Hobart CHAMP 2060 KOHLER User guide

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OM-499 197 850E

December 2001

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

CHAMP 2060

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 don’t have time to do it any other way.

This Owner’s 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.

We’ve 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, there’s 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 ISO 9001 Quality System Standard.

you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do – every power source from Hobart is backed by the best warranty in the business.

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. T o obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section

25249.5 et seq.)

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

WARNING

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

The following terms are used interchangeably throughout this manual: TIG = GTA W Stick = SMAW MIG = GMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers existant en relation avec le moteur 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Weld, Power, And Engine Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions, Weights, And Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Fuel Consumption (Kohler-Powered Units) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Fuel Consumption (Honda-Powered Units) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Duty Cycle 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Auxiliary Power Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Volt-Ampere Curves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Grounding Generator To Truck Or Trailer Frame 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Grounding Generator When Supplying Building Systems 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Engine Prestart Checks (Kohler-Powered Units) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Engine Prestart Checks (Honda-Powered Units) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting The Battery (Electric-Start Models Only) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Connecting To Weld Output Terminals 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Selecting Weld Cable Sizes 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING THE WELDING GENERATOR 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls (Kohler-Powered Units) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Controls (Honda-Powered Units) (See Section 5-3) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) 20. . . . . . . . . . . . . . . . . . . .

SECTION 6 – OPERATING AUXILIAR Y EQUIPMENT 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Auxiliary Power Panel 196 914 (CSA) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Optional Auxiliary Power Panels 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Auxiliary Power Panel Ratings 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) 24. . . . . . . . . .

SECTION 7 – MAINTENANCE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Maintenance Label 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Routine Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Overload Protection (Honda-Powered Units) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Adjusting Engine Speed (Kohler-Powered Units) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Adjusting Engine Speed (Honda-Powered Units) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – AUXILIARY POWER GUIDELINES 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – STICK WELDING (SMAW) GUIDELINES 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 – PARTS LIST 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 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 1-5. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and

repair this unit.

 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.

 Do not touch live electrical parts.  Wear dry, hole-free insulating gloves and body protection.  Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.  If AC output is required, use remote output control if present on

unit.

 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).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 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.

 When making input connections, attach proper grounding conduc-

tor first – double-check connections.

 Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

 Turn off all equipment when not in use.  Do not use worn, damaged, undersized, or poorly spliced cables.  Do not drape cables over your body.  If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

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.

 Wear a safety harness if working above floor level.  Keep all panels and covers securely in place.  Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

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 of f from t h e 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 mate-

rial (wool and leather) and foot protection.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

 If ventilation is poor, use an approved air-supplied respirator.  Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

 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 th e oxygen level causing injury or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

 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-499 Page 1

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

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.

 Protect yourself and others from flying sparks and hot metal.  Do not weld where flying sparks can strike flammable material.  Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.  Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 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).

 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.

 Do not use welder to thaw frozen pipes.  Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use ap-

proved air-supplied respirator.

 Allow cooling period before maintaining.  Wear protective gloves and clothing when

working on a hot engine.

 Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.  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.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.  Never drape a welding torch over a gas cylinder.  Never allow a welding electrode to touch any cylinder.  Never weld on a pressurized cylinder – explosion will result.  Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve.  Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

FUEL can cause fire or explosion.

 Stop engine and let it cool of f before checking or

adding fuel.

 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.

OM-499 Page 2

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

 If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.  Turn cap slightly and let pressure escape slowly before completely

removing cap.

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative ( –) battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator

components.

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

 Do not allow tools to cause sparks when working on a battery.  Do not use welder to charge batteries or jump start vehicles.  Observe correct polarity (+ and –) on batteries.  Disconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated

areas.

 If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.  Use approved engine exhaust spark arrestor in

required areas – see applicable codes.

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

 Wear a face shield to protect eyes and face.  Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.  Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Use only genuine MILLER replacement parts.  Perform engine maintenance and service

according to this manual and the engine manual.

OM-499 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician prompt-

ly 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.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American W elding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

 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 elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according t o 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.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

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.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic 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 committee’s judgment, has not demonstrated that exposure to power- frequency 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.

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.

OM-499 Page 4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT

UTILISATION

rom _nd_fre 11/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

 Identifie un message de sécurité particulier.

 Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

 Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant e t suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes ces normes de sécurité.

 L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

 Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.  Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

 S’isoler de la p i èce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

 Couper l ’alimentation ou arrêter le moteur avant de procéder à l’installation,

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée fixer d’abord le conducteur de

mise à la terre approprié et contre-vérifier les connexions.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

 Ne pas enrouler les câbles autour du corps.  Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.

 Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou

une électrode provenant d’une autre machine.

internes de l’appareil sont également sous tension à ce

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.  Maintenir solidement en place tous les panneaux et capots.  Fixer le c âble de retour de façon à obtenir un bon contact métal-métal avec

la pièce à souder ou la table de travail, le plus près possible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des composants.

LES RAYONS DE L ’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

 Porter u n casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

 Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

des rayons visibles et invisibles intenses (ultraviolets et

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.  À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

 T ravailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

OM-499 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

 Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

 Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.  Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

 Brancher l e c âble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.  En cas de non utilisation, enlever la baguette d’électrode du porte-électro-

de ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des gants

en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

DES PARTICULES VOLANTES peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

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

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

 Prévoir u n e p ériode de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

 Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

 Porteurs d e stimulateur cardiaque, restez à distance.  Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser .

 Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.  Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

 Ne jamais souder une bouteille pressurisée – risque d’explosion.  Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

 Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité.

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une sour-

ce d’étincelles ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

OM-499 Page 6

 Toujours vérifier le niveau de liquide de refroidissement dans le vase

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme

 Mettre des lunettes de sécurité et des gants, placer un torchon sur le

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

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

 Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter de se brûler.

d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).

bouchon du radiateur.

d’enlever le bouchon.

DES ORGANES MOBILES peuvent provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.  Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de d épannage.

 Pour e m p êcher tout démarrage accidentel pendant les travaux d’entre-

tien, débrancher le câble négatif (–) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-

ganes mobiles.

 Remettre en place les panneaux ou les dipositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise

en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-

hicules de démarrage rapide.

 Observer la polarité correcte (+ et –) sur les batteries.  Débrancher l e c âble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

L’ACIDE DE LA BATTERIE peut provoquer des br ûlures dans les YEUX et sur la PEAU.

 Ne pas renverser la batterie.  Remplacer une batterie endommagée.  Rincer immédiatement les yeux et la peau à l’eau.

LES GAZ D’ÈCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.

 Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

 En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti- ments.

LA CHALEUR DU MOTEUR peut provoquer un incendie.

 Ne pas placer l’appareil sur, au-dessus ou à proximité

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé –

voir codes en vigueur.

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

et la maintenance

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de

gaz, remorque, ou autres accessoires.

 Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.



En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie – éloigner toute substance

inflammable.

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

d’une tension et d’une fréquence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter l e facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.  Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

OM-499 Page 7

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio–navigation et de communication, les

services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Effectuer régulièrement le contrôle et l’entretien de l’installation.  Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

1-5. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Weld- ing Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

 L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de souda-

ge aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil- tres de ligne ou la pose de protecteurs dans la zone de travail.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New Y ork, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif. 2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps. 4 Garder le poste de soudage et les câbles le plus loin possible de

vous. 5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus.

OM-499 Page 8

2-1. Symbol Definitions

SECTION 2 – DEFINITIONS

NOTE

Engine Choke

Engine Oil Fuel Battery (Engine) Engine

Positive Negative

Hours

Read Operator’s

Manual A

Alternating Current

Seconds Time

Amperes

(AC)

Output

Protective Earth

(Ground)

Circuit Breaker Temperature

SECTION 3 – SPECIFICATIONS

This unit uses either a Kohler or a Honda engine. Differences between models are noted throughout this manual.

Volts

3-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

Weld Output

Range

40 – 180 A

(60 Hz)

40 – 160 A

(50 Hz)

Rated

Welding

Output

180 A, 25 V ,

30% Duty

Cycle

130 A, 25 V ,

60% Duty

Cycle

100 A, 25 V ,

100% Duty

Cycle

Maximum

Open Circuit

Voltage

(60 Hz)

(50 Hz)

Auxiliary Power

Rating

Single-Phase,

6 kVA/kW (Peak)

5.5 kVA/kW

(Continuous)

50/25 A, 110/220 V AC, 50 Hz 120/240 V AC, 60 Hz

Fuel Capacity Engine

Kohler CS12STG

Air-Cooled,

One-Cylinder,

Kohler:

1.8 gal (6.9 L) Tank Honda:

1.7 gal (6.4 L) Tank

Four-Cycle, 12 HP (360 CC), Gasoline Engine

Honda GX390

Air-Cooled,

One-Cylinder,

Four-Cycle, 13 HP (390 CC), Gasoline Engine

OM-499 Page 9

3-2. Dimensions, Weights, And Operating Angles



Dimensions

Height 20-3/4 i n (527 mm)

Width 22-3/4 i n (577 mm)

Depth 31-1/4 in (793 mm)  Do not exceed tilt angles or engine could

A 31-1/4 i n (793 mm) B 10-1/2 i n (268 mm) C 13-45/64 in (348 mm) D 22-3/4 in (577 mm) E 1-3/4 in (44 mm) F 19-1/2 in (495 mm) G 13/32 in (10 mm) Dia.

Weight

Kohler: 265 lb (120 kg)

Honda Electric-Start Model:

278 lb (126 kg)

Honda Recoil-Start Model:

253 lb (114 kg)

Engine End

Holes

802 096

be damaged or unit could tip. Do not move or operate unit where it

could tip.

802 524-A

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

15°

HIGH IDLE

 Fuel consumption at low idle

(2000 rpm): 0.2 U.S. gal/hr .

60 HZ–WELD

60 HZ–AUX

50 HZ–AUX

50 HZ–WELD

198 575

OM-499 Page 10

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

3-5. Duty Cycle

802 122

Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.

 Exceeding duty cycle can

damage unit and void warranty.

Continuous Welding

100% Duty Cycle at 100 Amperes CC/DC

802 093

OM-499 Page 11

3-6. Auxiliary Power Curves

A. 60 Hz Model

250

225

200

175

150

125

LOAD VOLTS

100

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

0 5 10 15 20 25 30 35

B. 50 Hz Model

250

225

200

175

150

125

LOAD VOLTS

100

LOAD AMPS

0 5 10 15 20 25 30 35

OM-499 Page 12

LOAD AMPS

198 570

3-7. Volt-Ampere Curves

A. 60 Hz Model

LOAD VOLTS

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

MAX

MID

0 25 50 75 100 125 150 175 200 225 250

MIN

LOAD AMPS

B. 50 Hz Model

LOAD VOLTS

MID

MIN

MAX

0 25 50 75 100 125 150 175 200 225 250

LOAD AMPS

198 570

OM-499 Page 13

SECTION 4 – INSTALLATION

4-1. Installing Welding Generator

Movement Airflow Clearance

18 in

(460 mm)

 Always securely fasten welding

generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Location

4-2. Grounding Generator To Truck Or Trailer Frame

GND/PE

18 in

(460 mm)

install1 10/00*– 802 524-A / Ref. 151 556 / 158 936-A / S-0854

 Always ground generator

frame t o vehicle frame to prevent electric shock and static electricity hazards.

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal

4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCIprotected extension cord.

OM-499 Page 14

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

install1 10/00* – Ref. 151 556 / S-0854

4-3. Grounding Generator When Supplying Building Systems

GND/PE

Use ground device as stated in electrical codes.

1 2

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 Ground generator to sys-

tem earth ground if supply-

ing power to a premises

(home, shop, farm) wiring

system.

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

1/2 in

(13 mm)

Gasoline

Closed

Open

Full

800 576-B

 Follow run-in procedure in engine

manual.

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.

Engine stops if oil level gets too low.

 This unit has a low oil level shut-

down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil level shutdown system to monitor oil level.

1 Fuel Valve Open valve by turning lever to vertical

position.

 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 is not up to full mark on dipstick, add oil (see maintenance label).

 To improve cold weather starting:

Keep battery in good condition. Store battery in warm area off concrete surface.

Use correct grade oil for cold weather.

802 511-A

OM-499 Page 15

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

1/2 in

(13 mm)

Gasoline

Open

Full

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.

Engine stops if oil level gets too low.

 Follow run-in procedure in en-

gine manual.

1 Fuel Valve Open valve.

 Close fuel valve before moving

unit or carburetor may flood and make starting difficult.

Fuel

Oil

After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

 To improve cold weather

starting: Keep battery in good condition.

Store battery in warm area off concrete surface.

Full

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

 Connect negative (–)

cable last.

–

Use correct grade oil for cold weather.

802 094-A

 Turn Engine Switch to Off

(electric-start models only).

Tools Needed:

OM-499 Page 16

3/8, 1/2 in

802 524 / Ref. S-0756-D

4-7. Connecting To Weld Output Terminals

1 Positive (+) Weld Output

Terminal

2 Negative (–) Weld Output

Terminal

For Direct Current Electrode Positive (DCEP), connect work cable to Negative (–) terminal and electrode holder to Positive (+) terminal.

For Direct Current Electrode negative (DCEN), reverse cable connections.

Tools Need e d :

3/4 in

4-8. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Stop engine before

connecting t o weld output terminals.

 Do not use worn, dam-

aged, undersized, or poorly spliced cables.

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

10 – 60%

Duty

Cycle

196 914 / 495 178

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 – 100%

Duty

10 – 100% Duty Cycle

Cycle

400 ft

(120 m)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

* This 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.

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

OM-499 Page 17

SECTION 5 – OPERATING THE WELDING GENERATOR

5-1. Controls (Kohler-Powered Units)

50 Hz

60 Hz

 Weld and auxiliary power output stops if

generator overheats or engine speed is too low.

1 Engine Switch Use switch to open ignition circuit, and to stop

engine.

2 Throttle Control Lever

Use lever to select engine speed. Use 50 Hz or 60 Hz position for 50 or 60 Hz auxiliary power. Use 60 Hz position for maximum weld output.

3 Choke Control Lever

Use lever to change engine air/fuel mix. Move lever to right if starting a cold engine. Move lever to left if starting a warm engine.

To Start (Electric): open fuel valve (see Section 4-4), move throttle lever to Idle, set choke, and turn engine switch to Start position. Open choke as engine warms. If engine does not crank, use recoil starting procedure following to start engine.

 If engine does not start, let engine

come to a complete stop before attempting restart.

4 Starter Handle To Start (Recoil): open fuel valve (see Sec-

tion 4-4), move throttle lever to Idle, set choke, and pull starter handle. Open choke as engine warms.

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.

802 511-A / 802 0511 / 495 178

5 Engine Hour Meter 6 Welding Range Label Use label to determine correct weld amper-

age based on electrode size, type, and material thickness.

7 Current Control Use control to select weld amperage. Control

may be adjusted while welding. To Set Current Control: Use label to deter-

mine correct size electrode for material thickness. Select electrode type and set current control to corresponding amperage range. Adjust control to obtain desired weld performance.

EXAMPLE: Material Thickness: 1/8 to 1/4 in Electrode Diameter: 1/8 Electrode Type: E-6013 Current Control Setting: 90 – 120 A

OM-499 Page 18

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

60 Hz

Recoil-Start

50 Hz

Electric-Start

802 094-A / 802 095 / 495 187

OM-499 Page 19

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

 Weld and auxiliary power output stops if

generator overheats or engine speed is too low.

1 Engine Switch On models with recoil-start, use switch to

open ignition circuit, and to stop engine. On models with electric-start, use switch to

open ignition circuit, and to start and stop engine.

2 Throttle Control Lever Use lever to select engine speed. Use 50 Hz

or 60 Hz position for auxiliary power. Use 60 Hz position for maximum weld output.

3 Choke Control Lever Use lever to change engine air/fuel mix. Move

lever to left if starting a cold engine. Move lever to right if starting a warm engine.

4 Starter Handle (Recoil-Start Models

Only)

Notes

To Start (Recoil): open fuel valve, turn engine

switch to On, move throttle lever to Idle, set choke, and pull starter handle. Open choke as engine warms.

To Start (Electric): open fuel valve, move throttle lever to Idle, set choke, and turn engine switch to Start position. Open choke as engine warms.

 If engine does not start, let engine

come to a complete stop before attempting restart.

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.

5 Engine Hour Meter 6 Welding Range Label

Use label to determine correct weld amperage based on electrode size, type, and material thickness.

7 Current Control Use control to select weld amperage. Control

may be adjusted while welding. To Set Current Control: Use label to deter-

mine correct size electrode for material thickness. Select electrode type and set current control to corresponding amperage range o n nameplate. Adjust control within selected range to obtain desired weld performance.

EXAMPLE: Material Thickness: 1/8 to 1/4 in Electrode Diameter: 1/8 Electrode Type: E-6013 Current Control Setting: 90 – 120 A

OM-499 Page 20

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. Auxiliary Power Panel 495 218 (USA)

1234 5

 If unit does not have GFCI recep-

tacles, use GFCI-protected extension cord.

 Power is still present at the 240 volt

receptacle when only one circuit breaker trips.

Unplug power cord before attempting to service accessories or tools.

 Auxiliary power decreases as weld

current increases. Set Amperage control at max. for full

auxiliary power.

 Place throttle lever in Run position (far

right) for a u x i l i a r y p o w e r.

1 120 V AC Twistlock Receptacle RC1

RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 3.5 kVA/kW.

2 120 V 20 A AC Duplex Receptacle

RC2

3 120 V 20 A AC Duplex Receptacle

RC3

RC2 and RC3 supply 60 Hz single-phase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW .

 Each receptacle of the duplex can pro-

vide 15A/1800W.

 Do not parallel the two 120V duplex

receptacles.

4 Circuit Breaker CB1

495 218

CB1 protects RC1 from overload. If CB1 opens, RC1 does not work.

5 Circuit Breakers CB2 And CB3 CB2 protects RC2 and CB3 protects RC3

from overload. If a circuit breaker opens, the receptacle does not work.

 Press button to reset circuit breaker. If

breaker continues to open, contact Factory Authorized Service Agent.

Combined output of all receptacles limited to 6 kVA/kW rating of the generator (See Section 10 – Auxiliary Power Guidelines).

EXAMPLE: I f 1 0 A i s drawn from each 120 volt duplex receptacle, only 9 A is available from the 120 V twistlock receptacle.

2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/ KW.

OM-499 Page 21

6-2. Optional Auxiliary Power Panels

Auxiliary Power Panel 495 315

Auxiliary Power Panel 495 278

(Canada–CSA)

Auxiliary Power Panel 495 219

(USA)

Auxiliary Power Panel 495 253

(South Africa)

(USA)

Auxiliary Power Panel 495 288

(South America)

Auxiliary Power Panel 495 289

(Australia)

 If unit does not have GFCI recep-

tacles, use GFCI-protected extension cord.

 Power may still be present at a re-

ceptacle when a circuit breaker trips.

Unplug power cord before attempting to service accessories or tools.

OM-499 Page 22

Auxiliary Power Panel 495 290

(Europe)

 Auxiliary power decreases as weld

current increases. Set Amperage control at max. for full

auxiliary power.

 Place throttle lever in Run position (far

right) for auxiliary power .

Auxiliary Power Panel 495 283

(S.E. Asia)

Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277

Circuit breakers protect the generator from overload.

 Press button to reset circuit breaker. If

breaker continues to open, contact Factory Authorized Service Agent.

6-3. Auxiliary Power Panel Ratings

NOTE

Receptacle

240 V

Twist Lock

240 V

Duplex

240 V

Duplex

230 V Single

120 V

Twist Lock

120 V

Duplex

120 V

Duplex

120 V

Duplex

120 V

Duplex

Total

Power NOT

to exceed

Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles.

Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)

Protected

CB1,2

CB3,4

CB1

CB2

CB1,2

CB3,4

CB1

CB1,3/

CB2,4

CB2

CB3

CB4

Panel

495 218

(USA)

60 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz

30A/

3500W

20A/

2400W

20A/

2400W

5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W

Panel

495 315

(USA)

15A/

3600W

See

Note 2

20A/

2400W

See

Note 3

20A/

2400W

See

Note 3

Panel

495 219

(USA)

25A/

5500W

See

Note 2

20A/

2400W

See

Note 3

20A/

2400W

See

Note 3

Panel

495 278

(Canada-

CSA)

25A/

5500W

See

Note 2

30A/

3600W

See

Note 1

Panel

495 253

(S. Africa)

15A/

3600W

15A/

3600W

Panel

495 288

(South

America)

15A/

3600W

15A/

3600W

Panel

495 289

(Australia)

15A/

3600W

15A/

3600W

Panel

495 290

(Europe)

15A/

3600W

15A/

3600W

Panel

495 283

(S.E. Asia)

15A/

3600W

15A/

3600W

Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.

2. Do not parallel the two 120V circuits.

3. Do not parallel the two duplex outlets.

Calculating total power provided by generator. (See Section 10 – Auxiliary Power Guidelines)

Each receptacle can provide the watts or amps as shown above. However, the total power can not exceed 5500W.

The rating plate on electrical apparatus will contain the watts

For example, for the 495 218 Auxiliary Power Panel, 120V, 3000W heater 3000W

120V, 10A chain saw 1200W 120V, 500W halogen lamp 500W

Total 4700W This loading is OK.

consumed or the rated input amps. Watts may be calculated by multiplying the rated voltage by the rated input amps.

watts = volts x amps

120V, 3000W heater 3000W 120V, 10A chain saw 1200W 120V, 5A router 600W 120V, 1000 W h a l o g e n l a m p 1000W

Total 5800W This loading is not OK.

It exceeds 5500W.

OM-499 Page 23

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

Tools Needed:

120 V

120V

240 V

1 Plug Wired For 120/240 V,

3-Wire Load

When wired for 120 V loads, each duplex receptacle shares a load with one half of the 240 V receptacle.

2 Neutral (Silver) Terminal 3 Load 1 (Brass) Terminal 4 Load 2 (Brass) Terminal 5 Ground (Green) Terminal 6 Cord Grip Strip cord jacket back enough to sep-

arate conductors. Strip conductors enough to make

good contact with plug terminals. Make plug connections and reinstall outer shell and cord grip.

Tighten assembly screws onto shell. Do not overtighten.

plug3-11/99 – 802 527

SECTION 7 – MAINTENANCE

NOTE

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

7-1. Maintenance Label

ENGINE MAINTENANCE

8 h

1.1 l (1.2 US qt,

1.94 lmp qt)

50 h

Unleaded 86 + Octane

6.5 l (1.7 US Gal,

11.4 lmp pt)

100 h

SG-SF/CC-CD

+40°C+104

+86+30

+20

+59

+10

+32

-10

-15

-20

-10

°F

10W-30

OM-499 Page 24

0.7 – 0.8 mm

(0.028 – 0.031 in)

200 h

Ref. S-175 679-A

7-2. Routine Maintenance

Recycle

engine

fluids.

 Stop engine before maintaining.

 See Engine Manual and Maintenance Label. Ser-

vice more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

Check fluid levels. See Section 4-4 or 4-5

Service air cleaner element. See engine manual.

Change oil. See engine manual and maintenance label.

Clean Fuel sediment cup.

8 h

Wipe up spills.

20 h

Check and clean spark arrestor screen. See engine manual.

50 h

Clean and tighten weld terminals.

100 h

Check spark plugs.

Clean an d t i g h ten battery connections (Electric

-Start models only).

Clean fuel tank and strainer.

Repair or replace cracked cables.

Check valve clearance.*

Blow out or vacuum inside. During heavy service, clean monthly.

200 h

Replace unreadable labels.

300 h

500 h

Service welding generator brushes and slip rings. Service more often in dirty conditions.*

1000 h

OM-499 Page 25

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

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

2000 ±150 rpm

3720 ± 50 rpm (60 Hz) 3250 ± 50 rpm (50 Hz)

Tools Needed:

1 Ignition Circuit Breaker

(Electric-Start Models Only)

The circuit breaker protects the engine battery charging circuit. A short circuit or a battery connected in reverse polarity will trip the circuit breaker.

Press button to reset breaker.

 If a switch or breaker opens, it

usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent.

Ref. 802 094-A

After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows:

Start engine and run until warm.

Weld/Power Speed Adjustment

1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (far right) posi-

tion. To increase speed, turn screw out (counterclockwise) while lightly pushing lever to the right. To decrease speed, turn screw in (clockwise).

Idle Speed Adjustment

3 Adjustment Screw Move lever to idle (far left) position.

To increase idle speed, turn screw in (clockwise). To decrease idle speed, turn screw out (counterclockwise).

 Stop engine. Close fuel

valve.

OM-499 Page 26

Top V iew

802 511-A / Kohler Dwg.

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

1400 ± 150 rpm 3720 ± 50 rpm (60 Hz)

3250 ± 50 rpm (50 Hz)

After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows:

Start engine and run until warm.

Weld/Power Speed Adjustment

1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (60 Hz) position.

Turn screw and move lever until en gine runs at weld/power speed.

Idle Speed Adjustment

3 Pilot Screw 4 Throttle Stop Screw Move lever to idle position. T urn pi-

lot screw until engine runs at highest idle speed. Turn stop screw until engine runs at rated idle speed (normally about 2-1/4 turns out.)

 Stop engine. Close fuel

valve.

Tools Needed:

1/4, 3/8 in

802 097-A

OM-499 Page 27

SECTION 8 – TROUBLESHOOTING

8-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check Amperage control setting.

Check weld connections. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is

too low. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

Low weld output. Check Amperage control and throttle lever settings.

Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Service air cleaner according to engine manual. Check weld cable size and length. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

High weld output. Check Amperage control setting.

Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, suppressor VR1/R2, resistor R3 (Kohler only), and circuit board PC1.

Erratic weld output. 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 engine speed, and adjust if necessary (see Section 7-4 or 7-5). Check throttle/governor linkage for smooth, non-binding operation. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

B. Auxiliary Power

Trouble Remedy

No output at auxiliary power receptacles.

High power output. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).

OM-499 Page 28

Reset circuit breakers (see Sections 6-1 and 6-2).

Check receptacle wiring and connections. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is

too low. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

Move throttle lever to 50 Hz position for 50 Hz equipment (see Section 5-1 or 5-2). Have Factory Authorized Service Agent check capacitor C1, resistor R3 (Kohler only), and circuit

board PC1.

Trouble Remedy

Low power output. Check Amperage control setting.

Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is too low.

Move throttle lever to 60 Hz position for 60 Hz equipment (see Section 5-1 or 5-2).

Erratic power output. Check fuel level.

Check receptacle wiring and connections. Check throttle/governor linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed is

too low. Have Factory Authorized Service Agent check brushes, slip rings, resistor R3 (Kohler only), and

circuit board PC1.

C. Engine

Trouble Remedy

Engine will not crank (electric-start models only).

Reset ignition circuit breaker (see Section 7-3).

Check battery voltage. Check battery connections and tighten if necessary. Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start. Check fuel level (see Section 4-4 or 4-5).

Move choke lever to correct position (see Section 5-1 or 5-2). Open fuel valve (see Section 4-4 or 4-5). Close fuel valve before moving unit or carburetor may flood and

make starting difficult. Check battery voltage (electric-start models only). Check battery connections and tighten if necessary (electric-start models only). Check oil level (see Section 4-4 or 4-5). Engine stops 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.

Battery discharges between uses (electric-start models only).

Check fuel level (see Section 4-4 or 4-5).

Open fuel valve (see Section 4-4 or 4-5). Close fuel valve before moving unit or carburetor may flood and make starting difficult.

Check oil level (see Section 4-4 or 4-5). Engine stops if oil level is too low. Have Factory Authorized Service Agent check low oil level shutdown switch. Check unit operating angle. Low oil level shutdown switch may stop engine if unit is tilted. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5).

Check throttle/governor linkage for smooth, non-binding operation. Tune-up engine according to engine manual.

OM-499 Page 29

SECTION 9 – ELECTRICAL DIAGRAMS

OM-499 Page 30

197 857-E

Figure 9-1. Circuit Diagram For Welding Generator (1 Of 2)

Figure 9-2. Circuit Diagram For Welding Generator (2 Of 2)

197 857-D

OM-499 Page 31

OM-499 Page 32

197 858-C

Figure 9-3. Wiring Diagram For Welding Generator

Figure 9-4. Wiring Diagram For Auxiliary Power Panels (1 Of 2)

201 026-A

OM-499 Page 33

OM-499 Page 34

201 026-A

Figure 9-5. Wiring Diagram For Auxiliary Power Panels (2 Of 2)

SECTION 10 – AUXILIARY POWER GUIDELINES

10-1. Selecting Equipment

1 Auxiliary Power Receptacles

– Neutral Bonded To Frame 2 3-Prong Plug From Case

Grounded Equipment 3 2-Prong Plug From Double

Insulated Equipment

10-2. Grounding Generator To Truck Or Trailer Frame

3 4

GND/PE

Be sure equipment has this symbol and/or wording.

aux_pwr 4/01 – Ref. ST-159 730 / ST-800 577

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by metal-to-metal contact.

S-0854

OM-499 Page 35

10-3. Grounding When Supplying Building Systems

1 2

GND/PE

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 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.

10-4. How Much Power Does Equipment Require?

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.

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

1 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-re-

sistive load and requires approximately six times more power while starting the motor than when running (see Section 10-8).

3 Rating Data Rating shows volts and amperes,

or watts required to run equipment.

OM-499 Page 36

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

10-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975 3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550 1/4 HP 1850 650 1/3 HP 2400 800 1/2 HP 3500 1100

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

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000 Grain Cleaner 1/4 HP 1650 650 Portable Conveyor 1/2 HP 3400 1000 Grain Elevator 3/4 HP 4400 1400 Milk Cooler 2900 1100 Milker (Vacuum Pump) 2 HP 10500 2800 FARM DUTY MOTORS 1/3 HP 1720 720 Std. (e.g. Conveyors, 1/2 HP 2575 975 Feed Augers, Air 3/4 HP 4500 1400 Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900

5 HP 23300 6800 High Torque (e.g. Barn 1-1/2 HP 8100 2000 Cleaners, Silo Unloaders, 5 HP 23300 6000 Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700 3-1/2 cu. ft. Mixer 1/2 HP 3300 1000 High Pressure 1.8 Gal/Min 500 PSI 3150 950 Washer 2 gal/min 550 PSI 4500 1400 2 gal/min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-499 Page 37

10-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400 1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900 8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600 Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800 Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500 Electric Cultivator 1/3 HP 2100 700 Elec. Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600 55 gal Drum Mixer 1/4 HP 1900 700 Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-499 Page 38

10-8. Power Required To Start Motor

4 1 3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJ KLMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000

VOLTS

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 230

= 12.2 A

VOLTS AMPS

CODE 60

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

1/4

= STARTING AMPERAGE

Hz PHASE

1 Motor Start Code 2 Running Amperage 3 Motor HP 4 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 amper-

age (see example). Welding generator amperage out-

put must be at least twice the motor’s running amperage.

S-0624

10-9. How Much Power Can Generator Supply?

1 Limit Load T o 90% Of

Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last.

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-499 Page 39

10-10.Typical Connections To Supply Standby Power

 Customer-supplied equipment is required if

generator is to supply standby power during emergencies or power outages.

120/240 Volt

60 Hz

Three-Wire

Service

Load

240 V

120 V

Neutral

240 V

120 V

 Have only qualified persons

perform these connections according to all applicable codes and safety practices.

1 Power Company Service

Meter

2 Main and Branch Overcurrent

Protection

3 Double-Pole, Double-Throw

Transfer Switch

Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.

4 Circuit Breakers or Fused

Disconnect Switch

Obtain and install correct circuit breakers or switch.

5 Extension Cord

Select as shown in Section 10-11. 6 Generator Connections Connect terminals or plug of ade-

quate amperage capacity to cord. Follow all applicable codes and safety practices.

Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting o r s t o p p i n g , t h e e ngine has low speed which causes low voltage and frequency.

7 Load Connections

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection

240 V

120 V

Ground

Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit.

S-0405-A

OM-499 Page 40

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

Cord Lengths for 120 Volt Loads  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)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15) 37 (11) 35 4200 125 (38) 75 (23) 50 (15) 40 4800 112 (34) 62 (19) 37 (11) 45 5400 100 (30) 62 (19) 50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38) 10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31) 15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18) 20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18) 25 6000 350 (107) 225 (69) 125 (38) 75 (23) 30 7000 300 (91) 175 (53) 100 (31) 75 (23) 35 8400 250 (76) 150 (46) 100 (31) 40 9600 225 (69) 125 (38) 75 (23) 45 10,800 200 (61) 125 (38) 50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

OM-499 Page 41

SECTION 11 – STICK WELDING (SMAW) GUIDELINES

1 1-1. Stick Welding Procedure

 Weld current starts when

electrode touches workpiece.

 Weld current can damage

electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp as close t o the weld as possible.

1 Workpiece Make sure workpiece is clean be-

fore welding. 2 Work Clamp 3 Electrode A small diameter electrode requires

less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 11-2).

4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the

electrode t o 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:

OM-499 Page 42

stick 12/96 – ST-151 593

11-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

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

100

150

200

250

300

350

400

450

DC*

ELECTRODE

6010

6011

EP,EN

6013

EP,EN

7014

7018

EP,EN

7024

NI-CL

308L

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

POSITION

ALL ALL ALL

ALL ALL

FLAT HORIZ FILLET

ALL ALL

PENETRATION

DEEP DEEP

LOW MED

LOW

LOW LOW

LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON STAINLESS

Ref. S-087 985-A

11-3. Striking an Arc – Scratch Start Technique

11-4. Striking an Arc – Tapping Technique

1 Electrode 2 Workpiece 3 Arc 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

1 Electrode 2 Workpiece 3 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.

S-0050

OM-499 Page 43

11-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

End View of Work Angle Side View of Electrode Angle

11-6. Poor Weld Bead Characteristics

FILLET WELDS

10°-30°

S-0060

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

11-7. Good Weld Bead Characteristics

OM-499 Page 44

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being w elded.

5234

4 No Overlap 5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

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.

Angle Too Small

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

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 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side to Side

Movement Along Seam 3 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-499 Page 45

11-10. Butt Joints

11-11. Lap Joint

Single-Layer Fillet Weld

1 Tack Welds

1/16 in

(1.6 mm)

30° Or Less

30°

30° Or Less

Multi-Layer Fillet Weld

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 Single V-Groove W eld 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.

Create 3 0 degree angle of bevel on materials in V-groove welding.

4 Double V-Groove W eld Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavi-

er fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.

S-0063 / S-0064

11-12. Tee Joint

OM-499 Page 46

45°

Or Less

1 Electrode 2 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.

For maximum strength weld both

sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavi-

er fillet is needed. Use any of the weaving patterns shown in Section 11-9. Remove slag before making another weld pass.

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

11-13. Weld Test

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2 1

11-14. Troubleshooting – Porosity

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

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise 2 Weld Joint 3 Hammer

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

S-0057-B

Damp electrode. Use dry electrode. Workpiece dirty. 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 Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage.

OM-499 Page 47

11-16. Troubleshooting – Incomplete Fusion

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

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. 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 Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. 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

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

OM-499 Page 48

Good Penetration

Increase and/or maintain steady travel speed.

11-19. Troubleshooting – Burn-Through

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

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

11-20. Troubleshooting – Waviness Of Bead

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

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

11-21. Troubleshooting – Distortion

Distortion – contraction of weld met- al during welding that forces base metal t o move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. 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-499 Page 49

SECTION 12 – PARTS LIST

 Hardware is common and

not available unless listed.

46 45

444243

802 509-A

OM-499 Page 50

Figure 12-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 495 096 LABEL, precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 SR1 200 759 RECTIFIER, silicon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 129 525 TERMINAL, output Dinse 50/70 series (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129 527 PLUG, weld cable (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC2 148 608 BOARD, PC filter (CSA only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 204 140 LABEL, moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 204 138 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 952 FILTER, air Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 954 FILTER, air pre Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 955 CAP, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 956 TANK, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 957 STRAINER, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 958 MUFFLER, exhaust engine Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 959 GASKET, muffler Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 960 SPARK PLUG, Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +495 055 ENGINE, Honda 13HP (recoil start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +495 053 ENGINE, Honda 13HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 194 509 FAN, generator (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 493 868 FAN, generator (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 495 211 GENERATOR, w/stator assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 495 113 LEAD, bonding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 194 504 FRAME, mtg assembly (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 495 132 FRAME, mtg assembly (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 R1 035 897 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 Figure 12-2 PANEL, aux power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-499 Page 51

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 R3 197 795 RESISTOR ASSEMBLY (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 201 223 LABEL, warning electric shock power still present 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts. +When ordering a component originally displaying a precautionary label, the label should also be ordered.

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

OM-499 Page 52

4536

 Hardware is common and not available unless listed.

Auxiliary Power Panel 495 218 (USA)

9 11

Auxiliary Power Panel 495 315 (USA)

Auxiliary Power Panel 495 253 (South Africa) Auxiliary Power Panel 495 289 (Australia)

16 17

18 19

22 23

Auxiliary Power Panel 495 219 (USA)

Auxiliary Power Panel 495 288 (S. America)

Auxiliary Power Panel 495 290 (Europe)

26 27

Auxiliary Power Panel 495 283 (S.E. Asia)

Auxiliary Power Panel 495 298 (USA)

Figure 12-2. Auxiliary Power Panels

Auxiliary Power Panel 495 278 (Canada–CSA)

OM-499 Page 53

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-2. Auxiliary Power Panels (Figure 12-1, Item 39)

Auxiliary Power Panel 495 218 (USA)

1 495 220 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 495 216 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 007 467 RECEPTACLE, twistlock grd 2P3W 30A 125 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 408 898 RECEPTACLE, duplex 115 V 20 A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 315 (USA)

7 495 314 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 404 089 RECEPTACLE, Duplex 230 V S. American 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 408 898 RECEPTACLE, Duplex 115 V 20 A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 253 (South Africa)

12 495 252 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 289 (Australia)

14 495 254 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB1 - CB4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 219 (USA)

16 495 220 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 495 217 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .

21 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 290 (Europe)

22 495 282 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 288 (S. America)

24 495 287 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 CB1-4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 283 (S.E. Asia)

26 495 282 Panel, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 298 (USA)

28 495 220 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 RC1 007 467 RECEPTACLE, tw lk grd 2P3W 30A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 797 PLUG, tw lk 3P3W 20A 125V. . . . . . . . . . . . . . . . . . . . . . .

32 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Panel 495 278 (Canada–CSA)

33 495 277 PANEL, auxiliary power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 CB1 203 095 CIRCUIT BREAKER, 25A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 631 COVER, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 630 BRACKET, mtg circuit breaker cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .

37 RC2 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.

OM-499 Page 54

Warranty Questions?

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

Service

Y ou 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.

Effective October 1, 1999

5/3/1 WARRANTY applies to all Handler 135 and 175 models, Airforce 250, 250A, and 375

models, and Champion 10,000 models.This warranty also applies to the Beta-Mig 1800, Champ

1435, 2060, 8500 models, Ironman 250, Stickmate models, Tigmate models, and HSW-15 and

HSW-25 spot welder models effective with Serial No. KK200262 and newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

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/Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart/Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart/Miller will provide instructions on the warranty claim procedures to be followed.

Hobart/Miller 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 and Labor

* Original Main Power Rectifiers * Transformers * Stabilizers * Reactors * Rotors, Stators and Brushes

2. 3 Years — Parts and Labor

* Drive Systems * PC Boards * Idle Module * Solenoid Valves * Switches and Controls * Spot Welder Transformer

3. 1 Year — Parts and Labor (90 days for industrial use)

* Motor-Driven Guns * MIG Guns/TIG Torches * Relays * Contactors * Regulators * Water Coolant Systems * HF Units * Running Gear/Trailers * Plasma Cutting Torches * Remote Controls * Replacement Parts (No labor) * Accessories * 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.)

4. Engines, batteries and tires are warranted separately by the manufacturer.

no other guarantees or warranties expressed or implied.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components such as contact tips,

cutting nozzles, slip rings, drive rolls, gas diffusers, plasma torch tips and electrodes, weld cables, and tongs and tips, or parts that fail due to normal wear.

2. Items furnished by Hobart/Miller, but manufactured by others, such as engines or trade accessories. These items are cov ered by the manufacturer’s warranty, if an y.

3. Equipment that has been modified by any party other than Hobart/Miller, 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 o f the specifications for the equipment.

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 Hobart’s/Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart/Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart/Miller 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 customer’s risk and expense. Hobart’s/Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart/Miller authorized service facility as determined by Hobart/Miller. 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/MILLER 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/MILLER IS EXCLUDED AND DISCLAIMED BY Hobart/Miller.

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.

hobart retail 4/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

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

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

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

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

An Ill inoi s 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

PRINTED IN USA  2002 Hobart Welding Products. 1/02

Hobart CHAMP 2060 KOHLER User guide

Specifications and Main Features

Frequently Asked Questions

User Manual