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
The following terms areused interchangeablythroughout this manual: Stick = SMAW The engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive harm. WARNING TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ...
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-493 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-493 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-493 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-493 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-493 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-493 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-493 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-493 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check Valve Clearance Do not switch while welding Work Connecti...
Page 14 - Dimensions, Weights, and Operating Angles; Auxiliary Power Curve
OM-493 Page 10 3-2. Dimensions, Weights, and Operating Angles Dimensions A Height 33-1/2 in (851 mm) B C Width 18-3/4 in (476 mm) C Depth 46 in (1164 mm) D Do not exceed tilt angles or engine couldbe damaged or unit could tip. A 18 in (457 mm) G Do not move or operate unit where it couldtip. B 16-1/...
Page 15 - Fuel Consumption; Duty Cycle
OM-493 Page 11 3-4. Fuel Consumption SB-191 556 Continuous Welding 3-5. Duty Cycle SB-191 554 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 210 Amperes CC/DC
Page 16 - SECTION 4 – INSTALLATION; Installing Welding Generator
OM-493 Page 12 3-6. Volt-Ampere Curve ST-191 555 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thecurves shown. SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 12/99 – R...
Page 17 - Engine Prestart Checks
OM-493 Page 13 4-2. Engine Prestart Checks Full Full Gasoline Check all fluids daily. Engine mustbe cold and on a level surface. Unitis shipped with 10W30 engine oil. Follow run-in procedure inengine manual. This unit has a low oil pressureshutdown switch. However,some conditions may causeengine dam...
Page 18 - Activating The Dry Charge Battery (If Applicable)
OM-493 Page 14 4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection – SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom of well (maximum). Do not ov...
Page 21 - SECTION 5 – OPERATING THE WELDING GENERATOR; Front Panel Controls
OM-493 Page 17 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls Ref. ST-192 519-A 5 1 Engine Control Switch Use switch to start engine, select speed, andstop engine. In Run/Idle position, engine runsat idle speed at no load, and weld/powerspeed under load. In Run position, engin...
Page 22 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Standard Receptacles
OM-493 Page 18 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Standard Receptacles Ref. ST-192 519 -A If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. Set Fine Adjust control R1 at 10for full auxiliary power. 1 240 V 30 A...
Page 23 - Optional Auxiliary Power Receptacles
OM-493 Page 19 6-2. Optional Auxiliary Power Receptacles Ref. ST-192 519 -A If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. Set Fine Adjust control R1 at 10for full auxiliary power. Combined output of all receptacleslimi...
Page 24 - SECTION 7 – MAINTENANCE; Routine Maintenance; Note
OM-493 Page 20 SECTION 7 – MAINTENANCE 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 Engine Manual and Maintenance Label. Ser-vice more often if us...
Page 25 - Maintenance Label
Page 26 - Servicing Air Cleaner; Overload Protection
OM-493 Page 22 7-3. Servicing Air Cleaner aircleaner3 1/97 – ST-156 852 / Ref. ST-192 519-A / S-0759 Stop engine. Do not run engine without aircleaner or with dirty element. 1 Wrapper (Foam Element) Wash wrapper with soap and watersolution. Allow wrapper to air drycompletely. Spread 1 tablespoon SAE...
Page 27 - Changing Engine Oil, Oil Filter, and Fuel Filter
OM-493 Page 23 7-5. Changing Engine Oil, Oil Filter, and Fuel Filter Ref. ST-192 519-A / ST-802 210-B / ST-802 211 / S-0842 Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord-ing to engine owner’s manual. Close valve and valve capbefore...
Page 28 - Adjusting Engine Speed
OM-493 Page 24 7-6. Adjusting Engine Speed ST-800 397 / Ref. ST-802 211 After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows: Start engine and run until warm.Turn Fine Adjust control to 10. Remove top cover to access speedadjustments. Idle Speed...
Page 29 - Servicing Optional Spark Arrestor
OM-493 Page 25 7-7. Servicing Optional Spark Arrestor ST-802 210-B / Ref. ST-801 682-A / Ref. ST-192 519–A Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replacespark arrestor if screen wires arebroken or missing. 1/4 in 1 Tools Needed:
Page 30 - SECTION 8 – TROUBLESHOOTING
OM-493 Page 26 SECTION 8 – TROUBLESHOOTING A. Welding Trouble Remedy No weld output. Check control settings. Check weld connections. Check fuse F1 and replace if open (see Section 7-4). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent c...
Page 32 - SECTION 9 – ELECTRICAL DIAGRAM; Figure 9-1. Circuit Diagram For Welding Generator
OM-493 Page 28 SECTION 9 – ELECTRICAL DIAGRAM ST-191 080-A Figure 9-1. Circuit Diagram For Welding Generator
Page 33 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame; OR
OM-493 Page 29 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 34 - 0-3. Grounding When Supplying Building Systems
OM-493 Page 30 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 35 - 0-5. Approximate Power Requirements For Industrial Motors
OM-493 Page 31 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 36 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-493 Page 32 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 38 - 0-10. Typical Connections To Supply Standby Power
OM-493 Page 34 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 40 - SECTION 11 – STICK WELDING (SMAW) GUIDELINES
OM-493 Page 36 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 43 - 1-8. Conditions That Affect Weld Bead Shape; NOTE
OM-493 Page 39 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 45 - 1-15. Troubleshooting – Excessive Spatter
OM-493 Page 41 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 47 - 1-20. Troubleshooting – Waviness Of Bead
OM-493 Page 43 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 48 - SECTION 12 – PARTS LIST
OM-493 Page 44 SECTION 12 – PARTS LIST ST-802 214-B Hardware is common andnot available unless listed. Figure 12-1. Main Assembly 1 2 3 4 5 6 7 8 9 13 14 15 16 17 18 19 20 21 22 – (Figure 12 – 3) 23 24 25 29 30 31 32 36 37 38 39 40 41 42 – (Figure 12 – 2) 43 44 45 46 47 48 49 50 51 26 27 28 52 53 11...
Page 55 - (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 56 - 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...
