Hobart OM-474 - Manuals - manualsarea.com

Page 2 - From Hobart to You

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Hobart distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-877-Ho...

Page 3 - CALIFORNIA; TABLE OF CONTENTS; WARNING

The following terms areused interchangeablythroughout this manual: Stick = SMAWMIG = GMAWTIG = GTAW CALIFORNIA Proposition 65Warning Diesel engine exhaust andsome of its constituentsare known to the State ofCalifornia to causecancer, birth defects, andother reproductive harm. TABLE OF CONTENTS SECTI...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.

OM-474 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This gro...

Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.

OM-474 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ove...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance; TILTING OF TRAILER can cause injury.

OM-474 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed 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 ne...

Page 8 - Principal Safety Standards

OM-474 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qualif...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-474 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message ...

Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur

OM-474 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendies...

Page 11 - LIRE LES INSTRUCTIONS.

OM-474 Page 7 DES ORGANES MOBILES peuventprovoquer 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 deprotection. Arrêter le moteur avant d’installer ou branch...

Page 13 - SECTION 2 – DEFINITIONS; Symbols And Definitions; SECTION 3 – SPECIFICATIONS

OM-474 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Glow Plug Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trained Me...

Page 14 - Dimensions, Weights, And Operating Angles; Fuel Consumption

OM-474 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 48-3/4 in (1238 mm) Width 24-5/8 in (625 mm) Depth 64-1/2 in (1638 mm) L Engine End Do not exceed tilt angles or engine could A 62 in (1575 mm) be damaged or unit could tip. Do not move or operate unit where it could B 5...

Page 15 - Duty Cycle And Overheating

OM-474 Page 11 6 Minutes Welding 4 Minutes Resting Continuous Welding 3-4. Duty Cycle And Overheating rduty1 5/95 – SB-111 076-A Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Exceeding duty cycle candamage unit and voidwarranty. 60% Duty Cycle At 350 Am...

Page 16 - Optional AC Power Plant Curves; AC AMPERES

OM-474 Page 12 3-6. Optional AC Power Plant Curves rsb13.1 12/94 - ST-111 118-D / ST-112 449-B The ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt orthree-phase 240 volt terminals. A. 8.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 12.5 ...

Page 18 - SECTION 4 – INSTALLATION; Installing Welding Generator; Connecting The Battery

OM-474 Page 14 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 12/99 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 Always ground generatorframe to vehicle frame to pre-vent ...

Page 19 - Installing Muffler; Engine Prestart Checks

OM-474 Page 15 muff1 4/96 – ST-154 088-B / Ref. ST-191 898 1/2 in Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake. Tools Needed: 4-3. Installing Muffler Full Full 1/2 in (13 mm) Full Capacity: 9 qt (8.5 L) Diesel Valve Open Check all fluids daily. Engine must be coldand...

Page 20 - Connecting To Weld Output Terminals; Selecting Weld Cable Sizes

OM-474 Page 16 4-5. Connecting To Weld Output Terminals Open left side door. 1 Bracket Route cables through bracket. 2 Positive (+) Weld OutputTerminal 3 Negative (–) Weld Output Ter-minal For Stick welding Direct CurrentElectrode Positive (DCEP), con-nect work cable to (–) terminal andelectrode hol...

Page 22 - SECTION 5 – OPERATING WELDING GENERATOR

OM-474 Page 18 SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) Ref. ST-154 862-A / Ref. ST-191 898 1 2 16 17 6 7 8 15 3 4 5 12 1413 0 s 10 s 20 s 70 ° F (21 ° C) 32 ° F (0 ° C) –4 ° F (–20 ° C) Glow Plug Time 9 ( ) 10 11

Page 25 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; 20 Volt Duplex And Optional GFCI Receptacles

OM-474 Page 21 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt Duplex And Optional GFCI Receptacles Ref. ST-191 898 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord. 1 120 V 15 A AC ReceptacleRC1 2 120 V 15 A AC ReceptacleRC2 3 120 V 15 A AC GFCI Recep-tacles GFCI1...

Page 27 - Connecting Optional Auxiliary Power Plant

OM-474 Page 23 6-3. Connecting Optional Auxiliary Power Plant Ref. S-185 000-A Stop engine. Power and weld outputs arelive at the same time. Discon-nect or insulate unusedcables. Have qualified person installaccording to circuit diagramand Auxiliary Power Guidelines(see Section 10). Place optional P...

Page 28 - Routine Maintenance

OM-474 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and MaintenanceLabel. ...

Page 29 - Maintenance Label

Page 30 - Servicing Air Cleaner

OM-474 Page 26 7-3. Servicing Air Cleaner aircleaner2 4/96 – ST-153 929-B / ST-153 585 / Ref. ST-191 898 / Ref. S-0698-B Stop engine. 1 Intake Manifold 2 Service Indicator 3 Window 4 Reset Button Service air cleaner element if redband appears in window. A greenband means air cleaner is okay.Press bu...

Page 31 - Servicing Fuel System

OM-474 Page 27 7-4. Servicing Fuel System Ref. ST-154 952-C / Ref. ST-154 954 / ST-155 872-A / Ref. ST-191 898 Stop engine and let cool. 1 Fuel Filter 2 Petcock 3 Bleeder Valve 4 Fuel Shutoff Valve 5 Fuel Line 6 Sludge Drain Plug To drain water from fuel system: Open filter petcock and drain waterin...

Page 32 - Adjusting Engine Speed

OM-474 Page 28 7-5. Adjusting Engine Speed Ref. ST-154 952-C / ST-091 065-A Engine speeds have been factoryset and should not requireadjustment. Start engine and check enginespeeds with a tachometer. Seetable for proper no load speeds. Ifnecessary, adjust speeds asfollows: Weld/Power Speed Adjustmen...

Page 33 - Changing Engine Oil And Filter

OM-474 Page 29 7-6. Changing Engine Oil And Filter ST-154 953 / Ref. ST-191 898 Stop engine and let cool. 1 Standard Oil Filter 2 Optional Remote Oil Filter 3 Optional Remote Oil FilterHoses And Adapter 4 Oil Drain Plug Change oil and filter according to en-gine manual. Install optional remote oil f...

Page 34 - Overload Protection

OM-474 Page 30 7-7. Overload Protection Ref. ST-191 898 / Ref. ST-154 862-A / Ref. ST-154 952-C Stop engine. If any fuse or circuit breakercontinues to open, contact Fac-tory Authorized Service Agent. 1 Magnetic ShutdownSwitch MS1 2 Fuse F (See Parts List) Fuse F protects magnetic shutdownswitch MS1...

Page 35 - Inspecting And Cleaning Optional Spark Arrestor Muffler; Troubleshooting

OM-474 Page 31 7-8. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. ST-191 898 / ST-162 256 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed toblow out cleanout hol...

Page 38 - Notes

Page 39 - SECTION 8 – ELECTRICAL DIAGRAMS

OM-474 Page 35 SECTION 8 – ELECTRICAL DIAGRAMS 193 981-A Figure 8-1. Circuit Diagram For Welding Generator For Standard Models

Page 42 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking

OM-474 Page 38 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking 1 Welding Generator Run diesel engines near rated out-put during run-in period to properlyseat piston rings and prevent wets-tacking. See nameplate or ratinglabel to find rated output. Do not idle engine longer thannecessary. ...

Page 43 - Run-In Procedure Using Load Bank

OM-474 Page 39 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Load Bank Turn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall receptacle or genera-tor auxi...

Page 44 - Run-In Procedure Using Resistance Grid

OM-474 Page 40 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Resistance Grid Use grid sized for generator ratedoutput. Turn Off grid. 2 Welding Generator Place A/V range switc...

Page 45 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame; OR

OM-474 Page 41 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this ...

Page 46 - 0-3. Grounding When Supplying Building Systems

OM-474 Page 42 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 U...

Page 47 - 0-5. Approximate Power Requirements For Industrial Motors

OM-474 Page 43 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 ...

Page 48 - 0-7. Approximate Power Requirements For Contractor Equipment

OM-474 Page 44 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 i...

Page 50 - 0-10. Typical Connections To Supply Standby Power

OM-474 Page 46 10-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection. ...

Page 52 - SECTION 11 – PARTS LIST

OM-474 Page 48 SECTION 11 – PARTS LIST Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 10 9 12 13 17 14 10 11 19 20 21 22 23 24 25 26 27 79 80 81 88 89 90 91 92 99 105 108 113 109 112 117 118 119 120 107 Fig 11-4 93 100 104 106 78 110 111 87 86 85 84 83 82 11 15 16 18 68 77 94 95 ...

Page 63 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-877-HOBART1for your localHobart distributor. hobart standard 7/00 ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contact your distributor orcall 1-800-33...

Page 64 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equ...