convenables pour cette application spcifique; les maintenir ainsi que les lments associs en bon tat. Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille. Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publication P-1 CGA numres dans les normes de scurit.

D D D D

1-3. Engine Hazards

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.
Fermer lalimentation du gaz protecteur en cas de non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu. D

LACIDE DE LA BATTERIE peut provoquer des brlures dans les YEUX et sur la PEAU.
D D D Ne pas renverser la batterie. Remplacer une batterie endommage. Rincer immdiatement les yeux et la peau leau.

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LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

D Toujours porter une protection faciale, des gants en caoutchouc et vtements de protection lors dune intervention sur la batterie.

D D D D D

D D D D D

Arrter le moteur avant de dbrancher ou de brancher les cbles de batterie. Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des vhicules de dmarrage rapide. Observer la polarit correcte (+ et ) sur les batteries. Dbrancher le cble ngatif () en premier lieu. Le rebrancher en dernier lieu.

Pour empcher tout dmarrage accidentel pendant les travaux dentretien, dbrancher le cble ngatif () de batterie de la borne. Ne pas approcher les mains, cheveux, vtements lches et outils des organes mobiles. Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux dentretien et avant de faire dmarrer le moteur. Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise en route accidentelle du moteur. Bloquer le volant moteur pour viter sa rotation lors dune intervention sur le gnrateur.

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brlures.

D Il est prfrable de vrifier le liquide de refroidissement une fois le moteur refroidi pour viter de se brler.

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

Arrter le moteur avant de vrifier le niveau de carburant ou de faire le plein. D Ne pas faire le plein en fumant ou proche dune source dtincelles ou dune flamme nue. Ne pas faire le plein de carburant ras bord; prvoir de lespace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renvers avant de faire dmarrer le moteur. Jeter les chiffons dans un rcipient ignifuge. D

D D D D

D D D

Toujours vrifier le niveau de liquide de refroidissement dans le vase dexpansion (si prsent), et non dans le radiateur (sauf si prcis autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme suivant : Mettre des lunettes de scurit et des gants, placer un torchon sur le bouchon du radiateur. Dvisser le bouchon lgrement et laisser la vapeur schapper avant denlever le bouchon.

LA CHALEUR DU MOTEUR peut provoquer un incendie.

D D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables. Tenir distance les produits inflammables de lchappement.

DES ORGANES MOBILES peuvent provoquer des blessures.

D D Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement. Maintenir ferms et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.

LES TINCELLES LCHAPPEMENT peuvent provoquer un incendie.

D D Empcher les tincelles dchappement du moteur de provoquer un incendie. Utiliser uniquement un pare-tincelles approuv voir codes en vigueur.

D D

Arrter le moteur avant dinstaller ou brancher lappareil. Demander seulement un personnel qualifi denlever les dispositifs de scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux dentretien et de dpannage.

1-4. Dangers lis lair comprim

RESPIRER LAIR COMPRIM peut provoquer des blessures graves ou causer la mort.
D Ne pas utiliser lair comprim pour respirer. D Utiliser lair comprim seulement pour le coupage, gougeage et les outils pneumatiques.

Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un incendie ou une explosion.
D Ne pas couper ou gouger proximit de produits inflammables. D Surveillez et garder un extincteur proximit.

LAIR COMPRIM peut provoquer des blessures.

D Porter des lunettes de scurit approuves. D Ne pas diriger le jet dair vers dautres ou soi mme.

DES PIECES CHAUDES peuvent provoquer des brlures et blessures.

D Ne pas toucher le compresseur ou dautres lments du circuit air comprim chauds. D Laisser lensemble se refroidir avant de toucher ou deffectuer la maintenance.

LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provoquer des blessures.
D Relcher la pression dair de loutillage ou du systme avant deffectuer la maintenance, avant de changer ou de rajouter des lments ou avant douvrir la purge ou le bouchon de remplissage dhuile.

LIRE LES INSTRUCTIONS.

D Lisez le manuel dinstructions avant lutilisation ou la maintenance de lappareil. D Arrter le moteur et relcher la pression avant deffectuer la maintenance.

1-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

LA CHUTE DE LAPPAREIL peut blesser.
D Utiliser lanneau de levage uniquement pour soulever lappareil lui-mme ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires.

D Utiliser un quipement de levage de capacit suffisante pour lever

D

lappareil. En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.

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LE SURCHAUFFEMENT peut endommager le moteur lectrique.

Arrter ou dconnecter lquipement avant de dmarrer ou darrter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque dendommager le moteur lectrique cause dune tension et dune frquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz, sil y a lieu. D

LIRE LES INSTRUCTIONS.

D D Utiliser seulement les pices de rechange dorigine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/compresseur (si applicable).

LES TINCELLES VOLANTES risquent de provoquer des blessures.

D D Porter un cran facial pour protger le visage et les yeux. D D D D D

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer des interfrences.

Le rayonnement haute frquence (H.F.) peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs. Demander seulement des personnes qualifies familiarises avec des quipements lectroniques de faire fonctionner linstallation. Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de linstallation. Si le FCC signale des interfrences, arrter immdiatement lappareil. Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des sources de haute frquence, maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour rduire les interfrences ventuelles. D

Affuterr llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manoeuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. Les tincelles risquent de causer un incendie loigner toute substance inflammable.

LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.

D D D Laisser lquipement refroidir ; respecter le facteur de marche nominal. Rduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages dair du poste.

LE SOUDAGE LARC risque de provoquer des interfrences.

Lnergie lectromagntique risque de provoquer des interfrences pour lquipement lectronique sensible tel que les ordinateurs et lquipement command par ordinateur tel que les robots. Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement. Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller souder une distance de 100 mtres de tout quipement lectronique sensible. Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi. En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. D

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D D tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprimes. D D D D D

UNE REMORQUE QUI BASCULE peut entraner des blessures.

D D Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqu dans le manuel sy rapportant.

1-6. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (tlphone : (305) 4439353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (tlphone : (305) 4439353, site Web : www.aws.org). National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, brochure CGA P1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900, site Web : www.cganet.com). Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800) 4636727 ou Toronto : (416) 7474044, site Web : www.csainternational.org). Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West 42nd Street, New York, NY 100368002 (tlphone : (212) 6424900, site Web : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de lU.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312) 3532220, site Web : www.osha.gov).

1-7. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et les effets des champs magntiques basse frquence sur lorganisme En parcourant les cbles de soudage, le courant cre des champs lectromagntiques. Les effets potentiels de tels champs restent proccupants. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de recherche de 17 ans, un comit de spcialistes du National Research Council a conclu : Laccumulation de preuves na pas dmontr que lexposition aux champs magntiques et aux champs lectriques haute frquence constitue un risque pour la sant humaine . Toutefois, les tudes et lexamen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de rduire lexposition aux champs lectromagntiques pendant le soudage ou le coupage. Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes : 1. Garder les cbles ensemble en les torsadant ou en les fixant avec du ruban adhsif. 2. Mettre tous les cbles du ct oppos loprateur. 3. Ne pas senrouler les cbles autour du corps. 4. Garder le poste de soudage et les cbles le plus loin possible de soi. 5. Placer la pince de masse le plus prs possible de la zone de soudage. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.

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SECTION 2 DEFINITIONS
2-1. Symbol Definitions
Engine Choke Read Operators Manual

Amperes

Volts

Engine Oil

Fuel

Battery (Engine)

Engine

Positive

Negative

Alternating Current (AC)

Output

Hours

Seconds

Time

Protective Earth (Ground)

Circuit Breaker

Temperature

SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding Mode Weld Output Range Rated Welding Output 140 A, 20 V, 30% Duty Cycle 130 A, 25 V 30% Duty Cycle 110 A, 25 V, 60% Duty Cycle 90 A, 25 V, 100% Duty Cycle Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine

CC/AC

60 140 A

80

Single-Phase, 4.5 kVA/kW (Surge) 4 kVA/kW (Continuous) 20/17 A, 120/240 V AC, 60 Hz

1 gal (3.75L) Tank

Briggs & Stratton Intek Air-Cooled, One-Cylinder, Four-Cycle, 8 HP (305 CC), Gasoline Engine

3-2. Dimensions, Weights, And Operating Angles

Dimensions Height Width Depth A B C D E F G 20-3/4 in (527 mm) 22-3/4 in (577 mm) 31-1/4 in (793 mm) 31-1/4 in (793 mm) 10-1/2 in (268 mm) 13-45/64 in (348 mm) 22-3/4 in (577 mm) 1-3/4 in (44 mm) 19-1/2 in (495 mm) G 13/32 in (10 mm) Dia. Weight 190 lb (86 kg) E F Engine End
803 403

Y Do not exceed tilt angles or engine could be damaged or unit could tip. Y Do not move or operate unit where it could tip.

A C

15 4 Holes 15

15 15

OM-4418 Page 9

3-3. Fuel Consumption

210 593

3-4. Duty Cycle

Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty.

Continuous Welding 100% Duty Cycle at 90 Amperes CC/AC

3 Minutes Welding 7 Minutes Resting 30% Duty Cycle at 140 Amperes CC/AC

212 950

OM-4418 Page 10

3-5. Generator Power Curve

The ac generator power curves show the generator power available in amperes at the receptacles.

210 592

3-6. Volt-Ampere Curves

The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

212 871

OM-4418 Page 11

SECTION 4 INSTALLATION
4-1. Installing Welding Generator

Movement

Airflow Clearance 18 in (460 mm) 18 in (460 mm)

18 in (460 mm)

18 in (460 mm) Location Y Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

18 in (460 mm)

install1 11/02 / Ref. 151 556 / 158 936-A / 803 467 / S-0854

4-2. Grounding Generator To Truck Or Trailer Frame

Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 2
GND/PE

3 3

Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable

Use #10 AWG or larger insulated copper wire. Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.

Electrically bond generator frame to vehicle frame by metal-to-metal contact. 1 Y Bed liners, shipping skids, and some running gear insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.

install1 11/02* Ref. 151 556 / S-0854

OM-4418 Page 12

4-3. Grounding Generator When Supplying Building Systems

1
GND/PE

1 2

Equipment Grounding Terminal Grounding Cable

Use #10 AWG or larger insulated copper wire. 3 Use ground device as stated in electrical codes. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.

800 576-B

4-4. Engine Prestart Checks

1/2 in (13 mm) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Full Engine stops if oil level gets too low. 1 Fuel Valve Open valve. Gasoline

. Close fuel valve before moving

unit or carburetor may flood and make starting difficult. Fuel Add fresh fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day. Oil After fueling, check oil with unit on level surface. If oil reservoir is not full, add oil until oil nearly overflows at oil fill (see maintenance label).

. This

Open

unit has a low oil level shutdown switch to prevent starting an engine that is low on oil. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the low oil level shutdown system to monitor oil level. ing, use correct grade oil for cold weather (see engine owners manual).

Closed

. To improve cold weather start-

. Always close fuel valve after

stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult.

803 468

OM-4418 Page 13

4-5. Connecting To Weld Output Terminals

1 AC Weld Output Terminals Connect work and electrode cables weld terminals. (Polarity does not matter for AC welding.)

Tools Needed: 3/4 in

803 469

4-6. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less Weld Output Terminals
Y Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

350 ft 400 ft (105 m) (120 m)

Welding Amperes

10 60% Duty Cycle

60 100% Duty Cycle

10 100% Duty Cycle

4 (20) 3 (30) 3 (30) 2 (35)

4 (20) 3 (30) 2 (35) 1 (50)

4 (20) 2 (35) 1 (50) 1/0 (60)

3 (30) 1 (50) 1/0 (60) 2/0 (70)

2 (35) 1/0 (60) 2/0 (70) 3/0 (95)

1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)

300
* This

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use
S-0007-E

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-4418 Page 14

SECTION 5 OPERATING THE WELDING GENERATOR

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

803 468 / 803 469 / 210 586

OM-4418 Page 15

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

Engine Switch

Open choke as engine warms.

Use switch to control ignition circuit, and to stop engine. 2 Choke Control Use control to change engine air/fuel mix. Move control to right if starting a cold engine. Move control to left if starting a warm engine. 3 Starter Handle To Start: D Open fuel valve (see Section 4-4). D Turn engine switch to On. D Set choke. D Pull starter handle until engine starts.

. This unit has a low oil level shutdown to

prevent starting an engine that is too low on oil. The low oil level shutdown may not stop a running engine. Check oil level if the engine does not start, or has stopped and cannot be restarted.

Use control to select weld amperage. Control may be adjusted while welding. Set Amperage control at max. for full generator power output at ac receptacles. To Set Current Control: Use electrode chart (see Section 5-3) to determine correct size electrode. Select electrode type and set current control to corresponding amperage range on nameplate. Adjust control within selected range to obtain desired weld performance. EXAMPLE: Electrode Type: 6013 Electrode Diameter: 1/8 Current Control Setting: 80 125 A

To Stop: turn engine switch to Off.

. Always close fuel valve after stopping

unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult.

Current Control

5-3. Amperage Selection Table For Stick (SMAW) Electrodes

Use table to select correct amperage for the electrode being used.

Values listed are suggested settings. Actual settings may vary depending on personal preference and/or specific application. Suggested electrode for beginners is E7018 AC.

211 457

OM-4418 Page 16

SECTION 6 OPERATING AUXILIARY EQUIPMENT NOTE

The welding generator provides power while welding and with the Current control in any position. However, under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under these conditions.

6-1. Generator Power Panel Receptacles

210 586

Y Use GFCI-protected cord. current increases.

extension

kVA/kW. 2 120 V 20 A AC Duplex Receptacle RC2

. Place switch in the On position to reset

circuit breaker. If breaker continues to open, contact Factory Authorized Service Agent. Combined output of all receptacles limited to 4 kVA/kW rating of the generator (See Section 10 Generator Power Guidelines). EXAMPLE: If 15 A is drawn from the 120 volt duplex receptacle, only 9 A is available from the 240 V duplex receptacle. (120 V x 15 A) + (240 V x 9 A) = 4 kVA/KW.

. Generator power decreases as weld

Set Amperage control at max. for full generator power. 1 240 V 20 A AC Duplex Receptacle RC1

RC2 supplies 60 Hz single-phase power at weld/power speed. Maximum output from RC2 is 2.4 kVA/kW. 3 Circuit Breaker CB1

RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 4

CB1 protects the receptacles from overload. If CB1 opens, the receptacles do not work.

OM-4418 Page 17

SECTION 7 MAINTENANCE NOTE

Follow the storage procedure in the engine owners manual if the unit will not be used for an extended period.

7-1. Routine Maintenance

Y Stop engine before maintaining. Recycle engine fluids.

. See Engine Manual and Maintenance Label.

*

Service more often if used in severe conditions.

To be done by Factory Authorized Service Agent.

Every 8 h
Check fluid levels. See Section 4-4. Wipe up spills. Clean area around muffler.

Every 25 h
Service air cleaner precleaner. See Section 7-2.

Every 50 h
Change oil. See engine manual. Clean and tighten weld terminals.

Every 100 h
Service air cleaner element. See Section 7-2. Check spark plugs. Clean cooling system. See Engine Manual.

Every 200 h
Replace unreadable labels. Check valve clearance.*

Every 300 h

Every 500 h
Repair or replace cracked cables. Service welding generator brushes and slip rings. Service more often in dirty conditions.*

Every 1000 h
Blow out or vacuum inside. During heavy service, clean monthly. OR

OM-4418 Page 18

7-2. Servicing Air Cleaner

Y Stop engine. Y Do not run engine without air cleaner or with dirty element. 1 2 3 Cover Precleaner Element

Remove air cleaner cover. Wash precleaner with soap and water solution. Allow precleaner to air dry completely.

. Do not oil precleaner.

Clean element by gently tapping on a hard surface.

. Do not use pressurized air to

clean element.

Washing Precleaner

aircleaner6 9/00 803 468

OM-4418 Page 19

SECTION 8 TROUBLESHOOTING
8-1. Troubleshooting

A. Welding
Trouble No weld output; no generator power output at ac receptacles. Remedy Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier SR1, and integrated rectifier SR2. No weld output; generator power output okay at ac receptacles. Check Amperage control setting. Check weld connections. Have Factory Authorized Service Agent check Amperage control R1, stator, and integrated rectifier SR1. Low weld output. Check Amperage control setting. Service engine air cleaner. Check weld cable size and length. Have Factory Authorized Service Agent check engine speed, and adjust if necessary. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier SR1, and integrated rectifier SR2. High weld output. Erratic weld output. Check Amperage control setting. Check Amperage control setting. Tighten and clean connections to electrode and workpiece. Use dry, properly-stored electrodes for Stick welding. Remove excessive coils from weld cables. Clean and tighten connections both inside and outside welding generator. Check governor linkage for smooth, non-binding operation. Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

B. Generator Power
Trouble No output at generator power ac receptacles; no weld output. Remedy Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier SR1, and integrated rectifier SR2. No output at generator power ac receptacles; weld output okay. Reset circuit breaker (see Section 6-1). Check Current control setting. Set Current control at max for generator power. Check receptacle wiring and connections. Have Factory Authorized Service Agent check engine speed, and adjust if necessary. Have Factory Authorized Service Agent check stator windings. High output at generator power ac receptacles. Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

Low output at generator power ac Check Current control setting. Set Current control at max for generator power. receptacles. Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

OM-4418 Page 20

Trouble Erratic output at generator power ac receptacles. Check fuel level.

Remedy

Check Current control setting. Set Current control at max for generator power. Check receptacle wiring and connections. Check governor linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

C. Engine
Trouble Engine will not start. Check fuel level (see Section 4-4). Move choke control to correct position (see Section 5-1). Open fuel valve (see Section 4-4). Close fuel valve before moving unit or carburetor may flood and make starting difficult. Check oil level (see Section 4-4). Low oil level shutdown may stop if oil level is too low. Refill crankcase with proper viscosity oil for operating temperature. Have Factory Authorized Service Agent check low oil level shutdown switch. Engine stopped during normal operation. Check fuel level (see Section 4-4). Open fuel valve (see Section 4-4). Close fuel valve before moving unit or carburetor may flood and make starting difficult. Check oil level (see Section 4-4). Low oil level shutdown may stop if oil level is too low. Refill crankcase with proper viscosity oil for operating temperature. Unstable or sluggish engine speeds. Check governor linkage for smooth, non-binding operation. Tune-up engine according to engine manual. Have Factory Authorized Service Agent check engine speed, and adjust if necessary. Remedy

OM-4418 Page 21

SECTION 9 ELECTRICAL DIAGRAMS

210 591-A

Figure 9-1. Circuit Diagram For Welding Generator

OM-4418 Page 22

SECTION 10 GENERATOR POWER GUIDELINES NOTE

The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

10-1. Selecting Equipment

1 2 3 Generator Power Receptacles Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment

Y Do not use 2-prong plug unless equipment is double insulated.

3 OR Be sure equipment has this symbol and/or wording.

gen_pwr 11/02 Ref. ST-159 730 / ST-800 577

10-2. Grounding Generator To Truck Or Trailer Frame

Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 1
GND/PE

3 2

Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. 3 Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Electrically bond generator frame to vehicle frame by metal-to-metal contact. Y Bed liners, shipping skids, an some running gear insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.

S-0854

OM-4418 Page 23

10-3. Grounding When Supplying Building Systems

1 1
GND/PE

Equipment Grounding Terminal Grounding Cable

Use #10 AWG or larger insulated copper wire. 3 Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.

Use ground device as stated in electrical codes. 3

ST-800 576-B

10-4. How Much Power Does Equipment Require?

1 3 2 1 VOLTS 115 AMPS 4.5 Hz 60 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 2 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 10-8). 3 3 Rating Data Rating shows volts and amperes, or watts required to run equipment.

AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts.
S-0623

OM-4418 Page 24

10-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Split Phase Rating 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP Starting Watts 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 Running Watts 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

10-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. (e.g. Conveyors, Feed Augers, Air Compressors) Rating Starting Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 Running Watts 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050

1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP

High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump

OM-4418 Page 25

10-7. Approximate Power Requirements For Contractor Equipment

Contractor Hand Drill Rating 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in 9 in 10 in 14 in 6 in 8 in 10 in 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in 2 HP, 14 in Standard 9 in Heavy Duty 12 in 1/3 HP 18 in HID Metal Halide Mercury Sodium Vapor 400 gph 900 gph 3/4 HP, 16 in 1 HP, 20 in 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP Starting Watts 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 Running Watts 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250

Circular Saw

Table Saw Band Saw Bench Grinder

Air Compressor

Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights

Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer

55 gal Drum Mixer Wet & Dry Vac

1000 200 500 1400 1600 950 1400 1600 700 900 1300

OM-4418 Page 26

10-8. Power Required To Start Motor

4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 2 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage

To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motors running amperage. N 12.5 P 14.0

Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP G 6.3 H 7.1 J 8.0 K 9.0 L 10.0 M 11.2

kVA/HP x HP x 1000 VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230

S-0624

10-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.

Ref. ST-800 396-A / S-0625

OM-4418 Page 27

10-10. Typical Connections To Supply Standby Power

Y Properly install and ground this equipment according to its Owners Manual and national, state, and local codes.

1 Utility Electrical Service

2 Transfer Switch

3 Fused Disconnect Switch (If Required)

4 Welding Generator Output

5 Essential Loads

Y Have only qualified persons perform these connections according to all applicable codes and safety practices. Y Properly install and ground this equipment according to its Owners Manual and national, state, and local codes.

Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored. Install correct switch (customer-supplied). Switch rating must be same as or greater than the branch overcurrent protection. 3 Fused Disconnect Switch Install correct switch (customer-supplied) if required by electrical code. 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring.

Connect generator with temporary or permanent wiring suitable for the installation. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. See Section 10-4).

. Customer-supplied

equipment is required if generator will supply standby power during emergencies or power outages.

1 Utility Electrical Service 2 Transfer Switch (Double-Throw)

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-4418 Page 28

10-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000 400 (122) 300 (91) 225 (68) 175 (53) 150 (46) 125 (38) 112 (34) 100 (30) 87 (26) 400 (122) 275 (84) 175 (53) 137 (42) 112 (34) 87 (26) 75 (23) 62 (19) 62 (19) 50 (15) 4 6 8 350 (106) 250 (76) 175 (53) 112 (34) 87 (26) 62 (19) 50 (15) 50 (15) 37 (11) 10 225 (68) 150 (46) 112 (34) 75 (23) 50 (15) 37 (11) 37 (11) 12 137 (42) 100 (30) 62 (19) 37 (11) 30 (9) 14 100 (30) 62 (19) 50 (15) 30 (9)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 1200 1680 2400 3600 4800 6000 7000 8400 9600 10,800 12,000 800 (244) 600 (183) 450 (137) 350 (107) 300 (91) 250 (76) 225 (69) 200 (61) 175 (53) 800 (244) 550 (168) 350 (107) 275 (84) 225 (69) 175 (53) 150 (46) 125 (38) 125 (38) 100 (31) 4 6 8 700 (213) 500 (152) 350 (107) 225 (69) 175 (53) 125 (38) 100 (31) 100 (31) 75 (23) 10 450 (137) 300 (91) 225 (69) 150 (46) 100 (31) 75 (23) 75 (23) 12 225 (84) 200 (61) 125 (38) 75 (23) 60 (18) 14 200 (61) 125 (38) 100 (31) 60 (18)

*Conductor size is based on maximum 2% voltage drop

OM-4418 Page 29

SECTION 11 STICK WELDING (SMAW) GUIDELINES

11-1. Stick Welding Procedure

Y Weld current starts when electrode touches workpiece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 5 4 2 Workpiece Make sure workpiece is clean before welding. 2 3 Work Clamp Electrode

A small diameter electrode requires less current than a large one. Follow electrode manufacturers instructions when setting weld amperage (see Section 11-2). 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length

3 6 1 7

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

Tools Needed:

stick 12/96 ST-151 593

OM-4418 Page 30

11-2. Electrode and Amperage Selection Chart

ELECTRODE AMPERAGE RANGE 100 150 200 250 300

DIAMETER

350

400

450

PENETRATION

50

ELECTRODE

POSITION

6010 & 6011

6013

7014

7018

7024

Ni-Cl

308L

3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32

6010 6011 6013 7014 7018 7024 NI-CL 308L

EP EP EP,EN EP,EN EP EP,EN EP EP

ALL ALL ALL ALL ALL FLAT HORIZ FILLET ALL ALL

DEEP DEEP LOW MED LOW LOW LOW LOW

MIN. PREP, ROUGH HIGH SPATTER GENERAL SMOOTH, EASY, FAST LOW HYDROGEN, STRONG SMOOTH, EASY, FASTER CAST IRON STAINLESS

*EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

USAGE Ref. S-087 985-A

DC*

11-3. Striking an Arc Scratch Start Technique

1 1 2 3 Electrode Workpiece Arc

AC

Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049

11-4. Striking an Arc Tapping Technique

1 1 2 3 Electrode Workpiece Arc

Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

3
S-0050

OM-4418 Page 31

11-5. Positioning Electrode Holder

10-30 90 90

End View of Work Angle

Side View of Electrode Angle

GROOVE WELDS

45

10-30

45

End View of Work Angle

Side View of Electrode Angle FILLET WELDS

S-0060

11-6. Poor Weld Bead Characteristics

1 2 3 4 5 1 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration

S-0053-A

11-7. Good Weld Bead Characteristics

1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 1 4 5 4 5 No Overlap Good Penetration into Base Metal

S-0052-B

OM-4418 Page 32

11-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
Correct Angle 10 - 30

Angle Too Small

Angle Too Large

Drag ELECTRODE ANGLE

Spatter

Too Short

Normal ARC LENGTH

Too Long

Slow

Normal TRAVEL SPEED

Fast
S-0061

11-9. Electrode Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.
1 1 2 2 3 Stringer Bead Steady Movement Along Seam Weave Bead Side to Side Movement Along Seam Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.

S-0054-A

OM-4418 Page 33

11-10. Butt Joints

1 2 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30 Single V-Groove Weld Good for materials 3/16 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 4 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm).
S-0662

11-11. Lap Joint

30 Or Less 1 30 Or Less 1 1 2 3 Electrode Single-Layer Fillet Weld Multi-Layer Fillet Weld

Move electrode in circular motion. Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.

2 Single-Layer Fillet Weld

3 Multi-Layer Fillet Weld

S-0063 / S-0064

11-12. Tee Joint

1 2 1 Electrode Fillet Weld

Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 2 For maximum strength weld both sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 11-9. Remove slag before making another weld pass. 1

45 Or Less

3
S-0060 / S-0058-A / S-0061

OM-4418 Page 34

11-13. Weld Test

3 1 2 3 3 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 2 1 Vise Weld Joint Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

1/4 in (6.4 mm)

2 1

S-0057-B

11-14. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas pockets in weld metal.

Possible Causes Arc length too long. Damp electrode. Workpiece dirty. Reduce arc length. Use dry electrode.

Corrective Actions

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.

11-15. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes Amperage too high for electrode. Arc length too long or voltage too high.

Corrective Actions Decrease amperage or select larger electrode. Reduce arc length or voltage.

OM-4418 Page 35

11-16. Troubleshooting Incomplete Fusion

Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes Insufficient heat input. Improper welding technique.

Corrective Actions Increase amperage. Select larger electrode and increase amperage. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.

11-17. Troubleshooting Lack Of Penetration

Lack Of Penetration shallow fusion between weld metal and base metal. Lack of Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. Good Penetration Corrective Actions Material too thick. Joint preparation and design must provide access to bottom of groove. Keep arc on leading edge of weld puddle. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed.

11-18. Troubleshooting Excessive Penetration

Excessive Penetration weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration

Possible Causes Excessive heat input.

Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed.

OM-4418 Page 36

11-19. Troubleshooting Burn-Through

Burn-Through weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Excessive heat input.

Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed.

11-20. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Unsteady hand. Use two hands. Practice technique.

Corrective Actions

11-21. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds.

OM-4418 Page 37

SECTION 12 PARTS LIST

not available unless listed. 14 16 13 17 20 18 19 12 21 11 24 22 25 23 26 27

. Hardware is common and

15

10

28

29 33 32 30

35

34

36

39

38

37

803 470

Figure 12-1. Main Assembly

OM-4418 Page 38

31

Item No.

Dia. Mkgs.

Part No.

Description Figure 12-1. Main Assembly

Quantity

. . . 1 . . . . RC1 . . . . . 193257 . . Rcpt, Str Dx Grd 2p3w 15/20a 250v *620r . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . RC2 . . . . . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *520r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . C1 . . . . . . 176007 . . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . SR1, SR2 . . . 200759 . . Rectifier, Integ Bridge 35. Amp 600v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . +209659 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . . 211457 . . Label, Electrode Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . CB1 . . . . . 210650 . . Circuit Breaker, Man Reset 2p 20a 250vac Screw90 . . . . . . . . . . . . . . . . . 9 . . . . . R1 . . . . . . 494618 . . Rheostat, Ww 100. W 35. Ohm Frict Term . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . AC-Z . . . . . 210588 . . Reactor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . 209339 . . Duct, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . 209340 . . Seal, Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . 209987 . . Engine, Gas Recoil Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . 211987 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . 211179 . . Cable, Bonding Machine To Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . 494606 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . 494629 . . Guard, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . STATOR . . . 210574 . . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . ROTOR . . . . 210572 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . 209004 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . 495154 . . . . Bearing, Ball Radial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . BRUSH . . . . 493509 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . 212267 . . Cover, Brush Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . 495349 . . Screw, 25020 Hwh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . . 494587 . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . . 495348 . . Screw, 31224 Hwh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . +494628 . . Panel, End Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . 211297 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . . . 208933 . . Frame, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . . . . 211459 . . Mount, Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . 495256 . . Mount, Shock Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . 097422 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . 209658 . . Base, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 083030 . . . . Stud,Brs .25020 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010915 . . . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602207 . . . . Washer,Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601836 . . . . Nut, 25020 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . 202631 . . Boot, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . . 202630 . . Brkt, Mtg Ckt Breaker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . . . 495281 . . Cover, Receptacle Duplex (Includes Gasket And Hardware) . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211069 . . Kit, Accessory (Includes15 Ft 6 AWG Cable w/Electrode Holder & . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ft 6 AWG Cable w/Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 2 1 2 1 1 1 1 2 1 1 1 1 2 1 1

+When ordering a part displaying a precautionary label, order label also. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4418 Page 39

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-4418 Page 40

Effective January 1, 2002 (Equipment with a serial number preface of LC or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed. Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts 3 Years Labor

Warranty Questions?

* * * * * * *

Call 1-877-HOBART1 for your local Hobart distributor.

Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Induction Heating Coils and Blankets APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers

HOBARTs Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

2.

3.

* *
2.

Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Maxstar 85, 140 Spot Welders Load Banks Racks Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)

3 Years Parts and Labor

* * * * * *

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobarts option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Hobarts option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

3.

1 Year Parts and Labor Unless Specified

* * * * * * * * * * * * * * * * * *

4. 5.

6 Months Batteries 90 Days Parts

MIG Guns/TIG Torches

hobart standard 6/02

Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)

Resources Available
Always provide Model Name and Serial/Style Number.
To locate a Distributor, retail or service location:
Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment

For technical assistance:

Call 1-800-332-3281

Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Hobart Welding Products
An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturers Transportation Department.

PRINTED IN USA

2003 Hobart Welding Products.

1/03