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-494 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-494 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; FLYING SPARKS can cause injury.; TILTING OF TRAILER can cause injury.
OM-494 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 - ARC WELDING can cause interference.; Principal Safety Standards
OM-494 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-494 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-494 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-494 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-494 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While Welding Or Under Load Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Cer...
Page 14 - SECTION 3 – SPECIFICATIONS; Description
OM-494 Page 10 SECTION 3 – SPECIFICATIONS 3-1. Description This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. AWelder Selector switch controls whether one or both sets of weld output terminals are active (see Section 5-2). Whenthe unit is ...
Page 15 - Fuel Consumption; AC Auxiliary Power; AC AMPERES IN 240V MODE
OM-494 Page 11 3-4. Fuel Consumption The curve shows typical fuel use un-der the combined weld loads of bothsides (Welder A and Welder B). 195 711 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 40% DUTY CYCLE CV CC 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....
Page 16 - Duty Cycle And Overheating; A or V
OM-494 Page 12 3-6. Duty Cycle And Overheating Ref. rduty1 5/95 – 194 313-A Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Exceeding duty cycle candamage unit and voidwarranty. If a weld module overheats, theHigh Temperature light goes on andthe thermost...
Page 18 - SECTION 4 – NSTALLATION; When facing the front panel, the Welder B; NOTE; Installing Welding Generator
OM-494 Page 14 SECTION 4 – NSTALLATION When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left. NOTE 4-1. Installing Welding Generator install1 10/00* – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854 1 2 ...
Page 19 - Activating The Dry Charge Battery
OM-494 Page 15 4-2. Activating The Dry Charge Battery 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 overfill battery c...
Page 21 - Engine Prestart Checks
OM-494 Page 17 4-5. Engine Prestart Checks Full 1/2 in (13 mm) Full Ref. 158 633-C / S-176 697 Diesel Check all fluids daily. Engine mustbe cold and on a level surface. Follow run-in procedure in enginemanual. If unburned fuel and oil col-lect in exhaust pipe during run-in,see Section 9. Fuel Do not...
Page 22 - Safety Information For Connecting To Weld Output Terminals; Weld Output Terminals
OM-494 Page 18 4-6. Safety Information For Connecting To Weld Output Terminals UNEXPECTED WELD OUTPUT can cause injury or fire. Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running. Disconnect or insulate any unused cables. Know where ...
Page 23 - Making Dual Operator CC Weld Connections w/ Separate Work Cables
OM-494 Page 19 4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC andCV welding (see Section 5-1). See Section 4-15 for proper cable size. 1 Strain Reliefs Route cables through st...
Page 24 - Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
OM-494 Page 20 4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, workcable must be able to carry combinedweld output of both CC weld output ter-minals (see Section 4-15 for prope...
Page 26 - -11. Making Dual Operator CV Weld Connections w/ Common Work Cable
OM-494 Page 22 4-11. Making Dual Operator CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, workcable must be able to carry combinedweld output of both CC weld output ter-minals (see Section 4-15 for propercab...
Page 29 - -14. Making Single Operator CC Weld Connections
OM-494 Page 25 4-14. Making Single Operator CC Weld Connections 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Welder A (left) weld output terminalsare disabled in Single Operator mode.Connect only to Welder B (right) termi-nals for Single Operator mode opera-tion. Use Single Ope...
Page 33 - Engine Controls
OM-494 Page 29 SECTION 5 – OPERATING THE WELDING GENERATOR When facing the front panel, the Welder B controls and weld terminals are on theright and the Welder A side controls and weld terminals are on the left. NOTE 5-1. Engine Controls See Section 5-3 for weld controldescriptions. 1 Engine Start B...
Page 36 - Routine Maintenance
OM-494 Page 32 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles 190 376 Be sure equipment connected to the240 V receptacles is GFCI-pro-tected. Auxiliary power is not affected by posi-tion of Welder Selector switch. 4 kVA/kW auxiliary power output isshared by a...
Page 38 - Maintenance Label
Page 39 - Servicing Air Cleaner
OM-494 Page 35 7-3. Servicing Air Cleaner aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. The air cleaner primary element canbe cleaned...
Page 40 - Servicing Fuel And Lubrication Systems
OM-494 Page 36 7-4. Servicing Fuel And Lubrication Systems Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil Fill Cap 5 Primary Fuel Filter (Fuel/Water Separator) 6 Petcock 7 Secondary Fuel Filter 8 Fuel Shutoff V...
Page 41 - Adjusting Engine Speed; RPM; Servicing Optional Ether Starting Aid
OM-494 Page 37 7-5. Adjusting Engine Speed Ref. 045 768-B Engine speed is factory set andshould not require adjustment. Af-ter tuning engine, check enginespeed with tachometer. See tablefor proper no load speed. If neces-sary, adjust speed as follows: 1 High Speed Stop Screw 2 Lock Nut Loosen nut. T...
Page 42 - Checking And Replacing Alternator Belt
OM-494 Page 38 7-7. Checking And Replacing Alternator Belt 158 632 / Ref. 190 377 Stop engine. To check belt tension: Remove rear panel. 1 Alternator V-Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul-leys. Pull down belt as far as it willgo, then measure distance frombel...
Page 43 - Resetting Fan Belt Safety Shutdown
OM-494 Page 39 7-8. Resetting Fan Belt Safety Shutdown 158 715 / Ref. 158 632 / Ref. 190 377 Stop engine. 1 Cooling Fan V-Belt See engine manual to replace ortighten belt. If belt breaks or becomes loose,safety shutdown stops engine. Correct problem, then reset safetyshutdown as follows: 2 Rod 3 Sto...
Page 44 - Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-494 Page 40 7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 800 633-B / Ref. 190 377 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run several min-utes to blow out cleanou...
Page 49 - Notes
Page 50 - SECTION 8 – ELECTRICAL DIAGRAMS; Figure 8-1. Circuit Diagram For Welding Generator
OM-494 Page 46 SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Welding Generator
Page 52 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking
OM-494 Page 48 SECTION 9 – RUN-IN PROCEDURE run_in3 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 53 - Run-In Procedure Using Load Bank
OM-494 Page 49 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 54 - Run-In Procedure Using Resistance Grid
OM-494 Page 50 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 Place Welder Selector...
Page 55 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame
OM-494 Page 51 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 s...
Page 56 - 0-3. Grounding When Supplying Building Systems
OM-494 Page 52 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 57 - 0-5. Approximate Power Requirements For Industrial Motors
OM-494 Page 53 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 58 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-494 Page 54 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 60 - 0-10. Typical Connections To Supply Standby Power
OM-494 Page 56 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 62 - SECTION 11 – PARTS LIST
OM-494 Page 58 SECTION 11 – PARTS LIST Hardware is common andnot available unless listed. 802 317-B 1 2 3 4 5 6 7 8 9 10 11 12 13 9 10 14 15 16 17 18 19 20 21 22 23 24 25–SEE FIG 11–4 26 9 10 27 28 29 30 31 32 33 34 35 363738 83 84 85 86 87 88 89 90 91 92–SEE FIG 11–2 93 94 95 96 97 98 99 Figure 11-...
Page 76 - 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...
