Hobart Mainliner Instructions Manual Download | Manualshive

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Summary of Contents for Mainliner

Page 1: ...T 964C 122062 INSTRUCTIONS installation operation maintenance WSf HOBART s x euw P1PEL1NER and MA1NLINER 250 AMPERE GASOLINE ENGINE DRIVEN ARC WELDER HOBART BROTHERS COMPANY HOBART SQUARE TROY OH ...

Page 2: ...on 4 installationof Unit 6 Section 5 Controls instruments andOutlets 8 Section 6 Operationof the Engine 11 Section 7 Operationof the Welding Unit 14 Section 8 Safety 16 PART THREE MAINTENANCE INSTRUCTIONS Section 9 Lubrication 18 Section 10 Preventive Maintenance 19 Section 11 Special Maintenance Problems 22 Section 12 Trouble Shooting Chart 2 4 ...

Page 3: ...ple who wear pacemakers or other electronic equipment vital to life should check with the life sup port manufacturers and their clini cian to determine whether a hazard exists C SHOCK PREVENTION Bare conductors or terminals in the output circuit or ungrounded electrically live equipment can fatally shock a person To protect against shock have a competent electrician verify that the equip ment is a...

Page 4: ... live parts of wire feeder 6 Service and Maintenance Shut OFF all power at the disconnect switch or line breaker before in specting or servicing the equipment Lock switch OPEN or remove line fuses so that power cannot be turned ON accidentally Disconnect power to equipment if it is to be left unattended or out of service 7 Replace fuses with equivalent sizes D BURN PREVENTION The welding arc is ve...

Page 5: ...gsten arc All 12 welding TIG Atomic hydrogen welding All 12 Carbon arc welding All 12 Plasma arc welding All 12 Carbon arc air gouging Light 12 Heavy 14 Plasma arc cutting Light Under 300 Amp 9 Medium 300 to 400 Amp 12 Heavy Over 400 Amp 14 WARNING THE USE OF GAS WELDING GOGGLES CAN CAUSE EYE DAMAGE WHEN ARC WELDING OR CUTTING Use helmet with proper lens shade instead Always lower the helmet befor...

Page 6: ...ainers Do not strike an arc on a compressed gas cylinder or other pressure vessel This may create brittle areas which may rup ture Do not weld or cut containers in which flammable material have been stored If absolutely neces sary to do so clean container thor oughly as described in AWS Standard A6 0 See Section K for ordering information for this Standard 4 Engine Fuel Use only approved fuel cont...

Page 7: ...vapors coming from degreasing cleaning or spraying operations The heat and rays from the arc react Instruction 910081 X0056 Jan 21 81 Revised June 2 87 Revised with the vapors to form highly toxic PHOSGENE Work in a confined space only if it is being adequately ven tilated and if ventilation is not adequate wear an air supplied res pirator see ANSI 2 37 Do not weld cut in an area where gas leaks a...

Page 8: ... person if he or she is in con tact with welding leads welding equipment or other live electrical parts Disconnect open power at wall switch and then use First Aid Dry wood wooden broom and other insulating material can be used to move cables if necessary away from person IF BREATHING IS DIFFICULT give ox ygen IF NOT BREATHING BEGIN ARTI FICIAL BREATHING such as raouth to mouth IF PULSE IS ABSENT ...

Page 9: ...der from the National Fire Pro tection Association Batterymarch Park Quincy Mass 02269 7 NFPA Standard 5IB CUTTING AND WELDING PROCESSES Order same as for Item 6 8 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS Order from the Compressed Gas As sociation 1235 Jeff Davis Hwg Arlington Virginia 22202 9 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING Order from Canadian Sta...

Page 10: ...nd the Mainliner See Pigs 1 2 The Pipeliner is available in two basic models Model G 257 which has a magneto ignition and is hand cranked and Model G 258 which is equipped with a battery ignition and a self starter The Main liner comes in two similar models Model G 260 equipped with magneto ignition and hand crank and Model G 261 equipped with a battery ignition and self starter Several variations...

Page 11: ...NE CONTROLS The engine controls for the battery equipped units are on the lower portion of the rear canopy panel They consist of the battery charging ammeter choke starter pushbutton and keylock ignition switch The engine controls for those units equipped with a magneto hand crank con sist of an ON OFF toggle switch and a choke conveniently mounted on the front can opy panel The starting crank is ...

Page 12: ...d Mainliner welders However certain variations of these standard welders are available at the customer s option and a few of the more common are discussed be low Most of these variations do not alter the fundemental operating characteris tics of the welder Any special instructions for the variations are included on an extra instruction sheet b MAGNETO IGNITION WITH BATTERY START When a welder is e...

Page 13: ...ol Panel vsa a M Fuel Tank Oil Filter Generator Starter Battery Mainliner Right Rear View Fig 1 Governor wgr i W 1 if 1 I m oUm Air Cleaner Idling Device Oil Pressure Gauge Mainliner Left Front View Fig 2 4 ...

Page 14: ... main generator fields The device will not affect the welding characteristics of the welder This idling device will close the throttle of the engine 12 to 15 seconds after welding has stopped Idling speed is then maintained until the arc is again struck Immediately on restricking the arc the idling device will allow the governor to open the throttle of the engine so that normal welding speed is ob...

Page 15: ...Pull description of parts in error SECTION 4 INSTALLATION OP UNIT 8 INSTALLATION PROCEDURE a GENERAL INSTALLATION Care should be taken to so locate the machine that there will be as little opportunity as possible for excess moisture dust paint spray or corrosive fumes to be drawn into the unit Moisture condenses on genera tor parts and electrical controls causing corrosion which can seriously affe...

Page 16: ...ommeded in the lubrication section DO NOT grease the generator bearing h Wipe off the entire unit being certain that all radiator air passages and cooling fins are free from foreign matter Use compressed air to blow dirt and dust out of the cooling passages and the control cabinet i Fill the gasoline tank with a clean regular grade 68 80 octane gasoline which is free from water and other foreign m...

Page 17: ...DLING DEVICE The idling device is a device which automatically shuts the gasoline engine down to idling speed in 10 15 sec after welding has been stopped To bring the engine to normal welding speed it is only necessary to strike an arc The idling device and governor are linked with the throttle in such a manner that the device can close the throttle without having to resist the governor action Whe...

Page 18: ...on of the exciter current through the generator shunt fields which in turn causes the cable connecting terminals to reverse polarity When the switch is in UP position the welder will operate on straight polarity and the meter hands if machine is equipped with factory installed meters will swing to the right When the switch is in the center position it is neutral and the meter hands will remain at ...

Page 19: ...ammeter is to measure the amount of current that is being used to weld However the ammeter also indicates polarity by the direc tion the pointer moves when welding is being done b WELDING VOLTMETER The welding voltmeter when furnished is in the upper right corner of the control panel It is a center reading meter with a range from 0 to 100 volts The purpose of the voltmeter is to register the volta...

Page 20: ...o r N 45 dj C J L Ol 24 57 i 634 OUTLINE AND DIMENSION Pig 4 10a ...

Page 21: ...to make sure the connections are secure and prop erly connected Check the battery electrolyte level h Make sure that no loose bars tools parts etc are in or on any part of the engine as the could cause serious damage to or wreckage of the engine or gen erator or personal injury to anyone standing nearby i If the unit is to be operated indoors make sure that an exhaust line is properly connected to...

Page 22: ...he engine by running it for a few minutes at the idling speed 900 rpm d While the engine is warming up check the engine components for leaks and loose connections 17 STOPPING THE ENGINE a Disconnect the welding load b Allow the engine to idle for a few minutes to cool valves and pistons c Turn the ignition switch OFF d If engine oil is to be changed it can be done more effectively while the en gin...

Page 23: ... lighter grade of oil Follow the recommendation given in the lubrication section In cold weather drain oil more frequently Water condenses and collects quickly mixes with the oil and increases carbon deposits to form a sludge Check oil frequently for sludge and water Water in the crankcase may freeze and shut off the oil supply or do serious damage to the oil pump g ELECTRICAL SYSTEM The complete ...

Page 24: ... circulation of air Remove side doors if the unit is so equipped Maintain a more frequent check of the water level in the radiator c BATTERY The specific gravity and proper level of the battery electrolyte should be maintained In hot climates batteries tend to self discharge if they are not in use 21 STORAGE a NIGHTLY After operation the following steps should be taken before storing the welder fo...

Page 25: ...of between 75 and 95 see par 13 b volts while the welder is running under no load d Start the engine and check for its proper operation 23 GENERAL OPERATION a Check that the open circuit voltage is between 75 and 95 volts see par 13b when the rheostat is in the max position b Strike an arc to begin welding If the setting of the multi range switch in position 1 is too low select the lowest range po...

Page 26: ...shock However these voltages are sufficiently high to be potential source of serious shock under certain conditions One of the principal dangers from low voltage welding circuits is the assump tion that they can be handled carelessly without injurious consequences The only way to be safe is to handle any electrical circuit with extreme caution High humidity and dampness of the operator s clothing ...

Page 27: ...nd invisible gas which if breathed into the lungs will cause serious illness or possible DEATH c Never make adjustments on the unit while it is connected to the engine with out first removing the ignition cables from the spark plugs d Never leave tools or parts on the operating machine as they could get among the moving parts and cause serious harm to the machine or nearby personnel otsmm ALWAYS B...

Page 28: ... or lubricate the bearing more often than every six months Over lubrication together with unclean lubrication ruins more bearings than neglect Always wipe clean the area around the bearing cap before removing it d LUBRICANT Ordinary cUp grease is not a satisfactory grease for the lubri cation of ball bearings Use only a clear non corrosive heat resistant medium bodied grease Such a grease H B No 3...

Page 29: ...ed OE CRANKCASE FILLER Fill crankcase every 50 hours of operation OE DISTRIBUTOR Place several drops of OE SAE 10 in oiler at side of distrib utor housing also a drop of oil on wick in shaft under the rotor and sparingly apply soft grease on the breaker arm cam and a drop of 0E SAE 10 on breaker arm pivot OE MAGNETO Use OE to lubricate cam wiper felt Apply no more oil than can be absorbed by wick ...

Page 30: ...nts 0E SAE 10 OE SAE 10 OE SAE lOW WP Grease Grease General Purpose CG NO 1 CG NO O CG NO 0 Water pump FITTINGS Clean before applying lubricant HOURS Reduce hours under severe operating conditions CLEAN parts with SOLVENT dry cleaning or OIL fuel Diesel Allow parts to dry thor oughly before lubricating CRANKCASES Drain only when hot Re fill to FULL mark on gauge Run engine a few minutes and re che...

Page 31: ...cal connections 32 DUR ING OPER AT I ON SERVICES AND INSPECTIONS a OIL GAUGE When unit is in operation if the oil gauge shows a changing pressure or no pressure at all check the crankcase oil level or check the oil lines for leaks b BATTERY CHARGING AMMETER Check the battery charging ammeter periodically while the unit is running to determine if the generator and voltage regulator are functioning ...

Page 32: ...finished Rust spots should be sanded down primed and refinished c ENGINE 1 Check crankcase block head and head gaskets for cracks or leaks Check that all bolts are tight see Willy s engine instruction book for correct torques 2 Run engine and listen for piston slap bearing knock or carbon knock 3 Remove valve covers and examine valve rods and spring and valve clear ances Replace cover gaskets if n...

Page 33: ...drain crankcase clean with flushing oil and renew oil filter cartridge h ENGINE ELECTRICAL SYSTEM 1 Inspect all wires and terminals for damage wear and looseness 2 Examine and test starter and switches 3 Test battery if unit is so equipped and check electrolyte 4 Inspect distributor or magneto Inspect breaker points for pitting or signs of wear 5 Check battery charging generator action for excessi...

Page 34: ...nt through the field coils for several seconds If the desired results are not secured reverse the connections and repeat the procedure A way to do this when an outside source of D C current is not available is to operate the welder with the rheostat in the maximum position with one exciter brush lifted Then raise the diametrically opposite brush and lower it quickly to the commutator If carried ou...

Page 35: ...mutator with a stick A burnishing action will result which effectively removes foreign accumulation If grease is found on the commuta te it must be removed to prevent arcing Use a solvent type cleaner and then grease bearings more sparingly 40 GENERATOR WINDINGS a Blow out dirt monthly with compressed air or remove with a suction type cleaner with a non metallic nozzle If the windings should becom...

Page 36: ...allow to cool test with hand crank Overhaul if internally jam med Replace starter Check 3 way valve fuel level and lines Allow 5 min for drainage crank 10 revolutions with choke wide open then re set choke Allow unit to cool loosen line at carburetor and turn engine over with ignition off to prime fuel pump Clean strainer drain fuel tank carburetor Check switch tighten con nections or replace defe...

Page 37: ...l thermo stat and water pump drive clear fluid or air flow obstruction Thaw out by off on operation at 5 min intervals with covering over radiator If leakage appears in block weld crack or replace engine Re fill locate leak if oil use rises suddenly Reduce load Adjust belt tension or re place belt Re time magneto or distribu te If valve clearance adjust ment or valve grinding does not correct over...

Page 38: ... load until cause of overheating is located or use heavier oil Readjust valve If none of above correct overhaul engine Tighten wire clamp or choke lever Replace float float valve and seat or entire carbur etor if not corrected by setting float level Adjust Replace if cleaning does not correct condition See above Check and re set lever or control Clean or replace Remove oil if below 0 F Replace car...

Page 39: ...ism Improper adjustment Improper adjustment Eyebolt maladjusted Governor to carburetor rod sticking Ball joints in rod stick ing Play or binding in rod Set screw maladjusted Plugged radiator or engine jacket passages Thermostat not opening Collapsed or rotted hose Test coil condenser if neither is bad replace mag neto or distributor Replace magneto Replace brush and spring Clean and turn commutato...

Page 40: ...oltage regulator defec tive Generator not charging Voltage regulator defec tive Low liquid level Internal short Loose connection Worn brushes Dirty commutator Poor connection Defective starter Re locate to clear air flow Adjust belt tension Blow with compressed air from shutter side Tighten or replace radiator Replace exposed seal or en tire pump Overhaul engine Replace capacitors Clean or replace...

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