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Engine drive welder fuel consumption

9.4K views 8 replies 9 participants last post by  Antibling  
#1 ·
Was curious the real world fuel consumption per hour of various engine drive welders Sa200 etc., I have a ex military 100kw Cat Powered generator to run my 3 phase Hobart 450 RVS with 2000 controller and my Esab 875 Plasma, I am doing some repair work on heavy vacuum trucks I have. The generator is probably overkill but I need the power to run some oil process equipment I have but I am using it just to power the welder and plasma when working on the trucks and its a pig uses probably 5 to 6gph of diesel which adds $$ up.

I had a old military Hobart engine drive from the 1960s with a 300 amp on a trailer with a Continental gas motor for a very short period, that unit used gas like it was going out of style along with issues from sitting in a field for the forest service for years so I sold it cheap.
 
#4 ·
My SA200 drinks like a fish. My Commander 500 with a Deutz sips fuel.
From the owners manual -
Low idle - .37 gph
High idle - .66 gph
DC CC welding at 500A - 1.94 gph
12KW generator full output - 1.31 gph
 
#8 ·
I can't say exactly but my TB302EFI definitely doesn't use anywhere near as much fuel as my old Legend. What I do know is that I've run 22 hours of mixed welding and idling with it on one tank of fuel. A little bit of the welding was heavy high amp but mostly low amp with a fair amount of idling thrown into the mix.
 
#9 ·
I had a guy I used to work with, should give him a call and tell him I'm out on my own, was talking to me about my Ranger 10,000. He said the Kohler (which I had) was a lot louder than the Honda they offered, and cold blooded, but was way better on gas. I've never been able to compare them to verify this though. I've never checked it, never really cared, I have it, it works, so it takes how ever much fuel it needs. But my guesstimate would be between 1 - 1.5 gals per hour. Welding a feedlot this summer I was working welding for about 9 hours a day and I'd use about 8 gallons, I figure I had at least a hour of downtime moving the pickup, taking drinks of water, eating my sandwich, and taking leaks.

I'll have to remember to check the hour meter next time I fill up.