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 - TABLE OF CONTENTS; WARNING
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 ...
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-498 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 - FLYING METAL can injure eyes.; BUILDUP OF GAS can injure or kill.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.
OM-498 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-498 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-498 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-498 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-498 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-498 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; Symbol Definitions; SECTION 3 – SPECIFICATIONS
OM-498 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds Time Protective Earth (Ground) Circuit Breaker Temperature SECTION 3 – SPECI...
Page 14 - Dimensions, Weights, And Operating Angles
OM-498 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) Width 22-3/4 in (577 mm) D Depth 31-1/4 in (793 mm) A 31-1/4 in (793 mm) B Do not exceed tilt angles or engine couldbe damaged or unit could tip. B 10-1/2 in (268 mm) Do not move or operate unit where ...
Page 15 - Duty Cycle
OM-498 Page 11 3-4. Fuel Consumption (Honda-Powered Units) 802 121 Continuous Welding 3-5. Duty Cycle 802 092 Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and voidwarranty. 100% Duty Cycle at 80 Amperes CC/DC 3 Min...
Page 16 - Auxiliary Power Curve
OM-498 Page 12 3-6. Auxiliary Power Curve 802 129 The ac auxiliary power curvesshow the auxiliary power availablein amperes at the receptacles. 3-7. Volt-Ampere Curves 198 453 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves o...
Page 17 - SECTION 4 – INSTALLATION; Installing Welding Generator; Grounding Generator To Truck Or Trailer Frame
OM-498 Page 13 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 1/97 – 802 512-A / Ref. 151 556 / 158 936-A / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location 4-2. Grounding Generator To Truck Or Trailer Frame...
Page 18 - Grounding Generator When Supplying Building Systems
OM-498 Page 14 4-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device asstated in electrical codes. 2 3 800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to sys-tem earth ground if sup...
Page 21 - SECTION 5 – OPERATING THE WELDING GENERATOR
OM-498 Page 17 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (Kohler-Powered Units) 802 512-A / 495 179 5 2 60 Hz 3 4 Weld and auxiliary power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch Use switch to open ignition circuit, and to stopengine. 2 Throttle ...
Page 23 - Notes
OM-498 Page 19 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) Weld and auxiliary power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch On models with recoil-start, use switch toopen ignition circuit, and to stop engine. On models with electric-star...
Page 25 - Optional Auxiliary Power Panels
OM-498 Page 21 6-2. Optional Auxiliary Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 Auxiliary Power Panel 495 315 (USA) Auxiliary Power Panel 495 279 (Canada) Auxiliary Power Panel 495 253 (South Africa) Auxiliary Power Panel 495 289 (Australia) If unit does not have GFCI recep-tacles, use G...
Page 26 - Auxiliary Power Panel Ratings; NOTE
OM-498 Page 22 6-3. Auxiliary Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles. NOTE Total power from generator NOT to exceed 3500 Watts (60 Hz) Receptacle Protected By Panel 495 218 (USA) Panel 495 315 (USA) Panel 495 298 (USA) Panel 4...
Page 28 - SECTION 7 – MAINTENANCE; Routine Maintenance
OM-498 Page 24 SECTION 7 – MAINTENANCE 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. 8 h 20 h Wipe up spills. Check fluidlevels...
Page 29 - Maintenance Label; ENGINE MAINTENANCE
OM-498 Page 25 Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-2. Maintenance Label Ref. S-175 679-A ENGINE MAINTENANCE 8 h 1.1 l (1.2 US qt,1.94 lmp qt) Unleaded86 + Octane6.5 l (1.7 US Gal, 11.4 lmp pt) 50 h 100 h 10W -30 ° F +3...
Page 32 - SECTION 8 – TROUBLESHOOTING; Troubleshooting
OM-498 Page 28 SECTION 8 – TROUBLESHOOTING 8-1. Troubleshooting A. Welding Trouble Remedy No weld output. Check Amperage control setting. Check weld connections. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings...
Page 34 - SECTION 9 – ELECTRICAL DIAGRAMS; Figure 9-1. Circuit Diagram For Welding Generator
OM-498 Page 30 SECTION 9 – ELECTRICAL DIAGRAMS SC-495 297 198 016-D Figure 9-1. Circuit Diagram For Welding Generator
Page 35 - Figure 9-2. Wiring Diagram For Welding Generator
OM-498 Page 31 198 014-C Figure 9-2. Wiring Diagram For Welding Generator
Page 38 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame
OM-498 Page 34 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 4/01 – 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 39 - 0-3. Grounding When Supplying Building Systems
OM-498 Page 35 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 40 - 0-5. Approximate Power Requirements For Industrial Motors
OM-498 Page 36 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 41 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-498 Page 37 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 43 - 0-10. Typical Connections To Supply Standby Power
OM-498 Page 39 10-10. Typical Connections To Supply Standby Power S-0405-A Have only qualified personsperform these connectionsaccording to all applicablecodes and safety practices. 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain...
Page 45 - SECTION 11 – STICK WELDING (SMAW) GUIDELINES
OM-498 Page 41 SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure stick 12/96 – ST-151 593 Weld current starts whenelectrode touches work-piece. Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp ascl...
Page 48 - 1-8. Conditions That Affect Weld Bead Shape
OM-498 Page 44 11-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness 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 An...
Page 50 - 1-15. Troubleshooting – Excessive Spatter
OM-498 Page 46 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 doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 11-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting fr...
Page 52 - 1-20. Troubleshooting – Waviness Of Bead
OM-498 Page 48 11-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel...
Page 54 - SECTION 12 – PARTS LIST
OM-498 Page 50 SECTION 12 – PARTS LIST Hardware is common andnot available unless listed. 802 513-A / 802 153-B 19 25 29 22 23 28 26 27 20 21 32 33 30 31 – Fig 12-2 34 35 37 36 1 6 24 3 5 4 7 8 2 18 17 16 15 14 13 12 9 11 10 38 39 40 41 42 43 44 Figure 12-1. Main Assembly
Page 60 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA 2001 Hobart Welding Products. 1/01 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...
