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-478 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-478 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; OVERUSE can cause OVERHEATING.
OM-478 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-478 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-478 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-478 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-478 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
OM-478 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Check engine belt Check Air Cleaner Ether Starting Aid Engine Battery (Engine) OPT Jump start/Battery Charge Battery Charge Jump Start Do Not Switch Under Load Read Operato...
Page 14 - SECTION 3 – SPECIFICATIONS; Air Compressor Specifications
OM-478 Page 10 SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open-Circuit Voltage (Nominal) Auxiliary Power Rating 5 kVA/kW Auxiliary Power Plant (Optional) 15 kVA/kW Auxiliary Power Plant Engine Fuel Tank Capacity ...
Page 15 - Fuel Consumption; Duty Cycle And Overheating; WELD AMPERES; CONSTANT AIR DELIVERY
OM-478 Page 11 3-4. Fuel Consumption The curve shows typical fuel useunder weld or auxiliary powerloads. ST-188 312 0.00 2.00 U.S. GAL/HR. IM P . GAL/HR. 1.67 LITERS/HR. 7.57 0.00 0.00 0 50 100 150 200 250 300 350 400 450 500 0.76 0.17 0.20 1.51 0.33 0.40 2.27 0.50 0.60 3.03 0.67 0.80 3.79 0.83 1.00...
Page 18 - Optional AC Power Plant Curves
OM-478 Page 14 3-9. Optional AC Power Plant Curves ST-188 214 / ST-188 213 The ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt orthree-phase 240 volt terminals. A. 10 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 15 KVA/KW Three-Phase Auxi...
Page 19 - -10. Optional Battery Charging Output Curve
OM-478 Page 15 3-10. Optional Battery Charging Output Curve ST-188 221 The battery charging curves showthe charging amperage and voltageoutput of the welding generator. As battery voltage nears the charg-ing voltage, charging current de-creases. 0 0 DC AMPERES DC VOL T S 100 200 300 400 500 600 700 ...
Page 20 - SECTION 4 – INSTALLATION; Installing Welding Generator; Connecting The Battery
OM-478 Page 16 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 21 - Installing Precleaners, Exhaust Pipe, And Rain Cap; Engine Prestart Checks
OM-478 Page 17 4-3. Installing Precleaners, Exhaust Pipe, And Rain Cap Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake. Remove rear, left side panel. 1 Air Cleaner 2 Precleaner Remove tape from air cleaneropenings. Install precleaners on aircleaners. 3 Exhaust Pipe 4 Mu...
Page 22 - Connecting To Weld Output Terminals; Selecting Weld Cable Sizes
OM-478 Page 18 4-5. Connecting To Weld Output Terminals 2 3 1 Access Door 2 Work Weld Output Terminal 3 Electrode Weld Output Terminal 4 Torch Cable Adapter Adapter connects power and water totorch and cooling system or drain. Use only a proper torch cableadapter positioned so it doesnot hit frame, ...
Page 24 - Terminal Strip 3T Connections
OM-478 Page 20 4-9. Terminal Strip 3T Connections Ref. ST-121 578-F / Ref. S-184 781-A Stop engine. If remote control plug does not fit inreceptacle RC3, wire cord directlyto terminal strip 3T. Do not connect to Remote 14receptacle RC3 and terminalstrip 3T at the same time. Useonly one remote contro...
Page 25 - Notes
Page 26 - SECTION 5 – OPERATING THE WELDING GENERATOR
OM-478 Page 22 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) 20 19 18 ST-184 780-C / Ref. ST-121 578-F 23 12 1 2 4 5 6 7 8 9 10 11 1415 21 22 13 3 16 17 24
Page 28 - Example Of Remote Amperage Control
OM-478 Page 24 5-3. Example Of Remote Amperage Control Ref. ST-184 780-C Set Switches Adjust Remote Control Set Polarity Set Percentage Set Range Min (90 A DC/CC) Max (140 A DC/CC) 2 In Example:Min = 90 A DC/CCPercentage of Range = 50 %Max = 140 A DC/CC(50% of 90 to 190)
Page 29 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; 20 Volt GFCI Duplex Receptacles; Optional 230 Volt South African Receptacle
OM-478 Page 25 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt GFCI Duplex Receptacles Ref. ST-184 781-A 1 1 120 V 15 A AC GFCIReceptacle GFCI1 2 120 V 15 A AC GFCIReceptacle GFCI2 Receptacles supply 60 Hz single-phase power at weld/power speed. 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB...
Page 30 - Optional 5 kVA/kW Power Plant Receptacles
OM-478 Page 26 120V AC 6-3. Optional 5 kVA/kW Power Plant Receptacles 1 240 V 13 A AC DuplexReceptacle RC1 2 120 V 15 A AC GFCIReceptacle GFCI2 RC1 and GFCI2 supply 60 Hz sing-le-phase power at weld/powerspeed. 3 Circuit Breaker CB1 And CB2 CB1 and CB2 protect RC1 fromoverload. CB2 also protects GFC...
Page 31 - Connecting Auxiliary Power Plant
OM-478 Page 27 6-4. Connecting Auxiliary Power Plant Ref. S-160 620C Stop engine. Power and weld outputs arelive at the same time. Discon-nect or insulate unusedcables. Have qualified person installaccording to circuit diagram andSection 12 – Auxiliary Power Guide-lines. Place CC/CV switch in CCposi...
Page 32 - Jump Start/Battery Charge Cable Connections
OM-478 Page 28 SECTION 7 – OPERATING OPTIONAL BATTERY CHARGER Follow jump starting procedure to quickly start equipment having a weak or deadbattery. Follow charging procedure to trickle-charge a battery. NOTE 7-1. Jump Start/Battery Charge Cable Connections ST-153 653-A Stop engine. Do not charge o...
Page 33 - Jump Start/Battery Charge Controls; Determining Battery Charging Current
OM-478 Page 29 7-2. Jump Start/Battery Charge Controls Ref. ST-184 780-C 1 Output Selector Switch Do not switch under load. Use switch to select weld or batterycharge/jump start output. Outputautomatically stops when terminalvoltage is 15 to 25 percent aboverequired battery voltage. Moveswitch to we...
Page 34 - Battery Charging Procedure
OM-478 Page 30 7-4. Battery Charging Procedure Ref. ST-184 780-C / S-115 587-B Stop Engine. Connect Cables (Observe Correct Polarity). Set Battery Voltage Switch. Set Charge/Jump Start Switch To Charge. Set Amperage/Voltage Switch To Panel And Out- put (Contactor) Switch To Remote. Turn OffRemote De...
Page 35 - Jump Starting Procedure; SECTION 8 – MAINTENANCE & TROUBLESHOOTING
OM-478 Page 31 7-5. Jump Starting Procedure Ref. ST-184 780-C Charge battery for 10 minutesbefore jump starting battery(see Section 7-4). Set Output (Contactor) Switch to Remote. Turn Off Remote Device. Set A/V control to max (100) and Ampere Range switch to CV position. Charge Battery For 10 MInute...
Page 36 - Routine Maintenance
OM-478 Page 32 8-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Mainte-nance Label. Service engine more oftenif used in severe conditions. * To be done by Factory AuthorizedService Agent. 8 h Check Fluid Levels. See Section 4-4. Wipe Up Spill...
Page 37 - Servicing Air Cleaner
OM-478 Page 33 1000 h Change Fuel Filters. See Section 8-4. Drain Sludge From Fuel Tank. See Section 8-4. FUEL SLUDGE Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. OR Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Check Valve Clearance.* ...
Page 40 - Adjusting Engine Speed
OM-478 Page 36 8-6. Adjusting Engine Speed Stop engine. Engine speeds have been factoryset and should not require adjust-ment. After tuning engine, checkengine speeds with a tachometer.See table for proper no loadspeeds. If necessary, adjustspeeds as follows: Idle Speed Adjustment 1 Throttle Solenoi...
Page 41 - Overload Protection
OM-478 Page 37 8-7. Overload Protection Ref. ST-184 780-F / Ref. ST-184 781-A / Ref. ST-153 653-A / ST-153 702-A Stop engine. If a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedService Agent. 1 Circuit Breaker CB3 CB3 protects the 115 vol...
Page 44 - B. Auxiliary Power Trouble
OM-478 Page 40 Min or max CV weld output only. Check position of Amperage/voltage control and Amperage/Voltage Control switch. Repair or replace remote control device. Have Factory Authorized Service Agent check optional CV regulator board PC2. Tungsten electrode oxidizing and notremaining bright at...
Page 45 - D. Optional Battery Charging System
OM-478 Page 41 Engine remains at weld rpm when En-gine Control switch is in the Run/Idle po-sition and load is removed. Check fuse F11, and replace if open (see Section 8-7). Move CC/CV switch to CC position. Unit does not run at idle speed in CV mode. Have Factory Authorized Service Agent check con...
Page 46 - SECTION 9 – ELECTRICAL DIAGRAMS; Figure 9-1. Circuit Diagram For Welding Generator
OM-478 Page 42 SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
Page 52 - SECTION 10 – RUN-IN PROCEDURE
OM-478 Page 48 SECTION 10 – RUN-IN PROCEDURE run_in1 6/96 10-1. 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 55 - SECTION 11 – AIR COMPRESSOR TABLES
OM-478 Page 51 SECTION 11 – AIR COMPRESSOR TABLES 11-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters Gauge Pressure In Receiver (lb) Orifice Diameter (in) And Free Air Flow (CFM) 1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4 1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85 2 0.038 0.153 0.342 0...
Page 57 - SECTION 12 – AUXILIARY POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame; OR
OM-478 Page 53 SECTION 12 – AUXILIARY POWER GUIDELINES 12-1. 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 58 - 2-3. Grounding When Supplying Building Systems
OM-478 Page 54 12-3. 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 59 - 2-5. Approximate Power Requirements For Industrial Motors
OM-478 Page 55 12-5. 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 60 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-478 Page 56 12-7. 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 62 - 2-10. Typical Connections To Supply Standby Power
OM-478 Page 58 12-10. 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 66 - SECTION 14 – GUIDELINES FOR TIG WELDING (GTAW)
OM-478 Page 62 SECTION 14 – GUIDELINES FOR TIG WELDING (GTAW) 14-1. Positioning The Torch ST-161 892 Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. 1 Workpiece Make sure workpiece is clea...
Page 67 - 4-3. Positioning Torch Tungsten For Various Weld Joints
OM-478 Page 63 14-3. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 68 - ARTS LIST; Figure
OM-478 Page 64 SECTION 15 – P ARTS LIST ST-121 286-H (Part 1 of 2) Figure 15-1. Main Assembly (Part 1 Of 2) 1 2 3 4 5 6 7 8 9 10 11 12 13 25 14 15 24 18 26 17 16 14 18 27 28 23 22 20 14 19 29 30 31 32 21 34 35 36 37 38 39 40 41 4243 44 45 46 47 48 49 31 32 21 50 51 52 53 54 31 32 55 56 57 58 60 59 3...
Page 83 - (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 84 - 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...
