Hobart Champion 4500 Users Manual O4418a_hob

Champion 4500 to the manual b457f597-41e0-402d-be5b-bff8b4de96f7

2015-02-05

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Processes

Description

Stick (SMAW) Welding

Engine Driven Welding Generator

OM-4418 210 597A

February 2003

Visit our website at

www.HobartWelders.com

Champion 4500



Hobart Welders manufactures a full line

of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart

distributor to receive the latest full line catalog or individual catalog sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1.

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 is registered to the

ISO 9001:2000 Quality

System Standard.

From Hobart to You

Hobart offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

TABLE OF CONTENTS

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

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

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

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

1-4. Compressed Air Hazards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-6. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

1-3. Engine Hazards 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Dangers liés à l’air comprimé 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement

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

1-6. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

3-2. Dimensions, Weights, And Operating Angles 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Fuel Consumption 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Duty Cycle 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Generator Power Curve 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Grounding Generator To Truck Or Trailer Frame 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Grounding Generator When Supplying Building Systems 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Engine Prestart Checks 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting To Weld Output Terminals 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Selecting Weld Cable Sizes* 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING THE WELDING GENERATOR 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls (See Section 6-2) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Controls (See Section 6-1) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Amperage Selection Table For Stick (SMAW) Electrodes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – OPERATING AUXILIARY EQUIPMENT 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Generator Power Panel Receptacles 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Servicing Air Cleaner 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – GENERATOR POWER GUIDELINES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – STICK WELDING (SMAW) GUIDELINES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 – PARTS LIST 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

The following terms are

used interchangeably

throughout this manual:

Stick = SMAW

The engine exhaust from

this product contains

chemicals known to the

State of California to

cause cancer, birth

defects, or other

reproductive harm.

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

WARNING

Battery posts, terminals

and related accessories

contain lead and lead

compounds, chemicals

known to the State of

California to cause

cancer and birth defects

or other reproductive

harm. Wash hands after

handling.

OM-4418 Page 1

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

rom _nd_10/02

Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Marks a special safety message.

Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-6. Read and follow all

Safety Standards.

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

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

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

or ground.

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

there is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present

on unit.

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 unavoid-

able 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 volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to its

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

Always verify the supply ground — check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

When making input connections, attach proper grounding conduc-

tor first – double-check connections.

Frequently inspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after

stopping engine.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

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

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-4418 Page 2

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use

approved air-supplied respirator.

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.

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes from arc rays and sparks when welding or

watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your

helmet.

Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (wool and leather) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

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

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

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

easily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

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

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Wear approved safety glasses with side

shields even under your welding helmet.

HOT PARTS can cause severe burns.

Allow cooling period before maintaining.

Wear protective gloves and clothing when

working on a hot engine.

Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

Wear approved ear protection if noise level

is high.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away.

Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

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

use or connected for use.

Read and follow instructions on compressed gas cylinders,

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

Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and –) on batteries.

Disconnect negative (–) cable first and connect it last.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or

adding fuel.

Do not add fuel while smoking or if unit is near

any sparks or open flames.

Do not overfill tank — allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Always keep nozzle in contact with tank when fueling.

OM-4418 Page 3

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

Stop engine before installing or connecting unit.

Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (–) battery cable from battery.

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

parts.

Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

STEAM AND HOT COOLANT can burn.

If possible, check coolant level when engine is

cold to avoid scalding.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

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

Turn cap slightly and let pressure escape slowly before

completely removing cap.

ENGINE EXHAUST GASES can kill.

Use equipment outside in open, well-ventilated

areas.

If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

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

surfaces or flammables.

Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can

cause serious injury or death.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

Release air pressure from tools and system

before servicing, adding or changing attach-

ments, or opening compressor oil drain or oil

fill cap.

HOT METAL from air arc cutting and

gouging can cause fire or explosion.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air system

parts.

Let system cool down before touching or

servicing.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Stop engine and release air pressure before

servicing.

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

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other

accessories.

Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

Turn off or unplug equipment before starting or

stopping engine.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

OM-4418 Page 4

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

Use only genuine MILLER/Hobart replacement

parts.

Perform engine and air compressor (if applica-

ble) maintenance and service according to this

manual and the engine/air compressor (if appli-

cable) manuals.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and

communications equipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

If notified by the FCC about interference, stop using the

equipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere with

sensitive electronic equipment such as micro-

processors, computers, and computer-driven

equipment such as robots.

Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Be sure this welding machine is installed and grounded

according to this manual.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-6. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-

ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.

sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:

www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or

in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,

website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:

617-770-3000, website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there

are 10 Regional Offices—phone for Region 5, Chicago, is

312-353-2220, website: www.osha.gov).

1-7. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from

operator as practical.

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

possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-4418 Page 5

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT

UTILISATION

rom_10_02fre

Avertissement: Protégez vous et les autres des blessures – lisez et suivez ces précautions.

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure

présente des risques de danger ! Ceux-ci sont identifiés par

des symboles adjacents aux directives.

Identifie un message de sécurité particulier.

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

Ce groupe de symboles si-

gnifie Mise en garde !

Soyez vigilant ! Il y a des

risques de danger reliés

aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux

PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-

sous afin de connaître les mesures à prendre pour éviter tout danger.

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

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

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne font

que résumer l’information contenue dans les normes de sécu-

rité énumérées à la section 1-5. Veuillez lire et respecter toutes

ces normes de sécurité.

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

doivent être confiés qu’à des personnes qualifiées.

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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension dès

que l’appareil est sur ON. Le circuit d’entrée et les circuits

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.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel

avec la pièce ou la terre.

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

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

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

procédé de soudage le demande.

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

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

Des précautions de sécurité supplémentaires sont requises dans des envi-

ronnements 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 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 ma-

nuel 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!

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

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation

selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

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

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

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

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre

du sectionneur ou que la fiche du cordon est raccordée à une prise

correctement mise à la terre.

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

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

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

dommagé ou dénudé – remplacer le cordon immédiatement s’il est

endommagé – un câble dénudé peut provoquer une électrocution.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement avec un

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

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

une électrode provenant d’une autre machine.

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

les pièces endommagées. Entretenir l’appareil conformément à ce

manuel.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le 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.

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

avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur

des onduleurs après avoir coupé l’alimentation.

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

comme indiqué dans la Section Maintenance avant de toucher des compo-

sants.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation

peut être dangereux pour votre santé.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

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

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

homologué.

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

tions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant

dûment formé de se tenir à proximité. Des fumées et des gaz de soudage

peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des

blessures ou des accidents mortels. S’assurer que l’air de respiration ne

présente aucun danger.

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

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de

l’arc peuvent réagir en présence de vapeurs et former des gaz hautement

toxiques et irritants.

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

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été

enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-

saire, en portant un respirateur à alimentation d’air. Les revêtements et

tous les métaux renfermant ces éléments peuvent dégager des fumées

toxiques en cas de soudage.

OM-4418 Page 6

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

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.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Porter un casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

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

trop élevé.

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

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

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

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

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.

LE SOUDAGE peut provoquer un in-

cendie ou une explosion.

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

chaud.

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

substances inflammables.

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

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

des protections homologués.

Des étincelles et des matériaux chauds du soudage peuvent facilement

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

ouvertures.

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

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

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés

correctement conformément à AWS F4.1 (voir les normes de sécurité).

Brancher le câble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des che-

mins inconnus éventuels en provoquant des risques d’électrocution et

d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

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

de ou couper le fil à la pointe de contact.

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

en cuir, une chemise en matériau lourd, des pantalons sans revers, des

chaussures hautes et un couvre chef.

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

qu’un allumeur au butane ou des allumettes.

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 proxi-

mité.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

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

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

des étincelles et des particules métalliques vo-

lantes. Pendant la période de refroidissement des soudures, elles ris-

quent de projeter du laitier.

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

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

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

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter

l’ouïe.

Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher

des opérations de soudage à l’arc, de gougeage ou

de soudage par points.

Si des BOUTEILLES sont endomma-

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous

haute pression. Si une bouteille est endommagée, elle peut

exploser. Du fait que les bouteilles de gaz font normale-

ment partie du procédé de soudage, les manipuler avec

précaution.

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

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

arcs.

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

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

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

électriques.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

Ne jamais souder une bouteille pressurisée – risque d’explosion.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords convenables pour cette application spécifique; les maintenir ainsi

que les éléments associés en bon état.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

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

les équipements associés et les publication P-1 CGA énumérées dans les

normes de sécurité.

1-3. Engine Hazards

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

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

OM-4418 Page 7

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

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

batterie.

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

batterie.

Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-

cules de démarrage rapide.

Observer la polarité correcte (+ et –) sur les batteries.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

LE CARBURANT MOTEUR peut pro-

voquer un incendie ou une explosion.

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

rant ou de faire le plein.

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

ce d’étincelles ou d’une flamme nue.

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

expansion.

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

rant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

Arrêter le moteur avant d’installer ou brancher l’appareil.

Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-

tretien et de dépannage.

Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,

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

Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-

nes mobiles.

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

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

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

route accidentelle du moteur.

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

générateur.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter

de se brûler.

Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-

pansion (si présent), et non dans le radiateur (sauf si précisé autrement

dans la section maintenance du manuel du moteur).

Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-

vant :

Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-

chon du radiateur.

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

d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

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

de surfaces inflammables.

Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

Utiliser uniquement un pare-étincelles approuvé –

voir codes en vigueur.

1-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le coupa-

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou soi–

même.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer des blessures.

Relâcher la pression d’air de l’outillage ou du sys-

tème avant d’effectuer la maintenance, avant de

changer ou de rajouter des éléments ou avant

d’ouvrir la purge ou le bouchon de remplissage

d’huile.

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

Ne pas couper ou gouger à proximité de produits

inflammables.

Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

Ne pas toucher le compresseur ou d’autres élé-

ments du circuit air comprimé chauds.

Laisser l’ensemble se refroidir avant de toucher

ou d’effectuer la maintenance.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

1-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut

blesser.

Utiliser l’anneau de levage uniquement pour soulever

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

gaz, remorque, ou autres accessoires.

Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté

opposé de l’appareil.

OM-4418 Page 8

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

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

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

lieu.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Porter un écran facial pour protéger le visage et les

yeux.

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

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque

l’on porte l’équipement homologué de protection du visage, des mains et

du corps.

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

inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de

circuits imprimes.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

Utiliser seulement les pièces de rechange d’origine.

Effectuer la maintenance du moteur et du compres-

seur (si applicable) suivant ce manuel et le manuel du

moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

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

provoquer des interférences avec les équipements

de radio–navigation et de communication, les

services de sécurité et les ordinateurs.

Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

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

fié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et

utiliser une terre et et un blindage pour réduire les interférences

éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement com-

mandé par ordinateur tel que les robots.

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

électromagnétiquement.

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

ge aussi courts que possible, les grouper, et les poser aussi bas que pos-

sible (ex. par terre).

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

tronique sensible.

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

ment à ce mode d’emploi.

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

combe à l’utilisateur de prendre des mesures supplémentaires telles que

le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-

tres de ligne ou la pose de protecteurs dans la zone de travail.

1-6. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de

l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé-

phone : (305) 443–9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cutting

of Containers and Piping, norme American Welding Society AWS F4.1, de

l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé-

phone : (305) 443–9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection As-

sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101

(téléphone : (617) 770–3000, sites Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P–1, de

la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite

1004, Arlington, VA 22202–4102 (téléphone : (703) 412–0900, site Web :

www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-

dian Standards Association, Standards Sales, 178 boulevard Rexdale,

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463–6727 ou à To-

ronto : (416) 747–4044, site Web : www.csa–international.org).

Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de l’American National Standards Institute, 11 West

42nd Street, New York, NY 10036–8002 (téléphone : (212) 642–4900, site

Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,

norme NFPA 51B, de la National Fire Protection Association, P.O. Box

9101, 1 Battery March Park, Quincy, MA 02269–9101 (téléphone : (617)

770–3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent

of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux

régionaux – Téléphone pour la Région 5, Chicago : (312) 353–2220, site

Web : www.osha.gov).

1-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques

basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs électro-

magnétiques. Les effets potentiels de tels champs restent préoccupants.

Cependant, après avoir examiné plus de 500 études qui ont été faites pen-

dant une période de recherche de 17 ans, un comité de spécialistes du

National Research Council a conclu : « L’accumulation de preuves n’a pas

démontré que l’exposition aux champs magnétiques et aux champs électri-

ques à haute fréquence constitue un risque pour la santé humaine ».

Toutefois, les études et l’examen des preuves se poursuivent. En attendant

les conclusions finales de la recherche, il serait souhaitable de réduire l’ex-

position aux champs électromagnétiques pendant le soudage ou le

coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, respec-

ter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

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

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-

mandé de respecter les consignes ci-dessus.

OM-4418 Page 9

SECTION 2 – DEFINITIONS

2-1. Symbol Definitions

Engine Choke Read Operator’s

Manual AAmperes VVolts

Engine Oil Fuel Battery (Engine) Engine

Positive Negative Alternating Current

(AC) Output

hHours sSeconds Time Protective Earth

(Ground)

Circuit Breaker Temperature

SECTION 3 – SPECIFICATIONS

3-1. Weld, Power, And Engine Specifications

Welding

Mode

Weld

Output

Range

Rated

Welding Output

Maximum

Open Circuit

Voltage

Generator

Power Rating Fuel

Capacity Engine

CC/AC 60 – 140 A

140 A, 20 V,

30% Duty Cycle

130 A, 25 V

30% Duty Cycle

110 A, 25 V,

60% Duty Cycle

90 A, 25 V,

100% Duty Cycle

Single-Phase,

4.5 kVA/kW (Surge)

4 kVA/kW

(Continuous)

20/17 A,

120/240 V AC,

60 Hz

1 gal (3.75L)

Tank

Briggs & Stratton

Intek

Air-Cooled,

One-Cylinder,

Four-Cycle,

8 HP (305 CC),

Gasoline Engine

3-2. Dimensions, Weights, And Operating Angles

Dimensions

Height 20-3/4 in (527 mm) D

Width 22-3/4 in (577 mm)

Do not exceed tilt angles or engine could

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

be damaged or unit could tip.

A31-1/4 in (793 mm) Do not move or operate unit where it

could ti

B10-1/2 in (268 mm)

could tip

C13-45/64 in (348 mm) A

D22-3/4 in (577 mm) C

E1-3/4 in (44 mm)

F19-1/2 in (495 mm)

15°

G13/32 in (10 mm) Dia. 4

Holes

G15°

15°

Weight

Holes

190 lb (86 kg) 803 403

Engine End

OM-4418 Page 10

3-3. Fuel Consumption

210 593

3-4. Duty Cycle

212 950

Duty cycle is the percentage of 10

minutes that unit can weld at rated

load without overheating.

Exceeding duty cycle can

damage unit and void

warranty.

Continuous Welding

100% Duty Cycle at 90 Amperes CC/AC

3 Minutes Welding 7 Minutes Resting

30% Duty Cycle at 140 Amperes CC/AC

OM-4418 Page 11

3-5. Generator Power Curve

210 592

The ac generator power curves

show the generator power available

in amperes at the receptacles.

3-6. Volt-Ampere Curves

212 871

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-4418 Page 12

SECTION 4 – INSTALLATION

4-1. Installing Welding Generator

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

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm) 18 in

(460 mm)

18 in

(460 mm)

Movement Airflow Clearance

Location

Always securely fasten welding generator

onto transport vehicle or trailer and comply

with all DOT and other applicable codes.

4-2. Grounding Generator To Truck Or Trailer Frame

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

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

1 Metal Vehicle Frame

2 Equipment Grounding

Terminal

3 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

If unit does not have GFCI

receptacles, use GFCI-

protected extension cord.

Electrically bond generator frame

to vehicle frame by metal-to-metal

contact.

GND/PE

Bed liners, shipping skids, and some running

gear insulate the welding generator from the ve-

hicle frame. Always connect a ground wire from

the generator equipment grounding terminal to

bare metal on the vehicle frame as shown.

OM-4418 Page 13

4-3. Grounding Generator When Supplying Building Systems

GND/PE 1 2

Use ground device as

stated in electrical codes.

800 576-B

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Ground Device

Ground generator to sys-

tem earth ground if supply-

ing power to a premises

(home, shop, farm) wiring

system.

Open

Closed

4-4. Engine Prestart Checks

803 468

Full

Gasoline

1/2 in

(13 mm)

Check all fluids daily. Engine must

be cold and on a level surface. Unit

is shipped with 10W30 engine oil.

Engine stops if oil level gets too low.

1 Fuel Valve

Open valve.

Close fuel valve before moving

unit or carburetor may flood

and make starting difficult.

Fuel

Add fresh fuel before starting

engine the first time (see mainte-

nance label for specifications). Fill

fuel tank up to 1/2 in. (13 mm) from

top to allow room for expansion.

Check fuel level on a cold engine

before use each day.

Oil

After fueling, check oil with unit on

level surface. If oil reservoir is not

full, add oil until oil nearly overflows

at oil fill (see maintenance label).

This unit has a low oil level

shutdown switch to prevent

starting an engine that is low on

oil. However, some conditions

may cause engine damage be-

fore the engine shuts down.

Check oil level often and do not

use the low oil level shutdown

system to monitor oil level.

To improve cold weather start-

ing, use correct grade oil for

cold weather (see engine own-

er’s manual).

Always close fuel valve after

stopping unit. Moving unit

with fuel valve open may

cause carburetor flooding

and make starting difficult.

OM-4418 Page 14

4-5. Connecting To Weld Output Terminals

803 469

1 AC Weld Output Terminals

Connect work and electrode cables

weld terminals. (Polarity does not

matter for AC welding.)

Tools Needed:

3/4 in

4-6. Selecting Weld Cable Sizes*

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

Not Exceeding***

100 ft (30 m) or Less 150 ft

(45 m) 200 ft

(60 m) 250 ft

(70 m) 300 ft

(90 m) 350 ft

(105 m) 400 ft

(120 m)

Weld Output

Terminals

Turn off power before

connecting to weld out-

put terminals.

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

Welding

Amperes

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle 10 – 100% Duty Cycle

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) 2 ea. 2/0

(2x70) 2 ea. 2/0

(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 3/0

(2x95)

* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger

cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use S-0007-E

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

OM-4418 Page 15

SECTION 5 – OPERATING THE WELDING GENERATOR

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

803 468 / 803 469 / 210 586

OM-4418 Page 16

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

1 Engine Switch

Use switch to control ignition circuit, and to

stop engine.

2 Choke Control

Use control to change engine air/fuel mix.

Move control to right if starting a cold engine.

Move control to left if starting a warm engine.

3 Starter Handle

To Start:

Open fuel valve (see Section 4-4).

Turn engine switch to On.

Set choke.

Pull starter handle until engine starts.

Open choke as engine warms.

This unit has a low oil level shutdown to

prevent starting an engine that is too low

on oil. The low oil level shutdown may not

stop a running engine. Check oil level if

the engine does not start, or has stopped

and cannot be restarted.

To Stop: turn engine switch to Off.

Always close fuel valve after stopping

unit. Moving unit with fuel valve open may

cause carburetor flooding and make

starting difficult.

4 Current Control

Use control to select weld amperage. Control

may be adjusted while welding. Set Amper-

age control at max. for full generator power

output at ac receptacles.

To Set Current Control: Use electrode chart

(see Section 5-3) to determine correct size

electrode. Select electrode type and set cur-

rent control to corresponding amperage

range on nameplate. Adjust control within se-

lected range to obtain desired weld

performance.

EXAMPLE:

Electrode Type: 6013

Electrode Diameter: 1/8

Current Control Setting: 80 – 125 A

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

211 457

Use table to select correct amper-

age for the electrode being used.

Values listed are suggested settings. Actual settings may vary depending on personal preference and/or specific application.

Suggested electrode for beginners is E7018 AC.

OM-4418 Page 17

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

The welding generator provides power while welding and with the Current control

in any position. However, under these conditions equipment connected to the

welding generator may be subject to larger than normal voltage fluctuations. It is

recommended that only lamps be powered under these conditions.

NOTE

6-1. Generator Power Panel Receptacles

Use GFCI-protected extension

cord.

Generator power decreases as weld

current increases.

Set Amperage control at max. for full

generator power.

1 240 V 20 A AC Duplex Receptacle

RC1

RC1 supplies 60 Hz single-phase power at

weld/power speed. Maximum output is 4

kVA/kW.

2 120 V 20 A AC Duplex Receptacle

RC2

RC2 supplies 60 Hz single-phase power at

weld/power speed. Maximum output from

RC2 is 2.4 kVA/kW.

3 Circuit Breaker CB1

CB1 protects the receptacles from over-

load. If CB1 opens, the receptacles do not

work.

Place switch in the On position to reset

circuit breaker. If breaker continues to

open, contact Factory Authorized Ser-

vice Agent.

Combined output of all receptacles limited

to 4 kVA/kW rating of the generator (See

Section 10 – Generator Power Guide-

lines).

EXAMPLE: If 15 A is drawn from the 120

volt duplex receptacle, only 9 A is available

from the 240 V duplex receptacle.

(120 V x 15 A) + (240 V x 9 A) = 4 kVA/KW.

210 586

123

OM-4418 Page 18

SECTION 7 – MAINTENANCE

Follow the storage procedure in the engine owner’s manual if the unit will not be

used for an extended period.

NOTE

7-1. Routine Maintenance

Recycle

engine

fluids.

Stop engine before maintaining.

See Engine Manual and Maintenance Label.

Service more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

Every 8 h

Clean area

around muffler.

Check fluid levels.

See Section 4-4. Wipe up spills.

Every 25 h

Service air cleaner

precleaner. See

Section 7-2.

Every 50 h

Clean and

tighten weld

terminals.

Change oil. See

engine manual.

Every 100 h

Check

spark

plugs.

Service air

cleaner ele-

ment. See

Section 7-2.

Clean cooling

system. See

Engine Manual.

Every 200 h Every 300 h

Replace

unreadable

labels.

Check valve

clearance.*

Every 500 h

Repair or

replace cracked

cables.

Service welding generator

brushes and slip rings. Service

more often in dirty conditions.*

Every 1000 h

Blow out or vacuum

inside. During heavy

service, clean monthly.

OM-4418 Page 19

7-2. Servicing Air Cleaner

aircleaner6 9/00 – 803 468

Stop engine.

Do not run engine without air

cleaner or with dirty element.

1 Cover

2 Precleaner

3 Element

Remove air cleaner cover. Wash

precleaner with soap and water so-

lution. Allow precleaner to air dry

completely.

Do not oil precleaner.

Clean element by gently tapping

on a hard surface.

Do not use pressurized air to

clean element.

Washing Precleaner

OM-4418 Page 20

SECTION 8 – TROUBLESHOOTING

8-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output; no generator power

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

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier

SR1, and integrated rectifier SR2.

No weld output; generator power out-

put okay at ac receptacles. Check Amperage control setting.

Check weld connections.

Have Factory Authorized Service Agent check Amperage control R1, stator, and integrated rectifier

SR1.

Low weld output. Check Amperage control setting.

Service engine air cleaner.

Check weld cable size and length.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier

SR1, and integrated rectifier SR2.

High weld output. Check Amperage control setting.

Erratic weld output. Check Amperage control setting.

Tighten and clean connections to electrode and workpiece.

Use dry, properly-stored electrodes for Stick welding.

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check governor linkage for smooth, non-binding operation.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

B. Generator Power

Trouble Remedy

No output at generator power ac re-

ceptacles; no weld output. Be sure all equipment is disconnected from receptacles when starting unit.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier

SR1, and integrated rectifier SR2.

No output at generator power ac re-

ceptacles; weld output okay. Reset circuit breaker (see Section 6-1).

Check Current control setting. Set Current control at max for generator power.

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check stator windings.

High output at generator power ac

receptacles. Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

Low output at generator power ac

receptacles. Check Current control setting. Set Current control at max for generator power.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

OM-4418 Page 21

Trouble Remedy

Erratic output at generator power ac

receptacles. Check fuel level.

Check Current control setting. Set Current control at max for generator power.

Check receptacle wiring and connections.

Check governor linkage for smooth, non-binding operation.

Service air cleaner according to engine manual.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

C. Engine

Trouble Remedy

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

Move choke control to correct position (see Section 5-1).

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

starting difficult.

Check oil level (see Section 4-4). Low oil level shutdown may stop if oil level is too low. Refill crankcase

with proper viscosity oil for operating temperature.

Have Factory Authorized Service Agent check low oil level shutdown switch.

Engine stopped during normal

operation. Check fuel level (see Section 4-4).

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

starting difficult.

Check oil level (see Section 4-4). Low oil level shutdown may stop if oil level is too low. Refill crankcase

with proper viscosity oil for operating temperature.

Unstable or sluggish engine speeds. Check governor linkage for smooth, non-binding operation.

Tune-up engine according to engine manual.

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

OM-4418 Page 22

SECTION 9 – ELECTRICAL DIAGRAMS

210 591-A

Figure 9-1. Circuit Diagram For Welding Generator

OM-4418 Page 23

SECTION 10 – GENERATOR POWER GUIDELINES

The views in this section are intended to be representative of all engine-driven

welding generators. Your unit may differ from those shown.

NOTE

10-1. Selecting Equipment

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

1 Generator Power Receptacles

– Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

Do not use 2-prong plug un-

less equipment is double in-

sulated.

Be sure equipment

has this symbol

and/or wording.

10-2. Grounding Generator To Truck Or Trailer Frame

S-0854

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

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 #10 AWG or larger

insulated copper wire.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by

metal-to-metal contact.

GND/PE

Bed liners, shipping skids, an some running

gear insulate the welding generator from the ve-

hicle frame. Always connect a ground wire from

the generator equipment grounding terminal to

bare metal on the vehicle frame as shown.

OM-4418 Page 24

10-3. Grounding When Supplying Building Systems

ST-800 576-B

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Ground Device

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

GND/PE

1 2

Use ground device as stated

in electrical codes.

10-4. How Much Power Does Equipment Require?

S-0623

1 Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

2 Non-Resistive Load

Equipment with a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when running

(see Section 10-8).

3 Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

VOLTS 115

4.5

AMPS

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.

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

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

AMPERES x VOLTS = WATTS

OM-4418 Page 25

10-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500

1/4 HP 1600 600

1/3 HP 2100 700

1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975

3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550

1/4 HP 1850 650

1/3 HP 2400 800

1/2 HP 3500 1100

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

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000

Grain Cleaner 1/4 HP 1650 650

Portable Conveyor 1/2 HP 3400 1000

Grain Elevator 3/4 HP 4400 1400

Milk Cooler 2900 1100

Milker (Vacuum Pump) 2 HP 10500 2800

FARM DUTY MOTORS 1/3 HP 1720 720

Std. (e.g. Conveyors, 1/2 HP 2575 975

Feed Augers, Air 3/4 HP 4500 1400

Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

High Torque (e.g. Barn 1-1/2 HP 8100 2000

Cleaners, Silo Unloaders, 5 HP 23300 6000

Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700

3-1/2 cu. ft. Mixer 1/2 HP 3300 1000

High Pressure 1.8 Gal/Min 500 PSI 3150 950

Washer 2 gal/min 550 PSI 4500 1400

2 gal/min 700 PSI 6100 1600

Refrigerator or Freezer 3100 800

Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4418 Page 26

10-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400

1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900

8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800

Band Saw 14 in 2500 1100

Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600

Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500

Electric Cultivator 1/3 HP 2100 700

Elec. Hedge Trimmer 18 in 400 400

Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000

Submersible Pump 400 gph 600 200

Centrifugal Pump 900 gph 900 500

Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600

55 gal Drum Mixer 1/4 HP 1900 700

Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4418 Page 27

10-8. Power Required To Start Motor

S-0624

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiply running amperage by six to

find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

VOLTS AMPS

230 2.5

1/4

PHASE

CODE 60

AC MOTOR

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GH J K LMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Starting the motor requires 12.2 amperes.

11.2 x 1/4 x 1000

230 = 12.2 A

kVA/HP x HP x 1000

VOLTS = STARTING AMPERAGE

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

10-9. How Much Power Can Generator Supply?

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

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to small-

est, 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-4418 Page 28

10-10. Typical Connections To Supply Standby Power

Have only qualified persons perform

these connections according to all

applicable codes and safety practic-

es.

Properly install and ground this

equipment according to its Owner’s

Manual and national, state, and local

codes.

Customer-supplied equipment is re-

quired if generator will supply standby

power during emergencies or power out-

ages.

1 Utility Electrical Service

2 Transfer Switch (Double-Throw)

Switch transfers the electrical load from

electric utility service to the generator. Trans-

fer load back to electric utility when service is

restored.

Install correct switch (customer-supplied).

Switch rating must be same as or greater

than the branch overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-supplied) if

required by electrical code.

4 Welding Generator Output

Generator output voltage and wiring must be

consistent with regular (utility) system volt-

age and wiring.

Connect generator with temporary or perma-

nent wiring suitable for the installation.

Turn off or unplug all equipment connected to

generator before starting or stopping engine.

When starting or stopping, the engine has

low speed which causes low voltage and

frequency.

5 Essential Loads

Generator output may not meet the electrical

requirements of the premises. If generator

does not produce enough output to meet all

requirements, connect only essential loads

(pumps, freezers, heaters, etc. – See Sec-

tion 10-4).

Properly install and ground this equipment according to

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

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Utility

Electrical

Service

1234

Welding

Generator

Output

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4418 Page 29

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

Cord Lengths for 120 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes) Load (Watts) 4 6 8 10 12 14

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

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes) Load (Watts) 4 6 8 10 12 14

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-4418 Page 30

SECTION 11 – STICK WELDING (SMAW) GUIDELINES

11-1. Stick Welding Procedure

stick 12/96 – ST-151 593

Weld current starts when

electrode touches work-

piece.

Weld current can damage

electronic parts in vehicles.

Disconnect both battery

cables before welding on a

vehicle. Place work clamp as

close to the weld as possible.

1 Workpiece

Make sure workpiece is clean be-

fore welding.

2 Work Clamp

3 Electrode

A small diameter electrode requires

less current than a large one. Fol-

low electrode manufacturer’s

instructions when setting weld am-

perage (see Section 11-2).

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.

7 Slag

Use a chipping hammer and wire

brush to remove slag. Remove slag

and check weld bead before mak-

ing another weld pass.

Tools Needed:

OM-4418 Page 31

11-2. Electrode and Amperage Selection Chart

Ref. S-087 985-A

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

LOW

MED

LOW

ALL

FLAT

HORIZ

FILLET

ALL

EP,EN

6010

6011

6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

ELECTRODE

AMPERAGE

RANGE

DIAMETER

11-3. Striking an Arc – Scratch Start Technique

S-0049

1 Electrode

2 Workpiece

3 Arc

Drag electrode across workpiece

like striking a match; lift electrode

slightly after touching work. If arc

goes out electrode was lifted to

high. If electrode sticks to work-

piece, use a quick twist to free it.

11-4. Striking an Arc – Tapping Technique

S-0050

1 Electrode

2 Workpiece

3 Arc

Bring electrode straight down to

workpiece; then lift slightly to start

arc. If arc goes out, electrode was

lifted too high. If electrode sticks to

workpiece, use a quick twist to free it.

OM-4418 Page 32

11-5. Positioning Electrode Holder

S-0060

90°90°

10°-30°

45°

GROOVE WELDS

FILLET WELDS

End View of Work Angle Side View of Electrode Angle

10°-30°

11-6. Poor Weld Bead Characteristics

S-0053-A

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

11-7. Good Weld Bead Characteristics

S-0052-B

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

5234

OM-4418 Page 33

11-8. Conditions That Affect Weld Bead Shape

Weld bead shape is affected by electrode angle, arc length, travel speed, and

thickness of base metal.

NOTE

S-0061

ELECTRODE ANGLE

ARC LENGTH

TRAVEL SPEED

Slow Normal Fast

10° - 30°

Drag

Too Short Normal Too Long

Spatter

Angle Too Small Angle Too Large

Correct Angle

11-9. Electrode Movement During Welding

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;

however, for wide groove weld joints or bridging across gaps, a weave bead or

multiple stringer beads work better.

NOTE

S-0054-A

1 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side to Side

Movement Along Seam

3 Weave Patterns

Use weave patterns to cover a wide

area in one pass of the electrode.

Do not let weave width exceed

2-1/2 times diameter of electrode.

OM-4418 Page 34

11-10. Butt Joints

S-0662

1 Tack Welds

Prevent edges of joint from drawing

together ahead of electrode by tack

welding the materials in position be-

fore final weld.

2 Square Groove Weld

Good for materials up to 3/16 in (5

mm) thick.

3 Single V-Groove Weld

Good for materials 3/16 – 3/4 in

(5-19 mm) thick. Cut bevel with oxy-

acetylene or plasma cutting equip-

ment. Remove scale from material

after cutting. A grinder can also be

used to prepare bevels.

Create 30 degree angle of bevel on

materials in V-groove welding.

4 Double V-Groove Weld

Good for materials thicker than 3/16

in (5 mm).

30°

1/16 in

(1.6 mm)

11-11. Lap Joint

S-0063 / S-0064

1 Electrode

2 Single-Layer Fillet Weld

Move electrode in circular motion.

3 Multi-Layer Fillet Weld

Weld a second layer when a heavi-

er fillet is needed. Remove slag be-

fore making another weld pass.

Weld both sides of joint for maxi-

mum strength.

30°

Or Less

Single-Layer Fillet Weld Multi-Layer Fillet Weld

30°

Or Less

11-12. Tee Joint

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

1 Electrode

2 Fillet Weld

Keep arc short and move at definite

rate of speed. Hold electrode as

shown to provide fusion into the

corner. Square edge of the weld

surface.

For maximum strength weld both

sides of upright section.

3 Multi-Layer Deposits

Weld a second layer when a heavi-

er fillet is needed. Use any of the

weaving patterns shown in Section

11-9. Remove slag before making

another weld pass.

45°

Or Less

OM-4418 Page 35

11-13. Weld Test

S-0057-B

1 Vise

2 Weld Joint

3 Hammer

Strike weld joint in direction shown.

A good weld bends over but does

not break.

2 To 3 in

1/4 in

2 To 3 in

(51-76 mm)

(6.4 mm)

(51-76 mm)

11-14. Troubleshooting – Porosity

Porosity – small cavities or holes resulting from gas

pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

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

welding.

11-15. Troubleshooting – Excessive Spatter

Excessive Spatter – scattering of molten metal particles

that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-4418 Page 36

11-16. Troubleshooting – Incomplete Fusion

Incomplete Fusion – failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

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

welding.

11-17. Troubleshooting – Lack Of Penetration

Lack Of Penetration – shallow fusion between weld metal and

base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

11-18. Troubleshooting – Excessive Penetration

Good Penetration

Excessive Penetration – weld metal melting through base metal and

hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

OM-4418 Page 37

11-19. Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal resulting

in holes where no metal remains.

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

11-20. Troubleshooting – Waviness Of Bead

Waviness 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.

11-21. Troubleshooting – Distortion

Distortion – contraction of weld met-

al during welding that forces base

metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4418 Page 38

SECTION 12 – PARTS LIST

Hardware is common and

not available unless listed.

803 470

Figure 12-1. Main Assembly

OM-4418 Page 39

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly

Quantity

1 RC1 193257 Rcpt, Str Dx Grd 2p3w 15/20a 250v *6–20r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 RC2 141432 Rcpt, Str Dx Grd 2p3w 20a 125v *5–20r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C1 176007 Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 177136 Clamp, Capacitor 1.375 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SR1, SR2 200759 Rectifier, Integ Bridge 35. Amp 600v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +209659 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 211457 Label, Electrode Chart 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB1 210650 Circuit Breaker, Man Reset 2p 20a 250vac Screw–90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 R1 494618 Rheostat, Ww 100. W 35. Ohm Frict Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 AC-Z 210588 Reactor, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 209339 Duct, Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 209340 Seal, Air Duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 209987 Engine, Gas Recoil Start 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 211987 Bracket, Mtg Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 211179 Cable, Bonding Machine To Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 494606 Adapter, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 494629 Guard, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 STATOR 210574 Stator, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ROTOR 210572 Rotor, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 209004 Fan, Rotor Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 495154 Bearing, Ball Radial 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 BRUSH 493509 Brushholder Assy, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 212267 Cover, Brush Block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 495349 Screw, 250–20 Hwh 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 494587 Endbell, Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 495348 Screw, 312–24 Hwh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 +494628 Panel, End Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 211297 Label, Warning General Precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 208933 Frame, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 211459 Mount, Engine Vibration 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 495256 Mount, Shock Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 097422 Terminal, Pwr Output Neutral 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 209658 Base, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 097924 Knob, Pointer 1.625 Dia. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 197203 Grounding Stud Assy, Brass (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083030 Stud,Brs .250–20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010915 Washer, Flat .257idx0.640odx.031t Brs 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602207 Washer,Lock .255idx0.489odx.062t Stl Pld Split.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601836 Nut, 250–20 .50hex .19h Brs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 202631 Boot, Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 202630 Brkt, Mtg Ckt Breaker Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 495281 Cover, Receptacle Duplex (Includes Gasket And Hardware) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 Label, Nameplate (Order By Model And Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211069 Kit, Accessory (Includes15 Ft 6 AWG Cable w/Electrode Holder & . . . . . . . . . . . . . . . . . . . . . . . . 10 Ft 6 AWG Cable w/Clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4418 Page 40

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

Warranty Questions?

Call

1-877-HOBART1

for your local

Hobart distributor.

hobart standard 6/02

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Support

Need fast answers to the

tough welding questions?

Contact your distributor or

call 1-800-332-3281. The

expertise of the distributor

and Hobart is there to

help you, every step of

the way.

Effective January 1, 2002

(Equipment with a serial number preface of “LC” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY – Subject to the terms and conditions

below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin

warrants to its original retail purchaser that new Hobart

equipment sold after the effective date of this limited warranty

is free of defects in material and workmanship at the time it is

shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN

LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING THE WARRANTIES OF

MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or

replace any warranted parts or components that fail due to

such defects in material or workmanship. Hobart must be

notified in writing within thirty (30) days of such defect or

failure, at which time Hobart will provide instructions on the

warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment

listed below in the event of such a failure within the warranty

time periods. All warranty time periods start on the date that

the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American

distributor or eighteen months after the equipment is sent to an

International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by

the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources

* Water Coolant Systems

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Maxstar 85, 140

* Spot Welders

* Load Banks

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered for the

remaining warranty period of the product they are

installed in, or for a minimum of one year —

whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,

relays or parts that fail due to normal wear.

2. Items furnished by Hobart, 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, 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.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Hobart’s option: (1) repair; or

(2) replacement; or, where authorized in writing by Hobart in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Hobart service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods

at customer’s risk and expense. Hobart’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Hobart authorized service facility as determined by

Hobart. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE

FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY HOBART IS EXCLUDED

AND DISCLAIMED BY HOBART.

Some states in the U.S.A. do not allow limitations of how long

an implied warranty lasts, or the exclusion of incidental,

indirect, special or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty

provides specific legal rights, and other rights may be

available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations

and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may

be available, but may vary from province to province.

PRINTED IN USA  2003 Hobart Welding Products. 1/03

Hobart Welding Products

An Illinois Tool Works Company

600 West Main Street

Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281

For Literature Or Nearest Dealer:

Call 1-877-Hobart1

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

To locate a Distributor,

retail or service location:

Call 1-877-Hobart1 or visit our website at

www.HobartWelders.com

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

Resources Available

Owner’s Record

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

For technical assistance:

Call 1-800-332-3281

Hobart Champion 4500 Users Manual O4418a_hob

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