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; CALIFORNIA; WARNING
The following terms areused interchangeablythroughout this manual:MIG = GMAW, Wire WeldingTIG = GTAWStick = SMAW TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - SECTION 12 – SAFETY PRECAUTIONS - READ BEFORE USING; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-492 Page 1 SECTION 12 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 12-1. 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 g...
Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; STEAM AND HOT COOLANT can burn.
OM-492 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 - OVERUSE can cause OVERHEATING.
OM-492 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 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-492 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-492 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-492 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-492 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil On Check Valve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire Stick (SMA...
Page 14 - Dimensions, Weights, and Operating Angles; Duty Cycle And Overheating; A or V
OM-492 Page 10 3-2. Dimensions, Weights, and Operating Angles Dimensions A Height 36 in (914 mm) B C Width 24 in (610 mm) C Depth 59 in (1499 mm) D Do not exceed tilt angles or engine couldbe damaged or unit could tip. A 19-7/8 in (505 mm) G Do not move or operate unit where it couldtip. B 18 in (45...
Page 16 - Fuel Consumption; SECTION 4 – INSTALLATION; Installing Welding Generator
OM-492 Page 12 193 458 3-5. Fuel Consumption 0 50 1 0 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 4 5 0 5 0 0 DC WELD AMPERES AT 100% DUTY CYCLE 3 6 0 0 R P M 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0.40 0.21 0.62 0.83 1.25 1.04 1.46 1.70 1.98 0.95 2.84 3.78 5.67 4.73 6.62 7.57 U.S. GAL./HR. IM P . GAL....
Page 17 - Engine Prestart Checks
OM-492 Page 13 4-2. Engine Prestart Checks 802 330-B 1/2 in (13 mm) Full Diesel Check all fluids daily. Engine must be coldand on a level surface. Unit is shipped with10W30 engine oil. Engine stops if oil pressure is too low or en-gine temperature is too high. This unit has a low oil pressure shut-d...
Page 18 - Adding Coolant To Radiator; Connecting The Battery
OM-492 Page 14 4-3. Adding Coolant To Radiator Ref. 802 330-B Stop engine and let cool. Check coolant level accordingto Section 4-2 before startingthis procedure. If coolant level is below bottom ofradiator filler neck, add coolant asfollows: 1 Radiator Air Bleed Screw Remove radiator air bleed scre...
Page 20 - Selecting Weld Cable Sizes; Remote 14 Receptacle RC5 Information; NOTE
OM-492 Page 16 4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding Amperes 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) 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4...
Page 21 - Notes
Page 22 - SECTION 5 – OPERATING WELDING GENERATOR
OM-492 Page 18 SECTION 5 – OPERATING WELDING GENERATOR 5-1. Controls (See Section 5-2) Ref. 200 379 / 802 330-B 5 6 8 9 11 12 13 14 7 10 3 2 1 4 15
Page 24 - Meter Functions; PPP; Mode Switch Settings; The Stick and CC modes provide the Adaptive Hot Start
OM-492 Page 20 5-3. Meter Functions The meters display the actual weld output values for approximately three secondsafter the arc is broken. NOTE Mode Meter Reading At Idle Meter Reading While Welding Scratch Start TIG V A Actual Volts (OCV) Preset Amps 80.0 85 Actual Volts Actual Amps V A 10.3 85 L...
Page 25 - Lift-Arc TIG Procedure
OM-492 Page 21 5-5. Lift-Arc TIG Procedure With Mode Switch in the Lift-ArcTIG position, start an arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work-piece at weld start point, holdelectrode to workpiece for 1-2seconds, and slowly lift electrode.An arc will form when electro...
Page 26 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Auxiliary Power Receptacles And Circuit Breakers
OM-492 Page 22 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord. Auxiliary power decreases as weldcurrent increases. 1 240 V 50 A AC Receptacle RC3 RC3 supplies 60 Hz single-pha...
Page 28 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; Note
OM-492 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period. Note Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label.S...
Page 30 - Maintenance Label
Page 31 - Servicing Air Cleaner; Servicing Optional Spark Arrestor
OM-492 Page 27 7-3. Servicing Air Cleaner Ref. 189 438-A / 801 964 Stop engine. Do not run engine without aircleaner or with dirty element. 1 Evacuator Valve 2 Dust Cap 3 Element 4 Housing Open evacuator valve weekly to re-move dust. Clean or replace ele-ment if dirty or damaged. Replaceelement year...
Page 32 - Servicing Engine Lubrication And Fuel Systems
OM-492 Page 28 7-5. Servicing Engine Lubrication And Fuel Systems Ref. 189 438-A / 802 330-B / S-0842 Tools Needed: 5 4 4 2 3 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Valve 3 1/2 ID x 12 in Hose 4 Fuel Line 5 Primary Fuel Filter 6 Secondary Fuel Filter 7 Petcock 8 Fuel Tank Sludge Drain To...
Page 33 - Servicing Engine Cooling System
OM-492 Page 29 7-6. Servicing Engine Cooling System 802 330-B / 802 581 Stop engine and let cool. 1 Radiator Draincock 2 Radiator Cap 3 Radiator Air Bleed Screw Change coolant according to enginemanual. Add coolant according to Sec-tion 4-3). Run engine until engine reaches normaloperating temperatu...
Page 34 - Adjusting Engine Speed
OM-492 Page 30 7-7. Adjusting Engine Speed 802 330-B After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows: Start engine and run until warm.Turn V/A control to max. Adjusting Idle Speed Turn Engine Control switch to Run/Idle position. 1 Throttle ...
Page 35 - Overload Protection
OM-492 Page 31 Stop engine. When a circuit breaker opens,it usually indicates a more seri-ous problem exists. ContactFactory Authorized ServiceAgent. 1 Circuit Breaker CB12 CB12 protects the 115 volt ac out-put to Remote 14 receptacle RC5.If CB12 opens, 115 volt ac output toRC5 stops. 2 Circuit Brea...
Page 36 - Voltmeter/Ammeter Help Displays
OM-492 Page 32 7-9. Voltmeter/Ammeter Help Displays Use the voltmeter/ammeter help displays tohelp determine the cause of no weld output.When a help display is shown, the invertermodule weld output has stopped but the en-gine continues to run. Correct the problembefore resuming operation. The displa...
Page 42 - SECTION 8 – ELECTRICAL DIAGRAMS; Figure 8-2. Circuit Diagram For Welding Generator
OM-492 Page 38 SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-2. Circuit Diagram For Welding Generator
Page 44 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking
OM-492 Page 40 SECTION 9 – RUN-IN PROCEDURE run_in4 6/99 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 45 - Run-In Procedure Using Load Bank
OM-492 Page 41 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 46 - Run-In Procedure Using Resistance Grid
OM-492 Page 42 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 3 Weld Cables Connect...
Page 47 - SECTION 10 – AUXILIARY POWER GUIDELINES; Selecting Equipment; Grounding Generator To Truck Or Trailer Frame
OM-492 Page 43 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 48 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?
OM-492 Page 44 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 50 - Approximate Power Requirements For Contractor Equipment
OM-492 Page 46 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 51 - Power Required To Start Motor; How Much Power Can Generator Supply?
OM-492 Page 47 10-8. Power Required To Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table tofind kVA/HP. If code is not listed,multiply running amperage by six tofind starting amperage. Step 2: Find Motor HP ...
Page 52 - 0-10. Typical Connections To Supply Standby Power
OM-492 Page 48 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 54 - SECTION 11 – PARTS LIST
OM-492 Page 50 SECTION 11 – PARTS LIST Hardware is common andnot available unless listed. 20 21 103 96 – Fig 11-2 100 99 98 101 90 111 – Fig. 11-3 102 112 1 3 2 4 5 6 8 26 25 24 23 95 94 97 107 108 106 104 105 22 109 110 27 28 18 10 11 10 7 9 13 12 15 17 16 14 93 19 91 Figure 11-5. Main Assembly
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...
