Page 2 - From Hobart to You; Register your product at:; Protect Your Investment!
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local Hobartdistributor to receive the latest full line catalog or individual specification sheets.To locate your nearest distributor or service agency call ...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING; Symbol Usage; Arc Welding Hazards
OM-4418 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are...
Page 7 - Engine Hazards; ENGINE HEAT can cause fire.; Compressed Air Hazards; COMPRESSED AIR can cause injury.
OM-4418 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective 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 batter...
Page 8 - Additional Symbols For Installation, Operation, And Maintenance
OM-4418 Page 4 HOT METAL from air arc cutting andgouging 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 systemparts. Let system cool down before touching or ser-vicin...
Page 9 - California Proposition 65 Warnings; Principal Safety Standards
OM-4418 Page 5 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 quali...
Page 10 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-4418 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2007−04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si onl’évite pas peu...
Page 12 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-4418 Page 8 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux à chaud et avoir de la surveillance et unextincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecl’ouïe. Porter des protections approuvés pour les ore...
Page 13 - Dangers liés à l’air comprimé; LIRE LES INSTRUCTIONS.
OM-4418 Page 9 Dévisser le bouchon légèrement et laisser la vapeur s’échapperavant d’enlever le bouchon. L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde de carbone. C’est un poison invisi-ble et inodore. JAMAIS ut...
Page 15 - Proposition californienne 65 Avertissements; Principales normes de sécurité
OM-4418 Page 11 2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent desfumées et des gaz qui contiennent des produits chimiquesdont l’État de Californie reconnaît qu’ils provoquent des mal-formations congénitales et, dans certains cas, des cancers.(Co...
Page 16 - SECTION 3 − DEFINITIONS; Symbol Definitions; SECTION 4 − SPECIFICATIONS
OM-4418 Page 12 SECTION 3 − DEFINITIONS 3-1. 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 Protector Temperature SECTION 4 − S...
Page 18 - Duty Cycle; Generator Power Curve
OM-4418 Page 14 4-4. Duty Cycle 212 950 Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. NOTICE − Exceeding duty cyclecan damage unit and void warranty. Continuous Welding 100% Duty Cycle at 90 Amperes CC/AC 3 Minutes Welding 7 Minutes Resting 30% Duty C...
Page 19 - Notes; Pros weld and cut
OM-4418 Page 15 4-6. Volt-Ampere Curves 226 078 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thecurves shown. 90 80 70 60 50 40 30 20 10 0 0 50 100 150 200 AC V olts AC Amps Max Amp Min Am...
Page 20 - SECTION 5 − INSTALLATION; Installing Welding Generator
OM-4418 Page 16 SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Ref install1 8/06 − Ref. 151 556 / 158 936-A / 803 467-C / 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 weldinggenerator onto t...
Page 22 - Connecting To Weld Output Terminals
OM-4418 Page 18 5-4. Connecting To Weld Output Terminals 803 469-D / 226 005 / 803 778-A 1 AC Weld Output Terminals Connect work and electrode cablesto weld terminals. (Polarity does notmatter for AC welding.) ! Failure to properly connectweld cables may cause ex-cessive heat and start a fire,or dam...
Page 23 - Selecting Weld Cable Sizes*
OM-4418 Page 19 5-5. 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 beforeconnecting to w...
Page 24 - MATERIAL THICKNESS REFERENCE CHART
OM-4418 Page 20 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MATERIAL THICKNESS REFERENCE CHART
Page 25 - SECTION 6 − OPERATING THE WELDING GENERATOR
OM-4418 Page 21 SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) 803 468-D / 803 469-D / 226 005 2 3 1 4
Page 26 - Amperage Selection Table For Stick (SMAW) Electrodes
OM-4418 Page 22 6-2. Description Of Controls (See Section 6-1) 1 Engine Switch Use switch to control ignition circuit, and tostop engine. 2 Choke Control Use control to change engine air/fuel mix.Move control to right (Choke) if starting a coldengine. Move control to left (Run) if starting awarm eng...
Page 27 - SECTION 7 − OPERATING AUXILIARY EQUIPMENT; Generator Power Panel Receptacles
OM-4418 Page 23 SECTION 7 − OPERATING AUXILIARY EQUIPMENT The welding generator provides power while welding and with the Amperage control in any position. However, under these conditions equipmentconnected to the welding generator may be subject to larger than normal voltage fluctuations. It is rec...
Page 28 - SECTION 8 − MAINTENANCE; Routine Maintenance
OM-4418 Page 24 SECTION 8 − MAINTENANCE 8-1. Routine Maintenance ! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and storageinformation. Service engine more often ifused in severe conditions. Recycle engine fluids. = Check = Change = Clean = ...
Page 29 - Servicing Air Cleaner
OM-4418 Page 25 8-2. Servicing Air Cleaner aircleaner6 10/02 − 803 468-D ! Stop engine. NOTICE − Do not run engine with-out air cleaner or with dirty element. 1. Cover 2. Precleaner Remove air cleaner cover. Washprecleaner with soap and water so-lution. Allow precleaner to air drycompletely. Spread ...
Page 30 - SECTION 9 − TROUBLESHOOTING; Troubleshooting
OM-4418 Page 26 SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output; no generator poweroutput at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor, st...
Page 32 - SECTION 10 − ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For Welding Generator
OM-4418 Page 28 SECTION 10 − ELECTRICAL DIAGRAMS 226 004-A Figure 10-1. Circuit Diagram For Welding Generator
Page 33 - SECTION 11 − GENERATOR POWER GUIDELINES; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4418 Page 29 SECTION 11 − 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. 11-1. Selecting Equipment gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles− ...
Page 34 - 1-3. Grounding When Supplying Building Systems
OM-4418 Page 30 11-3. 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 Use ground device as stated inelectrical codes. Ground generator to systemearth ground if supplyingpower to a premi...
Page 35 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4418 Page 31 11-5. 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 36 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4418 Page 32 11-7. 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 ...
Page 38 - 1-10. Typical Connections To Supply Standby Power
OM-4418 Page 34 11-10. Typical Connections To Supply Standby Power Transfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 1 2 3 4 5 Welding Generator Output Have only qualified personsperform these connectionsaccording to all applicablecodes and safety pract...
Page 40 - SECTION 12 − STICK WELDING (SMAW) GUIDELINES
OM-4418 Page 36 SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure stick 2007−04 − ST-151 593 1 Workpiece Make sure workpiece is clean be-fore welding. 2 Work Clamp 3 Electrode A small diameter electrode requiresless current than a large one. Fol-low electrode manufacturer’si...
Page 43 - 2-8. Conditions That Affect Weld Bead Shape
OM-4418 Page 39 12-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle...
Page 45 - 2-15. Troubleshooting − Excessive Spatter
OM-4418 Page 41 12-13. 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) 12-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting f...
Page 47 - 2-20. Troubleshooting − Waviness Of Bead
OM-4418 Page 43 12-19. 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 trave...
Page 49 - SECTION 13 − PARTS LIST
OM-4418 Page 45 SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 803 470-E 4 1 2 3 5 6 9 10 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Figure 13-1. Main Assembly
Page 52 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 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 ...
