Hobart CHAMPION ELITE 225 User guide

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OM-289543D

Processes

Stick (SMAW) Welding

Description

Engine Driven Welder/Generator

Champion®Elite 225

2023-06

www.HobartWelders.com

OWNER’S MANUAL

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

Hobart Welders manufactures a full line of welders and welding-related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-332-3281, or visit us at

www.HobartWelders.com on the web.

For Technical Help call 1-800-332-3281.

Hobart is registered to the ISO 9001 Quality System Standard.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-5 Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-6 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-7 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-8 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-3 Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-4 Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-5 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . 11

2-6 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-7 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-8 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-2 Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-2 Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-3 Weld, Power, And Carbureted Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-4 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-5 Base Unit Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-6 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-7 Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-8 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-1 Installing Welder/Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-2 Grounding Generator to Truck or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-3 Ground Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-4 Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-5 Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-6 Connecting Or Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-7 Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-8 Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-9 Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-2 Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-3 Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-4 Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 7 – OPERATING AUXILIARY EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7-1 Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7-2 GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7-3 Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-4 Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-5 Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION 8 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8-2 Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8-3 Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8-4 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-5 Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8-6 Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8-7 Fault Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8-8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9-1 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

TABLE OF CONTENTS

SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 11 – GENERATOR POWER GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11-1 Selecting Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11-2 Grounding When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11-3 How Much Power Does Equipment Require? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11-4 Approximate Power Requirements For Industrial Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11-5 Approximate Power Requirements For Farm/Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

11-6 Approximate Power Requirements For Contractor Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

11-7 Power Required To Start Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

11-8 How Much Power Can Generator Supply? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

11-9 Typical Connections To Standby Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11-10 Selecting Extension Cord (Use Shortest Cord Possible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SECTION 12 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE – Indicates statements not related to personal injury.

Indicates special instructions.

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 Principal Safety Standards. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

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.

cuits 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.

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

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

l Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

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

unit.

l Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

l Do not connect to any electrical distribution system normally sup-

plied by utility power unless a proper transfer switch and grounding procedure are employed.

The input power circuit and machine internal cir-

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid these hazards.

l Disconnect input power or stop engine before installing or servic-

ing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

l Properly install, ground, and operate this equipment according to

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

l 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.

l When making input connections, attach proper grounding conduc-

tor first—double-check connections.

l Keep cords dry, free of oil and grease, and protected from hot met-

al and sparks.

l Frequently inspect input power cord and ground conductor for

damage or bare wiring — replace immediately if damaged —bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

l Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be present.

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

or worktable as near the weld as practical.

l Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

l Do not connect more than one electrode or work cable to any sin-

gle weld output terminal. Disconnect cable for process not in use.

l Use GFCI protection when operating auxiliary equipment. Test

GFCI receptacles at high speed.

HOT PARTS can burn.

l Do not touch hot parts bare handed. l Allow cooling period before working on equipment. l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

OM-289543 Page 1

FLYING METAL OR DIRT can injure

eyes.

l Welding, chipping, wire brushing, and grinding

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

l Wear approved safety glasses with side shields even under your

welding helmet.

FUMES AND GASES can be

hazardous.

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

l Keep your head out of the fumes. Do not breathe the fumes. l Ventilate the work area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

l If ventilation is poor, wear an approved air-supplied respirator. l Read and understand the Safety Data Sheets (SDSs) and the

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

l Work in a confined space only if it is well ventilated, or while wear-

ing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

l Do not weld in locations near degreasing, cleaning, or spraying

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

l Do not weld on coated metals, such as galvanized, lead, or cadmi-

um plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

l Shut off compressed gas supply when not in use.

l Always ventilate confined spaces or use approved

air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

l Wear an approved welding helmet fitted with a proper shade of fil-

ter lenses 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).

l Wear approved safety glasses with side shields under your

helmet.

l Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

WELDING can cause fire or

explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying

sparks, hot workpiece, and hot equipment can cause fires and burns.

OM-289543 Page 2

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.

l Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

l Do not weld where flying sparks can strike flammable material. l Protect yourself and others from flying sparks and hot metal. l Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

l Do not cut or weld on tire rims or wheels. Tires can explode if

heated. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

l Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 (see Safety Standards).

l Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

l 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, sparks, and fire hazards.

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

tact tip when not in use.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

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

from your person before doing any welding.

l After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

l Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

l Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

l Read and understand the Safety Data Sheets (SDSs) and the

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

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

l Wear approved ear protection if noise level is high.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

l Wearers of Pacemakers and other Implanted Med-

ical Devices should keep away.

l Implanted Medical Device wearers should consult their doctor and

the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the weld-

ing process, be sure to treat them carefully.

l Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

l Keep cylinders away from any welding or other electrical circuits. l Never drape a welding torch over a gas cylinder. l Never allow a welding electrode to touch any cylinder. l Never weld on a pressurized cylinder—explosion will result. l Use only correct compressed gas cylinders, regulators, hoses,

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

1-3. Engine Hazards

l Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

l Keep protective cap in place over valve except when cylinder is in

use or connected for use.

l Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

l Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

BATTERY EXPLOSION can injure.

l Always wear a face shield, rubber gloves, and pro-

tective clothing when working on a battery.

l Stop engine before disconnecting or connecting

battery cables, battery charging cables (if applica-

ble), or servicing battery.

l Do not allow tools to cause sparks when working on a battery. l Do not use welder to charge batteries or jump start vehicles unless

the unit has a battery charging feature designed for this purpose.

l Observe correct polarity (+ and -) on batteries. l Disconnect negative (-) cable first and connect it last. l Keep sparks, flames, cigarettes, and other ignition sources away

from batteries. Batteries produce explosive gases during normal operation and when being charged.

l Follow battery manufacturer’s instructions when working on or

near a battery. See Battery Service Manual (listed in Safety Standards) for additional information.

FUEL can cause fire or explosion.

ENGINE HEAT can cause fire.

l Stop engine and let it cool off before checking or

adding fuel.

l Do not add fuel while smoking or if unit is near any

sparks or open flames.

l Do not overfill tank — allow room for fuel to expand. l Do not spill fuel. If fuel is spilled, clean up before starting engine. l Dispose of rags in a fireproof container. l Always keep nozzle in contact with tank when fueling. l Do not locate unit on, over, or near combustible surfaces or

flammables.

l Keep exhaust and exhaust pipes way from flammables.

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

keep engine from kicking back or starting.

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

components.

EXHAUST SPARKS can injure.

l Do not let engine exhaust sparks cause fire.

l Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

HOT PARTS can burn.

l Do not touch hot parts bare handed.

l Allow cooling period before working on equipment.

l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

STEAM AND HOT COOLANT can

burn.

l If possible, check coolant level when engine is cold

to avoid scalding.

l Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

l If the engine is warm, checking is needed, and there is no overflow

tank, follow the next two statements.

l Wear safety glasses and gloves and put a rag over radiator cap.

l Turn cap slightly and let pressure escape slowly before completely

removing cap.

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts,

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

l Stop engine before installing or connecting unit. l Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

l To prevent accidental starting during servicing, disconnect nega-

tive (-) battery cable from battery.

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

parts.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

Using a generator indoors CAN KILL

YOU IN MINUTES.

l Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

l NEVER use inside a home or garage, EVEN IF doors and windows are open.

l Only use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and

EYES.

l Do not tip battery.

l Replace damaged battery.

l Flush eyes and skin immediately with water.

OM-289543 Page 3

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can

injure or kill.

l Incorrect installation or operation of this unit could

result in equipment failure and personal injury. On-

ly qualified persons should install, operate, and service this unit according to its Owner’s Manual, industry standards, and national, state, and local codes.

l Do not exceed the rated output or capacity of the compressor or

any equipment in the compressed air system. Design compressed air system so failure of any component will not put people or property at risk.

l Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.

l Do not work on compressed air system with unit running unless

you are a qualified person and following the manufacturer’s instructions.

l Do not modify or alter compressor or manufacturer-supplied

equipment. Do not disconnect, disable, or override any safety equipment in the compressed air system.

l Use only components and accessories approved by the

manufacturer.

l Keep away from potential pinch points or crush points created by

equipment connected to the compressed air system.

l Do not work under or around any equipment that is supported only

by air pressure. Properly support equipment by mechanical means.

HOT METAL from air arc cutting and

gouging can cause fire or explosion.

l Do not cut or gouge near flammables. l Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can injure or kill.

l Before working on compressed air system, turn off

and lockout/tagout unit, release pressure, and be

sure air pressure cannot be accidentally applied.

l Relieve pressure before disconnecting or connect-

ing air lines.

l Check compressed air system components and all

connections and hoses for damage, leaks, and

wear before operating unit.

l Do not direct air stream toward self or others.

l Wear protective equipment such as safety glasses, hearing pro-

tection, leather gloves, heavy shirt and trousers, high shoes, and a cap when working on compressed air system.

l Use soapy water or an ultrasonic detector to search for leaks—

never use bare hands. Do not use equipment if leaks are found.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting unit.

l If ANY air is injected into the skin or body seek medical help

immediately.

BREATHING COMPRESSED AIR can

injure or kill.

l Do not use compressed air for breathing. l Use only for cutting, gouging, and tools.

TRAPPED AIR PRESSURE AND

WHIPPING HOSES can injure.

l Release air pressure from tools and system before

servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

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

parts.

l Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.

l Have only qualified people remove guards or covers for mainte-

nance and troubleshooting as necessary.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

HOT PARTS can burn.

l Do not touch hot compressor or air system parts. l Allow cooling period before working on equipment. l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

READ INSTRUCTIONS.

l Read and follow all labels and the Owner’s Manual

carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

l Use only genuine replacement parts from the manufacturer. l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

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

FIRE OR EXPLOSION hazard.

l Do not install or place unit on, over, or near com-

bustible surfaces.

l Do not install unit near flammables.

l Do not overload building wiring — be sure power

supply system is properly sized, rated, and protected to handle this unit.

OM-289543 Page 4

l Use correct procedures and equipment of adequate capacity to lift

and support unit.

l If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

l Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

FALLING EQUIPMENT can injure.

l Use lifting eye to lift unit and properly installed ac-

cessories only, NOT gas cylinders. Do not exceed maximum lift eye weight rating (see Specifications).

l Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94-110) when manually lifting heavy parts or equipment.

OVERHEATING can damage motors.

l Turn off or unplug equipment before starting or

stopping engine.

l Do not let low voltage and frequency caused by

low engine speed damage electric motors.

l Use only equipment suitable for operation on 60 or 50/60 Hz

power.

FLYING SPARKS can injure.

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

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

l Sparks can cause fires—keep flammables away.

MOVING PARTS can injure.

l Keep away from moving parts.

l Keep away from pinch points such as drive rolls.

BATTERY CHARGING OUTPUT and

BATTERY EXPLOSION can injure.

Battery charging not present on all models.

HIGH PRESSURE FLUIDS can injure

or kill.

l Engine fuel system components can be under high

pressure.

l Before working on fuel system, turn off engine to

release pressure.

l If any fluid is injected into the skin or body seek medical help

immediately.

WELDING WIRE can injure.

l Do not press gun trigger until instructed to do so. l Do not point gun toward any part of the body, other

people, or any metal when threading welding wire.

OVERUSE can cause

OVERHEATING.

l Allow cooling period; follow rated duty cycle. l Reduce current or reduce duty cycle before start-

ing to weld again.

l Do not block or filter airflow to unit.

STATIC (ESD) can damage PC

boards.

l Put on grounded wrist strap BEFORE handling

boards or parts.

l Use proper static-proof bags and boxes to store,

move, or ship PC boards.

tective clothing when working on a battery.

l Always wear a face shield, rubber gloves, and pro-

l Stop engine before disconnecting or connecting battery cables,

battery charging cables (if applicable), or servicing battery.

l Do not allow tools to cause sparks when working on a battery. l Do not use welder to charge batteries or jump start vehicles unless

it has a battery charging feature designed for this purpose.

l Observe correct polarity (+ and -) on batteries. l Disconnect negative (-) cable first and connect it last. l Keep sparks, flames, cigarettes, and other ignition sources away

from batteries. Batteries produce explosive gases during normal operation and when being charged.

l Follow battery manufacturer’s instructions when working on or

near a battery. See Battery Service Manual (listed in Safety Standards) for additional information.

l Have only qualified persons do battery charging work. l If battery is being removed from a vehicle for charging, disconnect

negative (-) cable first and connect it last. To prevent an arc, make sure all accessories are off.

l Charge lead-acid batteries only. Do not use battery charger to sup-

ply power to an extra-low-voltage electrical system or to charge dry cell batteries.

l Do not charge a frozen battery. l Do not use damaged charging cables. l Do not charge batteries in a closed area or where ventilation is

restricted.

l Do not charge a battery that has loose terminals or one showing

damage such as a cracked case or cover.

l Before charging battery, select correct charger voltage to match

battery voltage.

l Set battery charging controls to the Off position before connecting

to battery. Do not allow battery charging clips to touch each other.

l Keep charging cables away from vehicle hood, door, or moving

parts.

TILTING OF TRAILER can injure.

l Use tongue jack or blocks to support weight. l Properly install welding generator onto trailer ac-

cording to instructions supplied with trailer.

RECYCLE.

l Recycle or dispose of used liquids in an environ-

mentally safe way. This is especially true for engine fluids such as drain oil and used coolant; this is also important for coolant from torch/gun cooling

systems.

l Contact your local recycling office or your local distributor for infor-

mation about how to dispose of parts and equipment in an environmentally safe way.

READ INSTRUCTIONS.

l Read and follow all labels and the Owner’s Manual

carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

l Use only genuine replacement parts from the manufacturer. l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

H.F. RADIATION can cause

interference.

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

gation, safety services, computers, and communications equipment.

l Have only qualified persons familiar with electronic equipment per-

form this installation.

l The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

OM-289543 Page 5

l If notified by the FCC about interference, stop using the equipment

at once.

l Have the installation regularly checked and maintained. l 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.

ARC WELDING can cause

interference.

l Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,

computers, and computer-driven equipment such as robots.

1-6. California Proposition 65 Warnings

WARNING – This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65Warnings.ca.gov.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian Standards Association. Website: www.csagroup.org.

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

l Be sure all equipment in the welding area is electromagnetically

compatible.

l To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

l Locate welding operation 100 meters from any sensitive electronic

equipment.

l Be sure this welding machine is installed and grounded according

to this manual.

l 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.

For Diesel Engines:

WARNING – Breathing diesel engine exhaust exposes you to chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

ll Always start and operate the engine in a well−ventilated

area.

ll If in an enclosed area, vent the exhaust to the outside. ll Do not modify or tamper with the exhaust system. ll Do not idle the engine except as necessary.

For more information, go to www.P65Warnings.ca.gov/diesel.

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U.S. Consumer Prod-

uct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National Fluid Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Website: www.batterycouncil.org.

ROM 2022–01

1-8. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers

−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

OM-289543 Page 6

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! – Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

AVIS – Indique des déclarations pas en relation avec des blessures personnelles.

Indique des instructions spécifiques.

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

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de ce symbole, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les Normes de sécurité principales. Lire et suivre toutes les Normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec succès sa capacité à résoudre les problèmes liés à la tâche, le travail ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.

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

cuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce 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.

l Ne jamais toucher les pièces électriques sous tension. l Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

l S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

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

l Ne pas utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

l Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

l Si l’utilisation d’une source électrique à courant électrique s’avère

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

l Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a un risque important

sous tension dès que l’appareil est sur ON. Le cir-

Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout danger.

de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder DC semi-automatique de type CV (MIG/MAG), 2) un poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul!

l Ne brancher aucun système de distribution électrique normale-

ment fourni par un réseau public à moins qu’un commutateur de transfert et une procédure de mise à la terre adéquats ne soient mis en place.

l 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).

l Installer et mettre à la terre correctement cet appareil conformé-

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

l Toujours vérifier la terre du cordon d’alimentation - Vérifier et s’as-

surer 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.

l En effectuant les raccordements d’entrée fixer d’abord le conduc-

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

l Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez-les contre les étincelles et les pièces métalliques chaudes.

l Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -, le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraîner la mort.

l Mettre l’appareil hors tension quand on ne l’utilise pas. l Ne pas utiliser des câbles usés, endommagés, sous dimension-

nés ou réparés.

l Ne pas enrouler les câbles autour du corps. l 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.

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

la terre ou une électrode provenant d’une autre machine.

l Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide doublée.

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

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

OM-289543 Page 7

l Ne pas toucher aux portes-électrodes qui sont raccordés à deux

machines à souder en même temps, car cela entraîne la présence d’une tension de circuit-ouvert double.

l Porter un harnais de sécurité quand on travaille en hauteur. l Maintenir solidement en place tous les panneaux et capots. l Fixer le câble 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.

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

contact avec tout objet métallique.

l Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.

l Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliai-

res. Testez les prises GFCI à haute vitesse.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues. l Prévoir une période de refroidissement avant de

travailler à l’équipement.

l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.

l 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 risquent de projeter du laitier.

l Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent être dangereux.

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

l Eloigner votre tête des fumées. Ne pas respirer les fumées. l À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquelles est exposé le personnel.

l Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

l Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant 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.

l Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, 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.

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

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit

OM-289543 Page 8

bien ventilé, et 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.

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

l Fermer l’alimentation du gaz comprimé en cas de

non utilisation.

l Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

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

l Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

l Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-

téger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles

peuvent être projetées de 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.

l 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.

l Ne pas souder dans un endroit là où des étincelles peuvent tom-

ber sur des substances inflammables.

l Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

l Des étincelles et des matériaux chauds du soudage peuvent faci-

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

l Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

l Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

l Ne pas couper ou souder des jantes ou des roues. Les pneus peu-

vent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les normes de sécurité.

l Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les Normes de Sécurité).

l Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

l Brancher le câble de masse 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, d’étincelles et d’incendie.

l Ne pas utiliser le poste de soudage pour dégeler des conduites

gelées.

l En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

l Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

l Une fois le travail achevé, assurez-vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

l Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

l Suivre les recommandations dans OSHA 1910.252 (a) (2) (iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

Le BRUIT peut endommager l’ouïe.

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

l Porter des protections approuvées pour les oreilles

si le niveau sonore est trop élevé.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

l Les porteurs de stimulateurs cardiaques et autres

implants médicaux doivent rester à distance.

l Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz comprimé 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.

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

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

l Placer les bouteilles debout en les fixant dans un support station-

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

l Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

l Ne jamais souder une bouteille pressurisée - risque d’explosion. l Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

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

l Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière lerégulateur lors de l’ouverture de la vanne.

l Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisation ou de branchement de la bouteille.

l Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter les bouteilles.

l Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peut

provoquer des blessures.

l Toujours porter une protection faciale, des gants

en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.

l Arrêter le moteur avant de débrancher ou de brancher des câbles

de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien.

l Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

l Ne pas utiliser l’appareil de soudage pour charger des batteries

ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

l Observer la polarité correcte (+ et -) sur les batteries. l Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

l Les sources d’étincelles, flammes nues, cigarettes et autres sour-

ces d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge.

l Suivre les instructions du fabricant de la batterie lors d’opérations

sur une batterie ou à proximité de celle-ci. Voir le manuel de service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.

l Arrêter le moteur avant de vérifier le niveau de carburant ou de

faire le plein.

l Ne pas faire le plein en fumant ou proche d’une source d’étincelles

ou d’une flamme nue.

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

pour son expansion.

l Faire attention de ne pas renverser de carburant. Nettoyer tout

carburant renversé avant de faire démarrer le moteur.

l Jeter les chiffons dans un récipient ignifuge. l Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. LA CHALEUR DU MOTEUR peut provoquer un incendie.

OM-289543 Page 9

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

inflammables.

l Tenir à distance les produits inflammables de l’échappement.

l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

Les PIÈCES MOBILES peuvent

causer des blessures.

l S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs deprotection.

l Arrêter le moteur avant d’installer ou brancher l’appareil. l Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

l Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien, débrancher le câble négatif (-) de batterie delaborne.

l Ne pas approcher les mains, cheveux, vêtements lâches etoutils

des organes mobiles.

l Remettre en place les portes, panneaux, recouvrements ou dispo-

sitifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche.

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

mise en route accidentelle du moteur.

l Bloquer le volant moteur pour éviter sa rotation lors d’une inter-

vention sur le générateur.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

l Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

l Utiliser uniquement un pare-étincelles approuvé - voir codes en

vigueur.

LES PIÈCES CHAUDES peuvent provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues. l Prévoir une période de refroidissement avant de

travailler à l’équipement.

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

l Il est préférable de vérifier le liquide de refroidisse-

ment une fois le moteur refroidi pour éviter de se

brûler.

l Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

comme suivant.

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

le bouchon du radiateur.

l Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.

l Les fumées d’un groupe autonome contient du mo-

noxyde de carbone. C’est un poison invisible et

inodore.

l JAMAIS utiliser dans une maison ou garage, même avec les por-

tes et fenêtres ouvertes.

l Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX ET SUR LA PEAU.

l Ne pas renverser la batterie. l Remplacer une batterie endommagée.

l Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé

Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort.

l Une installation ou une utilisation incorrecte de cet

appareil pourrait conduire à des dégâts matériels

ou corporels. Seul un personnel qualifié est autorisé à installer, utiliser et entretenir cet appareil conformément à son manuel d’utilisation, aux normes industrielles et aux codes nationaux, d’état ou locaux.

l Ne pas dépasser le débit nominal ou la capacité du compresseur

ou de tout équipement du circuit d’air comprimé. Concevoir le circuit d’air comprimé de telle sorte que la défaillance d’un composant ne risque pas de provoquer un accident matériel ou corporel.

l Avant d’intervenir sur le circuit d’air comprimé, couper l’alimenta-

tion électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance.

l Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil

fonctionne. Seul un personnel qualifié est autorisé, et appliquant les consignes du fabricant.

l Ne pas modifier ou altérer le compresseur ou les équipements

fournis par le fabricant. Ne pas débrancher, désactiver ou neutraliser les équipements de sécurité du circuit d’air comprimé.

OM-289543 Page 10

l Utiliser uniquement des composants et accessoires homologués

par le fabricant.

l Se tenir à l’écart de tout point présentant un danger de pincement

ou d’écrasement créé par l’équipement raccordé au circuit d’air comprimé.

l Ne pas intervenir sous ou autour d’un équipement qui n’est soute-

nu que par la pression pneumatique. Soutenir l’équipement de façon appropriée par un moyen mécanique.

MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion.

l Ne pas découper ou gouger à proximité de pro-

duits inflammables.

l Attention aux risques d’incendie: tenir un extincteur à proximité.

L’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort.

l Avant d’intervenir sur le circuit d’air comprimé,

couper l’alimentation électrique, verrouiller etétiqueter l’appareil, détendre la pression ets’assurer que le circuit d’air ne peut être mis sous pression par inadvertance.

l Détendre la pression avant de débrancher ou de

brancher des canalisations d’air.

l Avant d’utiliser l’appareil, contrôler lescomposants du circuit d’air

comprimé, lesbranchements et les flexibles en recherchant tout signe de détérioration, de fuite et d’usure.

l Ne pas diriger un jet d’air vers soi-même ou vers autrui. l Pour intervenir sur un circuit d’air comprimé, porter unéquipement

de protection tel que des lunettes de sécurité, des gants de cuir, une chemise et un pantalon en tissu résistant, des chaussures montantes et une coiffe.

l Pour rechercher des fuites, utiliser de l’eau savonneuse ou undé-

tecteur à ultrasons, jamais les mains nues. En cas dedétection de fuite, ne pas utiliser l’équipement.

l Remettre les portes, panneaux, recouvrements ou dispositifs de-

protection quand l’entretien est terminé et avant de mettre enmarche l’appareil.

l En cas d’injection d’air dans la peau ou le corps, demander immé-

diatement une assistance médicale.

L’INHALATION D’AIR COMPRIMÉ risque de provoquer des blessures ou même lamort.

l Ne pas inhaler d’air comprimé. l Utiliser l’air comprimé uniquement pour découper

ou gouger ainsi que pour l’outillage pneumatique.

Une PRESSION D’AIR RÉSIDUELLE ETDES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures.

l Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile ducompresseur.

Les PIÈCES MOBILES peuvent

causer des blessures.

l S’abstenir de toucher des parties mobiles telles

que des ventilateurs, courroies et rotors.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protection.

l Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

l Avant d’intervenir sur le circuit d’air comprimé, couper l’alimenta-

tion électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance.

l Demander seulement à un personnel qualifié d’enlever les disposi-

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

l Remettre en place les portes, panneaux, recouvrements ou dispo-

sitifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

l Ne pas toucher de pièces chaudes du compresseur

ou du circuit d’air.

l Prévoir une période de refroidissement avant d’in-

tervenir sur l’équipement.

l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

LIRE LES INSTRUCTIONS.

l Lire et appliquer les instructions sur les étiquettes

et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque

section.

l N’utiliser que des pièces de remplacement provenant du fabricant.

l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

2-5. Symboles de dangers supplémentaires en relation avec l’installation, le

fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

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

mité de surfaces inflammables.

l Ne pas installer l’appareil à proximité de produits inflammables

l Ne pas surcharger l’installation électrique – s’assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

l Utiliser seulement l’anneau de levage pour soule-

ver l’appareil et des accessoires correctement in-

stallés, non pas les bouteilles de gaz. Ne pas dépasser les capacités maximales de l’anneau de levage (voir Spécifications).

l Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

l 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.

l Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

l Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication № 94–110) lors du levage manuelle de pièces ou équipements lourds.

LE SURCHAUFFEMENT peut

endommager le moteur électrique.

l Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

l 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.

OM-289543 Page 11

l Utiliser uniquement des équipements adéquats pour un fonction-

nement avec une alimentation de 50/60 ou de 60 Hz.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

l Porter un écran facial pour protéger le visage et

les yeux.

l Affûter l'électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du visage, des mains et du corps.

l Les étincelles risquent de causer un incendie - éloigner toute sub-

stance inflammable.

Les PIÈCES MOBILES peuvent

causer des blessures.

l Ne pas s’approcher des organes mobiles.

l Ne pas s’approcher des points de coincement tels

que des rouleaux de commande.

LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent provoquer des blessures.

La recharge de batterie n’existe pas sur tous les modèles.

l Toujours porter une protection faciale, des gants en caoutchouc et

vêtements de protection lors d’une intervention sur la batterie.

l Arrêter le moteur avant de débrancher ou de brancher des câbles

de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien.

l Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

l Ne pas utiliser l’appareil de soudage pour charger des batteries

ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

l Observer la polarité correcte (+ et -) sur les batteries. l Débrancher le câble négatif (-) en premier lieu. Le rebrancher en

dernier lieu.

l Les sources d’étincelles, flammes nues, cigarettes et autres sour-

ces d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge.

l Suivre les instructions du fabricant de la batterie lors d’opérations

sur une batterie ou à proximité de celle-ci. Voir le manuel de service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.

l Les opérations de charge de batterie ne doivent être effectuées

que par des personnes qualifiées.

l Pour enlever la batterie d’un véhicule pour la recharge, débran-

cher tout d’abord le câble négatif (-) et le rebrancher en dernier lieu. Pour éviter un arc, s’assurer que tous les accessoires sont débranchés.

l Ne charger que des batteries plomb-acide. Ne pas utiliser le char-

geur de batterie pour alimenter un autre circuit électrique basse tension ou pour charger des batteries sèches.

l Ne pas charger une batterie gelée. l Ne pas utiliser de câbles de charge endommagés. l Ne pas charger des batteries dans un espace fermé ou en l’ab-

sence d’une ventilation.

l Ne pas charger une batterie dont les bornes sont desserrées ou

présentant une détérioration comme par exemple un boîtier ou un couvercle fissuré.

l Avant de charger une batterie, sélectionner la tension de charge

correspondant à la tension de la batterie.

OM-289543 Page 12

l Régler les commandes de charge de batterie sur la position d’arrêt

avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

l Ranger les câbles de charge à distance du capot, des portes et

des pièces mobiles du véhicule.

LES LIQUIDES PRESSURISÉS

peuvent blesser ou tuer.

l Les composants du système d’alimentation peu-

vent contenir du carburant sous pression élevée.

l Avant d’intervenir sur le système d’alimentation de

carburant, arrêter le moteur pour dépressuriser le système.

l En cas d’injection de tout liquide sous la peau ou dans le corps,

solliciter une aide médicale sur le champ.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

l Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

l Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

l Laisser l’équipement refroidir ; respecter le facteur

de marche nominal.

l Réduire le courant ou le cycle opératoire avant de

recommancer le soudage.

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

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

l Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

l Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut provoquer des blessures.

l Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

l Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

RECYCLER.

l Recycler ou éliminer les liquides usagés d’une ma-

nière respectueuse de l’environnement. Cela est particulièrement vrai pour les fluides du moteur tels que l’huile de vidange et le liquide de refroidisse-

ment usagés ; ceci est également important pour le liquide de refroidissement provenant des systèmes de refroidissement de la torche/du pistolet.

l Contactez votre bureau de recyclage local ou votre distributeur lo-

cal pour obtenir des informations sur la manière de mettre au rebut les pièces et l’équipement d’une manière respectueuse de l’environnement.

LIRE LES INSTRUCTIONS.

l Lire et appliquer les instructions sur les étiquettes

et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque

section.

l N’utiliser que des pièces de remplacement provenant du fabricant.

l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

l Le rayonnement haute fréquence (H. F.) peut pro-

voquer des interférences avec les équipements de

radio-navigation et de communication, les services de sécurité et les ordinateurs.

l Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installation.

l L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

l Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

l Effectuer régulièrement le contrôle et l’entretien de l’installation. l 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 un blindage pour réduire les interférences éventuelles.

commandé par ordinateur tel que les robots.

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

compatible électromagnétiquement.

l Pour réduire la possibilité d’interférence, maintenir les câbles de

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

l Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

l Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

l En cas d’interférences après avoir pris les mesures précédentes,

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

2-6. Proposition californienne 65 Avertissements

AVERTISSEMENT – ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

Pour les moteurs diesel :

Pour plus d’informations, consulter www.P65Warnings.ca.gov/diesel.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

l L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement

AVERTISSEMENT – les gaz d’échappement de moteurs diesel vous exposent à des produits chimiques, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.

ll Toujours démarrer et faire tourner le moteur dans une

zone bien aérée.

ll Si la zone est fermée, diriger l’échappement vers

l’extérieur.

ll Ne pas modifier ni altérer le système d’échappement. ll Ne pas faire tourner le moteur au ralenti, sauf si

nécessaire.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www. csa-

group.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian Standards Association. Website: www.csagroup.org.

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Ins-

titute. Website: www.ansi.org.

2-8. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U. S. Consumer Pro-

duct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National Fluid Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Website: www.batterycouncil.org.

ROM_fre 2022–01

de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour

OM-289543 Page 13

les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

OM-289543 Page 14

Complete Parts List is available at www.HobartWelders.com

Become trained and read the instructions before working on the machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground terminal. Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

Never use generator inside a home or garage, even if doors and win- dows are open.

Safe87 2012 07

Become trained and read the instructions before working on the machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground terminal. Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

Never use generator inside a home or garage, even if doors and win- dows are open.

Safe87 2012 07

Only use generator outside and far away from windows, doors, and vents.

Safe88 2012 07

SECTION 3 – DEFINITIONS

3-1. Additional Safety Symbol Definitions

Some symbols are found only on CE products.

3-2. Miscellaneous Symbol Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Never use generator inside a home or garage, even if doors and windows are open.

Only use generator outside and far away from windows, doors, and vents.

Amperage

Voltage

Seconds

Rated No-Load

Voltage (OCV)

Conventional Load

Voltage

Rated Welding

Current

Hours

Duty Cycle

Negative

Alternating Current

(AC)

Protective Earth

(Ground)

Output

Work Connection

Engine Temperature

Circuit Breaker

Supplementary

Protector

Clock

Engine Choke

Engine Start

Run (Fast)

Engine

Air Filter

Battery (Engine)

Fuel

Engine Oil

Check Valve

Clearance

Call for

Maintenance

Read Operator’s

Manual

Positive

Direct Current (DC)

Engine Stop

Idle (Slow)

Engine-Driven

Generator with

Rectifier

Do Not Switch While Welding

OM-289543 Page 15

Complete Parts List is available at www.HobartWelders.com

Shielded Metal Arc

Welding (SMAW)

Welding

Single Phase

Alternator

Hertz

Single Phase

OM-289543 Page 16

Complete Parts List is available at www.HobartWelders.com

SECTION 4 – SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number for this product is located on the front. The rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Hobart products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Hobart expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.

4-3. Weld, Power, And Carbureted Engine Specifications

This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C).

Welding

Mode

CC/DC 225A, 29V* 94.5V 20–235A

* Meets NEMA and IEC Ratings.

Rated Welding

Output

100% Duty

Cycle at 40° C

Maximum

Open-Circuit

Voltage

Weld

Output

Range

Generator Power Rating

Peak: 10.0 kVA/kW

Continuous: 9.5 kVA/kW,

40 A, 240 V AC, 20 A, 120 V AC,

60 Hz Single-Phase

Fuel

Capacity

11 Gallons

(42 L)

Engine Fuel Type

Vanguard 23

Air-Cooled, Two

Cylinder, Four-

Cycle,

23 HP Gasoline

Engine

Gasoline

Up to 10%

Ethanol

4-4. Environmental Specifications

A. IP Rating

IP Rating

IP23S

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

–20 to 104°F (–29 to 40°C) –40 to 131°F (–40 to 55°C)

*Output is derated at temperatures above 104°F (40°C).

sheltered.

OM-289543 Page 17

Complete Parts List is available at www.HobartWelders.com

P Q

DEPTH

15° 15°

15°

G G

WIDTH

HEIGHT

4-5. Base Unit Dimensions, Weights, And Operating Angles

Dimensions

External Dimensions

Height (With Exhaust) 31.16

Width 20.13 in. (511 mm)

Depth 37.06 in. (941 mm)

A 26.5 in. (673 mm) B 36.88 in. (937 mm) C 20 in. (508 mm) D 29.38 in. (746 mm) E (Top Door Clearance)

F (Output Cover Clear-

G (Side Door Clearance)

Exhaust Pipe Location

H 3.85 in. (98 mm)

J 3.51 in. (89 mm)

Fuel Fill Location

K 27.95 in. (710 mm)

L 1.88 in. (48 mm)

Top Door Location

M 15.33 in. (389 mm)

N 12.16 in. (309 mm) P 2.4 in. (61 mm) Q 15.2 in. (386 mm)

Mounting Hole Location

R 3.18 in. (81 mm) S 22.31 in. (567 mm) T 1.72 in. (44 mm) U 16.56 in. (421 mm) V 0.406 in. (10.31 mm)

Lifting Eye Weight Rating:

in. (791 mm)

11.91 in. (303 mm)

ance) 5.52 in. (140

mm)

9.97 in. (253 mm)

Weight

385 lb (175 kg)

1100 lb (499 kg)

Do not exceed tilt angles or engine could be damaged or unit could tip.

Do not move or operate unit where it could tip.

Do not operate suspended from lifting eye.

OM-289543 Page 18

Complete Parts List is available at www.HobartWelders.com

Continuous Welding

A or V

Reduce Duty Cycle

Minutes

Volts

Amps

20 AMP

140 AMP 225 AMP

100

0 50 100

150

200 250 300 350

4-6. Duty Cycle And Overheating

100% Duty Cycle at 225 Amperes DC

Overheating

4-7. Volt-Ampere Curves

STICK (CC Mode)

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

This unit is rated for welding at 225 am-

peres continuously.

NOTICE – Exceeding duty cycle can damage unit and void warranty.

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

OM-289543 Page 19

4-8. Fuel Consumption

0 2000 4000 6000 8000 10000

WATTS

Run No-Load

Idle

Aux Power

0.00

0.50

1.00

1.50

2.00

U.S. GAL/HR.

LITERS/HR.

1.89

3.78

5.67

7.57

0 50 100 150 200

230

AMPERES

Weld

Run No-Load

Idle

0.00

0.50

1.00

1.50

2.00

U.S. GAL/HR.

LITERS/HR.

1.89

3.78

5.67

7.57

Complete Parts List is available at www.HobartWelders.com

Auxiliary Fuel Consumption

Weld Fuel Consumption

The curves show typical fuel use under auxiliary and weld loads.

OM-289543 Page 20

Complete Parts List is available at www.HobartWelders.com



Complete Parts List available at www.MillerWelds.com

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

SECTION 5 – INSTALLATION

5-1. Installing Welder/Generator

Movement

Location/Airflow Clearance

Do not move or operate unit where it could tip.

Do not lift unit from end.

Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

NOTICE – Do not install unit where airflow is restricted or engine may overheat.

See Specifications for lifting eye rating.

Mounting:

Do not mount unit by supporting the base only at the four mounting holes. Do not use flexible mounts. Use cross-supports to adequately support unit and prevent damage to base.

1 Cross-Supports

Mount unit on flat surface or use cross-supports to support base.

Go to MillerWelds. com for more infor-

mation on truck installations.

Mounting

OM-289543 Page 21

Complete Parts List is available at www.HobartWelders.com

1-1. Grounding Generator To Truck Or Trailer Frame

GND/PE

5-2. Grounding Generator to Truck or Trailer Frame

Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards.

Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

5-3. Ground Cable Routing

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

1 Equipment Grounding Terminal (On

Front Panel)

2 Grounding Cable (Not Supplied)

3 Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire.

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

See Section 5-2 prior to routing ground-

ing wire.

1 Equipment Grounding Stud

2 Grounding Cable

3 Grounding Cable Retention Clip

Route cable from equipment grounding terminal to metal frame through cable retention clip.

Use #8 AWG insulated copper wire.

OM-289543 Page 22

Complete Parts List is available at www.HobartWelders.com

5-4. Installing Exhaust Pipe

Stop engine and let cool.

Engine backfire can cause severe burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet.

Do not point exhaust pipe toward LP fuel tank (if equipped). Do not point exhaust pipe towards shielding gas tank (if equipped).

Point exhaust pipe in desired direction but always away from front panel and direction of travel.

1/2 in.

OM-289543 Page 23

Complete Parts List is available at www.HobartWelders.com

5-5. Engine Prestart Checks

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with synthetic blend 10W-30 engine oil.

Follow run-in procedure in engine

manual.

This unit has a low oil pressure 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 pressure shutdown system to monitor oil level.

Fuel

1 Fuel Fill Cap

Add fresh fuel before starting engine the first time (see maintenance label for specifications). Stop fueling when fuel reaches bottom of fuel fill bowl. Do not overfill. Fuel tank has built in air expansion volume. Do not top off tank. Check fuel level on a cold engine before use each day.

To check fuel level, turn Engine Control switch to Run/Idle position. Fuel/hourmeter indicates fuel level in tank.

Oil

Open top service door.

2 Oil Fill 3 Oil Check

Do not exceed the "Full" mark on the oil

level dipstick. The fuel pump may operate erratically if crankcase is overfilled.

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

Use fuel/hourmeter to determine hours until next recommended oil change (see Front Panel Controls).

To improve cold weather starting:

Keep battery in good condition. Store battery in warm area. Use correct grade oil for cold weather.

Close top service door.

OM-289543 Page 24

Complete Parts List is available at www.HobartWelders.com

OFF

RUN

RUN/IDLE

START

5-6. Connecting Or Replacing The Battery

Connect negative (-) battery cable last.

Battery is most easily accessed through the side door. Connect battery, negative cable last. Close access door.

l Do not allow the battery cables to touch

opposing terminals. When connecting the battery cables attach the positive (+) cable to the positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal.

l Never start the engine when the cables

are loose or poorly connected to the battery terminals.

l Never disconnect the battery while the

engine is running.

l Never use a quick battery charger to

start the engine.

l Do not charge battery with Engine Con-

trol switch On.

l Always disconnect the negative (-) bat-

tery cable before charging battery.

3/8, 1/2 in.

1 Battery Holddown

To change battery, remove rear panel and battery holddown.

Be sure battery cables and fuel tank vent hose are not pinched when installing battery and replacing rear panel.

OM-289543 Page 25

OFF

RUN

RUN/IDLE

START



Complete Parts List available at www.MillerWelds.com

5-7. Weld Output Terminals

Complete Parts List is available at www.HobartWelders.com

1 Positive Weld Output Terminal

2 Negative Weld Output Terminal

Connect electrode or torch cable to positive terminal for Direct Current Electrode Positive (DCEP) or the negative terminal for Direct Current Electrode Negative (DCEN).

Use Process Selector switch to select type of weld output (see Section 6-1).

Stop engine.

Turn off power before connecting to weld output terminals.

Do not use worn, damaged, undersized, or repaired cables.

See Section 6-3 for typical process

connections and control settings.

5-8. Connecting Weld Output Cables

Stop engine.

Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

3/4 in. (19 mm)

Do not place anything between weld

cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.

1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar

Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar.

OM-289543 Page 26

Complete Parts List is available at www.HobartWelders.com

5-9. Selecting Cable Sizes*

NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***

)

350 ft

(105 m)

100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m)

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) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, 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.

( ) = mm

***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding Society at http://www.aws.org.

10 - 60%

Duty Cycle

AWG (mm

for metric use.

)

60 - 100%

Duty Cycle

AWG (mm2)

10 - 100% Duty Cycle AWG (mm

400 ft

(120 m)

OM-289543 Page 27

3 4

SECTION 6 – OPERATION

6-1. Front Panel Controls

Complete Parts List is available at www.HobartWelders.com

1 Engine Control Switch

Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/ power speed under load. In Run position, engine runs at weld/power speed.

To Start: pull out choke and turn Engine Control switch to Start position. Release switch when engine starts. Slowly push in choke.

If the engine does not start, let engine

come to a complete stop before attempting restart.

During cold weather some gasoline en-

gines encounter difficulties that are easily remedied. See Section and Troubleshooting Tables.

To Stop: turn Engine Control switch to Off position.

2 Engine Hour Meter/Fuel Gauge/Idle

Control

Low fuel is indicated by a fuel icon flashing in the center of the display..

A maintenance interval is reached when the wrench icon appears in the display.

Hour Meter: With engine off, place Engine Control switch in Run/Idle position to view engine hours.

Oil Change Interval: With engine off, place Engine Control switch in the Run position to see hours before next oil change. Oil hours start at 100 and count down to 0 (zero) (oil change due).

Negative hours indicated when past

recommended oil change interval.

To reset, cycle Engine Control switch from Run/Idle to Run three times within five seconds (engine off).

3 Ampere Setting

Use control to select weld amperage.

Ranges for common electrode sizes are shown on exterior of dial.

See Section 6-3 for typical process

connections and control settings.

4 Choke

Use control to control fuel flow during cold engine starts.

OM-289543 Page 28

Complete Parts List is available at www.HobartWelders.com

6-2. Fuel/Hour Gauge Descriptions

1 Fuel Gauge Shows fuel level. 2 Low Fuel Warning Flashes when fuel level is low.

Hour Display

Oil Change Interval

4 Oil Change Indicator

5 Fault Indicator Illuminates if error is present. See Section 8-7 if illuminated.

With engine off and engine control switch in “RUN/IDLE” position, displays engine hours. See Section 6-1 for more information.

With engine off and engine control switch in “RUN” position, displays remaining hours to next oil change. Past due will display negative hours to –99.

Flashes when oil change is due. To Reset: While engine is off, toggle engine control switch between “RUN/IDLE” and “RUN” positions three times within 5 seconds.

6-3. Typical Stick Welding Connections And Control Settings

1 Work Clamp

2 Electrode Holder

Connect Work cable to Negative terminal and Electrode holder cable to Positive terminal on welding generator.

Typical Settings For 7018 (1/8 in.) Electrode:

Stop engine.

This section provides general guide-

lines and may not suit all applications.

Consult the amperage selection tables

in section 12-2 for general guidance

Be sure to use the correct size weld ca-

bles (see Section 5-9).

l Adjust welding output between 90 and

135 amps.

Miller recommends Hobart filler metals.

3/4 in.

OM-289543 Page 29

Complete Parts List is available at www.HobartWelders.com

6-4. Cold Weather Engine Operation

1 Run Position – For cold starts and en-

gine warm up

2 Run/Idle Position – For use after engine

is at operating temperature

Carburetor Icing

Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the relative humidity is high. Ice forms on the throttle plate and inner bore of the carburetor. The engine typically restarts without problems but soon stalls again.

l Treat gasoline with a fuel de-icer prod-

uct (isopropyl alcohol).

l Place the Engine Control switch in the

Run position.

l Run engine only when expecting to fre-

quently load it.

Breather Icing

Oil breather/pulse line icing occurs in severe cold (continuously below 0° F). Moisture accumulates in the oil from piston ring blow-by if the engine is extensively idled. This may cause vacuum line freezing, oil breather tube freezing or ice in the carburetor. All of these cause operating problems. Due to ice in the lines, the engine may not restart until it is warmed to above freezing.

l Load engine and reduce idle times to

prevent engine shutdowns.

l Use an electric fuel pump to avoid pulse

line freezing.

l Install engine cold-weather kit.

Kohler (1-800-544-2444) offers a kit for cold weather operation. The user can install this kit. The kit pulls heated air from the muffler surface into the carburetor and shut the cold

air off. This increases engine temperature during operation in both idle and high speed.

When the ambient temperatures be-

come warmer (above 45°F) the air flow will have to be returned to normal.

Synthetic Oil

For temperatures below zero (0° F), synthetic oil improves engine starting.

Do not extend the recommended oil

change interval when using synthetic oil.

In severe cold, use synthetic grade 5W-30 oil or synthetic grade 10W-30. See engine maintenance label for additional information.

OM-289543 Page 30

Complete Parts List is available at www.HobartWelders.com

1 6 2 5

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment.

Unplug power cord before attempting to service accessories or tools.

Generator power decreases as weld

current increases.

1 120 V 20 A AC Duplex Receptacle

(GFCI Receptacle, protects both duplex receptacles)

2 120 V 20 A AC Duplex Receptacle (Non-

GFCI Receptacle)

3 120/240 V 50 A AC Receptacle

4 240 V 50 A AC Receptacle

Duplex receptacles supply 120 V 60 Hz single-phase power at weld/power speed. Maximum output from duplex receptacles is 2.4 kVA/kW.

120/240 V receptacle supplies 240 V 60 Hz single-phase power at weld/power speed. Maximum output is 9.5 kVA/kW.

240 V receptacle supplies 240 V 60 Hz single-phase power at weld/power speed. Maximum output is 9.5 kVA/kW.

Test GFCI monthly. See Section 7-2 for GFCI information and for resetting and testing procedures.

5 Supplementary Protector CB1

CB1 protects all receptacles from overload. If CB1 opens, the receptacles do not work. Place switch in On position to reset.

6 Supplementary Protector CB3

CB3 protects duplex receptacles from overload. If a supplementary protector opens, the receptacles do not work.

Press button to reset supplementary

protector. If supplementary protector continues to open, contact Factory Authorized Service Agent.

Combined output of all receptacles limited to

9.5 kVA/kW rating of the generator.

EXAMPLE: If 20 A is drawn from a 120 V duplex receptacle, only 29 A is available at the 120/240V receptacle:

(120 V x 20 A) + (240 V x 29 A) = 9.5 kVA/ kW

OM-289543 Page 31

Complete Parts List is available at www.HobartWelders.com

7-2. GFCI Receptacle Information, Resetting, And Testing

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment.

Unplug power cord before attempting to service accessories or tools.

1 120 V 20 A AC GFCI Receptacle 2 GFCI Receptacle Test Button 3 GFCI Receptacle Reset Button 4 Red GFCI Indicator Light (LED) 5 Green GFCI Indicator Light (LED) 6 Alternate Location For Red And Green

Indicator LEDs

Red and Green indicator lights may be

combined in a single LED.

Orientation of receptacle may be differ-

ent in other applications.

GFCI Receptacles

GFCI receptacles protect the user from electric shock if a ground fault occurs in equipment connected to the receptacle. A ground fault occurs when electrical current takes the shortest path to ground (which could be through a person) rather than follow its intended safe path.

If a ground fault is detected, the GFCI Reset button pops out, and the circuit opens to disconnect power to the faulty equipment. A GFCI receptacle does not protect against circuit overloads, short circuits, or shocks not related to ground faults. Reset and test GFCI receptacle according to the following procedures.

A solid green LED indicates power to the GFCI. A solid red LED indicates that the GFCI has been tripped.

Resetting/Testing GFCI Receptacle

Test GFCI monthly.

If Red LED blinks, stop using GFCI receptacle and have a Factory Authorized Service Agent replace it.

Extension cords with bad insulation or of extended length can allow enough leakage current to trip the GFCI circuit. Reset and test as follows.

Resetting GFCI Receptacles

If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle. Check for damaged or wet tools, cords, plugs, etc. connected to the receptacle. Start engine, place engine control switch in RUN position, and press GFCI Reset button. Reconnect equipment to GFCI receptacle. If GFCI Reset button pops out again, check the equipment and repair or replace if faulty.

Testing GFCI Receptacles

Start engine and place engine control switch in Run position. Press the GFCI Test button. The GFCI Reset button should pop out.

Press the GFCI Reset button.

Have a Factory Authorized Service Agent replace GFCI if any of the following occur: GFCI does not trip when tested Red LED blinks GFCI does not reset.

OM-289543 Page 32

Complete Parts List is available at www.HobartWelders.com



Complete Parts List available at www.MillerWelds.com

240V

120V

240 V AC

120 V AC

NGO’s

tools/

NGO’s

tools/

flathead philips head wrench

knife

allen_set

needlenose

steelbrush nutdriver

chippinghammer

crescent wrench

7-3. Simultaneous Weld And Power

Weld Current in Amperes Total Power in Watts 120 V Full kVA (4 Wire) Recep-

tacle Amperes

260 1600 13 6 180 4600 38 19 125 6300 53 26

90 7300 61 30

0 9500 79 39

240 V Full kVA Receptacle

7-4. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 14-50P)

The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram.

1 Plug Wired for 120/240 V, 3-Wire Load

When wired for 120 V loads, both duplex receptacle share a load with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire Load

3 Neutral (Silver) Terminal

4 Load 1 (Brass)Terminal

5 Load 2 (Brass) Terminal

6 Ground (Green) Terminal

Amperes

Current Available in Amperes

240 V Receptacle* Total 120 V Duplex

Receptacles

0 20

5 20 10 20 15 20 20 20 25 15 30 10 35 5 40 0

V x A = Watts

*One 240 V load or two 120 V loads

OM-289543 Page 33

Complete Parts List is available at www.HobartWelders.com

NGO’s

tools/

NGO’s

tools/

flathead philips head wrench

knife

allen_set

needlenose

steelbrush nutdriver

chippinghammer

crescent wrench

7-5. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P)

The plug can be wired for a 240 V, 2-wire load.

1 Plug Wired for 240 V, 2-Wire Load

2 Load 1 (Brass)Terminal

3 Load 2 (Brass) Terminal

4 Ground (Green) Terminal

Current Available in Amperes

240 V Receptacle* Each 120 V Duplex

0 20

5 20 10 20 15 20 20 20 25 15 30 10 35 5 40 0

V x A = Watts

Receptacle

OM-289543 Page 34

Complete Parts List is available at www.HobartWelders.com

SECTION 8 – MAINTENANCE AND TROUBLESHOOTING

8-1. Routine Maintenance

Stop engine before maintaining.

See Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in

severe conditions.

Recycle engine fluids.

ü = Check ¶ = Replace m = Clean Reference

Every

Hours

ü Fuel Level ü Oil Level m Oil, Fuel Spills

Every

Hours

üm Spark Arrestor Screen

Every

Hours

m Air Cleaner Wrapper

Every

Hours

m Weld Terminals

Every

100

Hours

Section 5-5

Section 8-3

Engine Manual, Sections 8-3 and 8-5

m Battery Terminals m Cooling System ¶ Oil and Oil Filter ü¶ Air Cleaner Element

Every

200

Hours

¶ Unreadable Labels ¶ Spark Plug ¶ Fuel Filter

Every

500

Hours

ü¶ Weld Cables ü Slip Rings*

ü¶ Brushes*

*To be done by factory authorized service agent.

NOTICE – This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative standards.

Engine Manual, Section 8-5

Engine Manual

OM-289543 Page 35

8-2. Maintenance Label

Complete Parts List is available at www.HobartWelders.com

OM-289543 Page 36

8-3. Servicing Air Cleaner

Complete Parts List is available at www.HobartWelders.com

Stop engine.

NOTICE – Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty.

1 Precleaner

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

Do not oil the precleaner.

2 Element

Replace element if damaged, dirty, or oily.

OM-289543 Page 37

OFF

RUN

RUN/IDLE

START

helmet weldshield faceshield

popriveter

tape

8-4. Overload Protection

Complete Parts List is available at www.HobartWelders.com

1 Fuse F6

F6 protects the engine wiring system from overload. If F6 opens, engine will not crank.

Replace any open fuses. Reinstall cover before operating.

Stop engine. Disconnect negative (-) battery cable.

If a fuse opens, it usually indicates a

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

OM-289543 Page 38

3/8 in.

Complete Parts List is available at www.HobartWelders.com

allen_wrench

NGO’s

tools/

flathead philips head wrench

allen_set

crescent wrench

NGO’s

tools/

helmet weldshield faceshield

popriveter

ear plugs

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter

Stop engine and let cool.

1 Oil Drain Plug

Change engine oil and filter according to engine owner’s manual.

NOTICE – Close valve and valve cap before adding oil and running engine.

Fill crankcase with new oil to full mark on dipstick (see Section 8-2).

2 Fuel Filter 3 Fuel Line

Replace line if cracked or worn. Install new filter with arrow pointing in the direction of fuel flow. Wipe up any spilled fuel.

Start engine, and check for fuel leaks.

Stop engine, tighten connections as necessary, and wipe up fuel.

See Section 6-2 to reset oil and oil filter maintenance countdown.

OM-289543 Page 39

Complete Parts List is available at www.HobartWelders.com

NGO’s

tools/

8-6. Adjusting Engine Speed

After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows:

Start engine and run until warm.

Open top and side access doors.

Idle Speed Adjustment

Move Engine Control switch to Run/Idle position.

1 Idle Speed Screw

Turn idle speed screw until engine runs at idle speed.

Weld/Power Speed Adjustment

Move Engine Control switch to Run position.

2 Weld/Power Speed Adjustment Nut

Turn adjustment nut until engine runs at weld/power speed. Tighten lock nut.

Stop engine.

Close side and top access doors.

1/4, 3/8 in.

2300–2400 rpm

(38.3–40.0 Hz)

3675–3750 rpm

(61.3–62.5 Hz)

OM-289543 Page 40

Complete Parts List is available at www.HobartWelders.com

8-7. Fault Indicator

Flash Code Problem Possible Cause Potential Solution

Not Illuminated No Fault Flashing Inverter Over-Temp Indicates the unit has

overheated.

Illuminated Solid Other Fault Contact a Factory Authorized

The unit has shut down to allow the fan to cool it. Operation will continue when the unit has cooled.

Service Agent.

8-8. Troubleshooting

A. Welding Troubleshooting

Trouble Remedy

Low or no weld output; generator power output okay at AC receptacles.

No weld output or generator power output at AC receptacles.

Low weld output. Check control settings.

High weld output. Check control settings.

Erratic weld output. Check control settings.

Check control settings.

Check weld connections.

Have Factory Authorized Service Agent check brushes and slip rings.

Be sure all equipment is disconnected from receptacles when starting unit.

Check plug PLG5 and RC4 connection.

Have Factory Authorized Service Agent check brushes and slip rings.

Check engine speed, and adjust if necessary (see Section 8-6).

Service air cleaner according to engine manual.

Have Factory Authorized Service Agent check brushes and slip rings.

Check engine speed, and adjust if necessary (see Section 8-6).

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 8-6).

Have Factory Authorized Service Agent check brushes and slip rings.

OM-289543 Page 41

Complete Parts List is available at www.HobartWelders.com

B. Generator Power Troubleshooting

Trouble Remedy

No or low generator power output at AC receptacles; weld output okay.

No generator power or weld output.

Low power output at AC receptacles.

High power output at AC receptacles. Check engine speed, and adjust if necessary (see Section 8-6).

Erratic power output at AC receptacles.

Reset supplementary protector(s) (see Section 7-1).

Press optional GFCI receptacle Reset button (see Section 7-1).

Check plug RC4 connection.

Have Factory Authorized Service Agent check brushes and slip rings.

Be sure all equipment is disconnected from receptacles when starting unit.

Check plug RC4 connection.

Have Factory Authorized Service Agent check brushes and slip rings.

Check engine speed, and adjust if necessary (see Section 8-6).

Have Factory Authorized Service Agent check brushes and slip rings.

Check fuel level.

Check engine speed, and adjust if necessary (see Section 8-6).

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check brushes and slip rings.

OM-289543 Page 42

C. Engine Troubleshooting

Trouble Remedy

Engine will not crank.

Engine will not start.

Engine starts but stops when Engine Control switch returns to Run position.

Engine stopped during normal operation.

Battery discharges between uses.

Engine idles but does not come up to weld speed.

Unstable or sluggish engine speeds.

Engine does not return to idle speed.

During operation in near freezing temperatures, engine starts and goes to idle but stalls after a few minutes.

During operation in severe cold weather, engine starts and goes to idle but stalls after a few minutes.

Complete Parts List is available at www.HobartWelders.com

Check fuse F6, and replace if open (see Section 8-4).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

Check fuel level.

Check battery voltage.

Check battery connections and tighten if necessary.

Check oil level (see Section 5-5).

Check low oil pressure shutdown switch.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (carbureted engine only).

Verify e-choke is operating. If not, contact engine service center.

Check oil level.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.

Check low oil pressure shutdown switch.

Check fuel level.

Replace fuel filter(s) (see Section 8-5).

Check oil level (see Section 5-5).

Check low oil pressure shutdown switch.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (carbureted engine only).

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.

Have Factory Authorized Service Agent check fuel gauge/hourmeter/idle control, and current transformer CT1.

Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.

Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if crankcase is overfilled.

Tune-up engine according to engine manual.

Remove weld and generator power loads.

Check throttle linkage for smooth, non-binding operation.

Have Factory Authorized Service Agent check idle module, current transformer CT1, Engine Control switch S2, and throttle solenoid TS1.

Treat fuel with isopropyl alcohol de-icer product.

Place Engine Control switch in the Run position until unit has been in operation and loaded for a period of time.

Install engine manufacturer's kit for cold-weather operation.

OM-289543 Page 43

Complete Parts List is available at www.HobartWelders.com

SECTION 9 – PARTS LIST

9-1. Recommended Spare Parts

Recommended Spare Parts

Dia. Mkgs. Part No. Description Quantity

283588 Electric Fuel Pump (High Altitude) 1 280236 Receptacle, GFCI 15/20A 1

Vanguard 23 HP

F6 239347 Fuse, 20 Amp Ato Type (Vanguard 23 HP) 1

293445 Switch, Oil Pressure (Vanguard 23 HP) 1 293446 Regulator, Voltage (Vanguard 23 HP) 1 294509 Pump, Fuel Pulse (Vanguard 23 HP) 1

See Section 8-2 for common maintenance parts.

NOTICE – This equipment meets US EPA Evaporative Standards. Be sure fuel system replacement parts meet EPA Evaporative standards.

OM-289543 Page 44

OM-289543 Page 45

SECTION 10 – ELECTRICAL DIAGRAMS

OM-289543 Page 46

Figure 10-1. Circuit Diagram

OM-289543 Page 47

289541B

SECTION 11 – GENERATOR POWER GUIDELINES

GND/PE

1 2

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

11-1. Selecting Equipment

1 Generator Power Receptacles – Neutral

Bonded To Frame

2 3-Prong Plug From Case Grounded

Equipment

3 2-Prong Plug From Double Insulated

Equipment

Be sure equipment has double insu-

lated symbol and/or wording on it.

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

11-2. Grounding When Supplying Building Systems

1 Equipment Grounding Terminal

2 Grounding Cable

Use #8 AWG or larger insulated copper wire.

3 Ground Device

Use ground device as stated in electri-

cal codes.

Ground generator to system earth ground if supplying power to a premises (shop, farm) wiring system.

Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

OM-289543 Page 48

11-3. How Much Power Does Equipment Require?

VOLTS 115

4.5 50/60

AMPS Hz

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-resistive load and requires approximately six times more power while starting the motor than when running (see Section 11-7).

3 Rating Data

Rating shows volts and amperes, or watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 amperes at 115

volts, calculate its running power requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

Example 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.

(3 x 200W) + 520 W = 1120 W

The total load applied by the three flood lamps and drill is 1120 watts.

11-4. 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 10,550 2850 3 HP 15,900 3900 5 HP 23,300 6800

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

Fan Duty 1/8 HP 1000 400

5 HP 23,300 6000

7-1/2 HP 35,000 8000

10 HP 46,700 10,700

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

OM-289543 Page 49

11-5. Approximate Power Requirements For Farm/Shop Equipment

Farm/Shop 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 10,500 2800 Farm Duty Motors Std. (e.g. Con-

veyors, Feed Augers, Air Compressors)

Farm Duty Motors High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders)

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

Shallow Well Pump 1/3 HP 2150 750

1/3 HP 1720 720 1/2 HP 2575 975 3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10,550 2850 3 HP 15,900 3900 5 HP 23,300 6800

1-1/2 HP 8100 2000

5 HP 23,300 6000

7-1/2 HP 35,000 8000

10 HP 46,700 10,700

700 PSI 6100 1600

1/2 HP 3100 1000

OM-289543 Page 50

11-6. Approximate Power Requirements For Contractor Equipment

Contractor Equipment 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 10,500 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-289543 Page 51

11-7. Power Required To Start Motor

VOLTS AMPS

230 2.5

1/4

Hz PHASE

CODE 60

AC MOTOR

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

Step 1: Find code and use table to find kVA/ HP. If code is not listed, multiply running amperage by six to find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amperage (see

example).

Welder/generator amperage output must be at least twice the motor’s running amperage.

(kVA/HP x HP x 1000) / Volts = Starting Amperage

Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP = 11.2

(11.2 x 1/4 x 1000) / 230 = 12.2A

Starting the motor requires 12.2 amperes.

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

11-8. How Much Power Can Generator Supply?

1 Limit Load To 90% Of Generator Output

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

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.

OM-289543 Page 52

11-9. Typical Connections To Standby Power

1. Utility Electrical Service

Have only qualified persons perform these connections according to all applicable codes and safety practices.

Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.

Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed.

Customer-supplied equipment is re-

quired if generator will supply standby power during emergencies or power outages.

2. Transfer Switch 3. Fused Disconnect

5. Essential Loads

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

Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored.

Install correct switch (customer-supplied). Switch rating must be same as or greater than the branch overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-supplied) if required by electrical code.

Switch (If Required)

4 Welder/Generator Output

Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring.

Connect generator with temporary or permanent wiring suitable for the installation.

Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency.

5 Essential Loads

Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads. See Section 11-3.

4. Welder/Generator Output

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

A. Cord Lengths For 120 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm

Current

(Amperes) Load (Watts) 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5)

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.

OM-289543 Page 53

B. Cord Lengths For 240 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm

Current

(Amperes) Load (Watts) 4 (25) 6 (16) 8 (10) 10 (6) 12 (4) 14 (2.5)

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.

OM-289543 Page 54

SECTION 12 – STICK WELDING (SMAW) GUIDELINES

crescent wrench

NGO’s

tools/

crescent wrench

12-1. Stick Welding Procedure

Tools Needed:

Equipment Needed:

Weld current starts when electrode touches workpiece.

Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

Always wear appropriate personal pro-

tective clothing.

1 Workpiece

Make sure workpiece is clean before welding.

2 Work Clamp

Place as close to the weld as possible.

3 Electrode

Before striking an arc, insert an electrode in the electrode holder. A small diameter electrode requires less current than a large one. Follow recommendations of the electrode manufacturer when setting weld amperage (see Section 12-2).

4 Insulated Electrode Holder

5 Electrode Holder Position

6 Arc Length

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. Correct arc length is related to electrode diameter. Examine the weld bead to determine if the arc length is correct.

Arc length for 1/16 and 3/32 in. diameter electrodes should be about 1/16 in. (1.6 mm); arc length for 1/8 and 5/32 in. electrodes should be about 1/8 in. (3 mm).

7 Slag

Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

OM-289543 Page 55

12-2. Electrode And Amperage Selection Chart

3/32

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

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

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

1/4 3/32

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

1/4 3/32

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

1/4 3/32

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

1/4 3/32

1/8 5/32 3/16 3/32

1/8 5/32

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

100

150

200

250

300

350

400

450

ELECTRODE

DC*

POSITION

PENETRATION

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON STAINLESS

DEEP DEEP

LOW MED

LOW LOW

LOW

ALL ALL ALL

ALL ALL

FLAT

HORIZ*

ALL ALL

EP EP

EP,EN EP,EN

EP,EN

EP EP

6010 6011 6013

7014 7018

7024

NI-CL

308L

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

ELECTRODE

AMPERAGE

RANGE

DIAMETER

MED

12-3. Striking An Arc

OM-289543 Page 56

Weld current starts when electrode touches workpiece.

1 Electrode

2 Workpiece

3 Arc

Scratch Technique

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

Tapping Technique

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.

12-4. Positioning Electrode Holder

10°-30°

10°-30

423

Groove Welds

Fillet Welds

1 End View Of Work Angle

2 Side View Of Electrode Angle

After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode.

Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the direction of travel) will be helpful.

To produce the best results, hold a

short arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it melts.

12-5. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

12-6. Good Weld Bead Characteristics

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 welded.

4 No Overlap

5 Good Penetration into Base Metal

OM-289543 Page 57

12-7. Conditions That Affect Weld Bead Shape

° - 30°

Electrode Angle

Arc Length

Travel Speed

Weld bead shape is affected by elec-

trode angle, arc length, travel speed, and thickness of base metal.

1 Angle Too Small

2 Correct Angle

3 Drag

4 Angle Too Large

5 Too Short

6 Normal

7 Too Long

8 Spatter

9 Slow

10 Normal

11 Fast

12-8. Electrode Movement During Welding

Normally, a single stringer bead is sat-

isfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better.

1 Stringer Bead - Steady Movement Along

Seam

2 Weave Bead - Side To Side Movement

OM-289543 Page 58

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.

12-9. Welding Lap Joints

≤ 30

1/16 in.

(1.6 mm)

12-10. Welding Groove (Butt) Joints

1 Electrode

2 Single-Layer Fillet Weld

Move electrode in circular motion.

3 Multi-Layer Fillet Weld

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

1 Tack Welds

Prevent butt joint distortion by tack welding the materials in position before final weld.

Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will curl up toward the weld. Distortion will also cause the edges of a butt joint to pull together ahead of the electrode as the weld cools.

2 Square Groove Weld

3 Single V-Groove Weld

4 Double V-Groove Weld

Materials up to 3/16 in. (5 mm) thick can often be welded without special preparation using the square groove weld. However, when welding thicker materials it may be necessary to prepare the edges (V-groove) of butt joints to ensure good welds.

The single or double V-groove weld is good for materials 3/16 - 3/4 in. (5-19 mm) thick. Generally, the single V-groove is used on materials up to 3/4 in. (19 mm) thick and when, regardless of thickness, you can weld from one side only. Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

OM-289543 Page 59

12-11. Welding T-Joints

≤ 30

1/16 in.

(1.6 mm)

≤ 45

≤ 30

1/16 in.

(1.6 mm)

≤ 45°

2 3 in.

1/4 in.

2 1

2 3 in.

(51-76 mm)

(6.4 mm)

(51-76 mm)

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 heavier fillet is needed. Use any of the weaving patterns shown in Section 12-8. Remove slag before making another weld pass.

12-12. Weld Test

1 Vise 2 Weld Joint 3 Hammer

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

If the weld breaks, examine it to determine the cause.

If the weld is porous (many holes), the arc length was probably too long.

If the weld contains bits of slag, the arc may have been too long or the electrode was moved incorrectly which allowed molten slag to be trapped in the weld. This may happen on a V-groove joint made in several layers and calls for additional cleaning between layers.

If the original beveled surface is visible the material was not fully melted which is often caused by insufficient heat or too fast a travel speed.

OM-289543 Page 60

12-13. Troubleshooting

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

Possible Causes Corrective Actions

Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

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.

welding.

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

Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceding 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

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.

Possible Causes Corrective Actions

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

welding.

Lack Of Penetration - shallow fusion between weld metal and base metal.

Reduce travel speed.

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

Increase and/or maintain steady travel speed.

OM-289543 Page 61

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.

Waviness Of 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.

Distortion - contraction of weld metal during welding that forces base metal to move. Illustration: 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-289543 Page 62

Effective January 1, 2023

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num-

ber preface of ND or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or

warranties expressed or implied.

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

LIMITED WARRANTY - Subject to the terms and conditions below, Miller Electric Mfg. LLC, dba Hobart Welding Products, 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. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITYAND 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. Notifications submitted as online warranty claims must provide detailed descriptions of the fault and troubleshooting steps taken to diagnose failed parts. Warranty claims that lack the required information as defined in the Miller Service Operation Guide (SOG) may be denied by Miller.

Hobart/Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods listed below. Warranty time periods start on the delivery date of the equipment to the original retail purchaser, or 12 months after the equipment is shipped to a US or Canada distributor, or 18 months after the equipment is shipped to an international distributor, whichever occurs first.

1 5 Years — Parts and Labor

l Original Main Power Rectifiers only to include

SCRs, diodes, and discrete rectifier modules in non-inverter products

l Reactors l Stabilizers l Transformers

2 3 Years — Parts and Labor Unless Specified

l Drive Systems l Idle Module l PC Boards l Rotors, Stators and Brushes l Solenoid Valves l Switches and Controls

3 1 Year — Parts and Labor Unless Specified(90

days for industrial use)

l Accessories (Kits)

l Field Options (NOTE: Field options are cov-

ered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

l HF Units l MIG Flowgauge Regulators (No Labor) l MIG Guns/TIG Torches l Plasma Cutting Torches l Remote Controls l Replacement Parts (No labor) - 90 days l Running Gear/Trailers l Spoolguns

4 6 Months — Parts

l 12 Volt Automotive-Style Batteries

5 Engines and tires are warranted separately by

the manufacturer.

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

1. Consumable components; such as contact

tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

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

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 of the specifications for the equipment.

4. Defects caused by accident, unauthorized repair, or improper testing.

HOBART PRODUCTS ARE INTENDED FOR COMMERCIAL AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at Hobart’s/Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Hobart/Miller, (3) the pre-approved 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 use). Products may not be returned without

Hobart’s/Miller’s written approval. Return shipment shall be at customer’s risk and expense.

The above remedies are F.O.B. Appleton, WI, or Hobart’s/Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO EVENT SHALL HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, ARE EXCLUDED AND DISCLAIMED BY HOBART/MILLER.

Some US states do not allow limiting the duration of an implied warranty or the exclusion of certain damages, so the above limitations may not apply to you. This warranty provides specific legal rights, and other rights may be available depending on your state. In Canada, some provinces provide additional warranties or remedies, and to the extent the law prohibits their waiver, the limitations set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary by province.

Warranty Questions?

Call 1-800-332-3281 8 AM – 5 PM EST

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Assistance

Visit the Hobart website:

www.HobartWelders.com

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date

Distributor

Address

City

State Zip

Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, operation, or service, contact us!

(Date which equipment was delivered to original customer.)

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Service Center:

Call 1-800-332-3281

or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:

Call 1-800-332-3281

8 AM to 5 PM EST – Monday through Friday

Miller Electric Mfg. LLC

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

For Assistance: Call 1-800-332-3281

Hobart CHAMPION ELITE 225 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

1-1. Symbol Usage

1-2. Arc Welding Hazards

1-3. Engine Hazards

1-4. Compressed Air Hazards

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

1-6. California Proposition 65 Warnings

1-7. Principal Safety Standards

1-8. EMF Information

2-1. Symboles utilisés

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

2-3. Dangers existant en relation avec le moteur

2-4. Dangers liés à l’air comprimé

2-6. Proposition californienne 65 Avertissements

2-7. Principales normes de sécurité

2-8. Informations relatives aux CEM

3-1. Additional Safety Symbol Definitions

3-2. Miscellaneous Symbol Definitions

4-1. Serial Number And Rating Label Location

4-2. Information About Default Weld Parameters And Settings

4-3. Weld, Power, And Carbureted Engine Specifications

4-4. Environmental Specifications

4-5. Base Unit Dimensions, Weights, And Operating Angles

4-6. Duty Cycle And Overheating

4-7. Volt-Ampere Curves

4-8. Fuel Consumption

5-1. Installing Welder/Generator

5-2. Grounding Generator to Truck or Trailer Frame

5-3. Ground Cable Routing

5-4. Installing Exhaust Pipe

5-5. Engine Prestart Checks

5-6. Connecting Or Replacing The Battery

5-7. Weld Output Terminals

5-8. Connecting Weld Output Cables

5-9. Selecting Cable Sizes*

6-1. Front Panel Controls

6-2. Fuel/Hour Gauge Descriptions

6-3. Typical Stick Welding Connections And Control Settings

6-4. Cold Weather Engine Operation

7-1. Generator Power Receptacles

7-2. GFCI Receptacle Information, Resetting, And Testing

7-3. Simultaneous Weld And Power

7-4. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 14-50P)

7-5. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P)

8-1. Routine Maintenance

8-2. Maintenance Label

8-3. Servicing Air Cleaner

8-4. Overload Protection

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter

8-6. Adjusting Engine Speed

8-7. Fault Indicator

8-8. Troubleshooting

Recommended Spare Parts

11-1. Selecting Equipment

11-2. Grounding When Supplying Building Systems

11-3. How Much Power Does Equipment Require?

11-4. Approximate Power Requirements For Industrial Motors

11-5. Approximate Power Requirements For Farm/Shop Equipment

11-6. Approximate Power Requirements For Contractor Equipment

11-7. Power Required To Start Motor

11-8. How Much Power Can Generator Supply?

11-9. Typical Connections To Standby Power

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