Hobart Welding Products OM-474 manual

Processes Description Contractor 40D Air Carbon Arc (CAC-A) Cutting and Gouging TIG (GT A W ) W elding Stick (SMA W) W elding Engine Driven Welding Generator OM-474 108 848X July 2000 With Optional Equipment: MIG (GMA W) W elding Flux Cored (FCA W) W elding[...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

The following terms are used interchangeably throughout this manual: Stick = SMAW MIG = GMAW TIG = GT AW CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth d e f e c t s , a n d other reproductive harm. T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS[...]

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OM-474 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means W arning! W[...]

OM-474 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks c a n fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and b e sure the a[...]

OM-474 Page 3 MOVING P ARTS can cause injury .  Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards closed 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 necessary .  T o prevent acci[...]

OM-474 Page 4 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

OM-474 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 1 1/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.  Identifie un message de s é curit é parti[...]

OM-474 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

OM-474 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement.  Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

OM-474 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences.  Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.  Demander seulement à des personnes qualifi ?[...]

OM-474 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Glow Plug Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Amperes V V olts Panel/L[...]

OM-474 Page 10 3-2. Dimensions, W eights, And Operating Angles Dimensions Height 48-3/4 in (1238 mm) Width 24-5/8 in (625 mm) Depth 64-1/2 in (1638 mm) L Engine End  Do not exceed tilt angles or engine could A 62 in (1575 mm) be damaged or unit could tip.  Do not move or operate unit where it could B 59-1/8 in (1502 mm)  Do not move or ope[...]

OM-474 Page 1 1 6 Minutes W elding 4 Minutes Resting Continuous W elding 3-4. Duty Cycle And Overheating rduty1 5/95 – SB-1 1 1 076-A Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 60% Duty Cycle At 350 Amperes 100% Duty Cycle At 300 Ampe[...]

OM-474 Page 12 3-6. Optional AC Power Plant Curves rsb13.1 12/94 - ST-1 1 1 1 18-D / ST -1 12 449-B Th e ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 8.5 KV A/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 12.5 KV A/KW Three-Phase Auxiliary Power Plan[...]

OM-474 Page 13 3-7. V olt-Ampere Curves rsb13.1 12/94 – ST-184 477-A / ST -184 475-A / ST-184 480-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of a l l other settings fall between the curves shown. A. CC/DC (Standard) B. CC/AC (Models with Optional Polarity/AC S[...]

OM-474 Page 14 SECTION 4 – INST ALLA TION 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 to vehicle frame by metal-to-metal contact. GND/PE 3 4  Always ground generator frame t o vehicle frame to pre- vent electric shock and static electri[...]

OM-474 Page 15 muff1 4/96 – ST-154 088-B / Ref. ST -191 898 1/2 in  Stop engine and let cool.  Do not blow exhaust toward air cleaner or air intake. T ools Needed: 4-3. Installing Muffler Full Full 1/2 i n (13 mm) Full Capacity: 9 qt (8.5 L) Diesel V alve Open Check all fluids daily . Engine must be cold and on a level surface. Follow run-i[...]

OM-474 Page 16 4-5. Connecting T o W eld Output T erminals Open left side door . 1 Bracket Route cables through bracket. 2 Positive (+) Weld Output T erminal 3 Negative ( – ) W eld Output T er- minal For Stick welding Direct Current Electrode Positive (DCEP), con- nect work cable to ( – ) terminal and electrode holder cable to (+) terminal. Fo [...]

OM-474 Page 17 4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8) Socket* Socket Information A 24 volts ac. Protected by circuit breaker CB4. B Contact closure to A completes 24 volts ac contactor control circuit. AJ I 1 15 volts ac. Protected by circuit breaker CB3. B K I C L NH J Contact closure to I completes 1 15 volts ac con[...]

OM-474 Page 18 SECTION 5 – OPERA TING WELDING GENERA TOR 5-1. Front Panel Controls (See Section 5-2) Ref. ST-154 862-A / Ref. ST -191 898 1 2 16 17 6 7 8 15 34 5 12 14 13 0 s 10 s 20 s 70 ° F (21 ° C) 32 ° F (0 ° C) – 4 ° F ( – 20 ° C) Glow Plug T ime 9 () 10 11[...]

OM-474 Page 19 5-2. Description Of Front Panel Controls (See Section 5-1)  This unit has a max OCV control circuit that resets Amperage/Voltage Adjust Control R1 to maximum when the arc breaks. When an arc is struck, weld out- pu t control returns to the R1 front panel o r combination front panel/remote control setting. The Amperage/V oltage Adj[...]

OM-474 Page 20 5-3. Remote Control (Optional)  W eld output terminals are energized when Output (Electrode) switch is On (Hot) and engine is running. 1 Remote 14 Receptacle RC3 Connect optional remote control to RC3 (see Section 4-7). S-0774 / Ref. ST-154 862-A / Ref. ST -191 898 Example: Combination remote amperage control In Example: Range = 8[...]

OM-474 Page 21 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt Duplex And Optional GFCI Receptacles Ref. ST-191 898  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 120 V 15 A AC Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 15 A AC GFCI Recep- tacles GFCI1 And GFCI2 (Optional) Receptacles su[...]

OM-474 Page 22 6-2. 240 V olt Duplex Receptacle (Optional) Ref. ST-174 408  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 240 V 15 A AC Receptacle RC1 Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kV A/kW . 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 and CB2 protect [...]

OM-474 Page 23 6-3. Connecting Optional Auxiliary Power Plant Ref. S-185 000-A  Stop engine.  Power and weld outputs are live a t the same time. Discon- nect or insulate unused cables.  Have qualified person install according to circuit diagram and Auxiliary Power Guidelines (see Section 10).  Place optional Process switch in Stick posi[...]

OM-474 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  See also Engine Manual and Maintenance Label. Service engine more often if used i[...]

OM-474 Page 25 7-2. Maintenance Label[...]

OM-474 Page 26 7-3. Servicing Air Cleaner aircleaner2 4/96 – ST-153 929-B / ST -153 585 / Ref. ST-191 898 / Ref. S-0698-B  Stop engine. 1 Intake Manifold 2 Service Indicator 3 Window 4 Reset Button Service air cleaner element if red band appears in window . A green band means air cleaner is okay . Press button to reset indicator .  Do not r[...]

OM-474 Page 27 7-4. Servicing Fuel System Ref. ST-154 952-C / Ref. ST -154 954 / ST-155 872-A / Ref. ST -191 898  Stop engine and let cool. 1 Fuel Filter 2 Petcock 3 Bleeder V alve 4 Fuel Shutoff V alve 5 Fuel Line 6 Sludge Drain Plug T o drain water from fuel system: Open filter petcock and drain water into metal container . Close petcock when [...]

OM-474 Page 28 7-5. Adjusting Engine Speed Ref. ST-154 952-C / ST -091 065-A Engine speeds have been factory set and should not require adjustment. Start engine and check engine speeds with a tachometer . See table for proper no load speeds. If necessary , adjust speeds as follows: W eld/Power Speed Adjustment Place engine control switch in Run pos[...]

OM-474 Page 29 7-6. Changing Engine Oil And Filter ST-154 953 / Ref. ST -191 898  Stop engine and let cool. 1 Standard Oil Filter 2 Optional Remote Oil Filter 3 Optional Remote Oil Filter Hoses And Adapter 4 Oil Drain Plug Change oil and filter according to en- gine manual. Install optional remote oil filter if loca- tion makes it dif ficult to [...]

OM-474 Page 30 7-7. Overload Protection Ref. ST-191 898 / Ref. ST -154 862-A / Ref. ST-154 952-C  Stop engine.  If any fuse or circuit breaker continues to open, contact Fac- tory Authorized Service Agent. 1 Magnetic Shutdown Switch MS1 2 Fuse F (See Parts List) Fuse F protects magnetic shutdown switch MS1. If fuse F opens, the en- gine stops[...]

OM-474 Page 31 7-8. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. ST-191 898 / ST -162 256  Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly c[...]

OM-474 Page 32 T rouble Remedy Have Factory Authorized Service Agent check field current regulator board PC1. Low open-circuit voltage. Place optional Process switch in correct position (see Section 5-1) Check engine weld/power speed, and adjust if necessary (see Section 7-5). Have F a c t o r y Authorized Service Agent check field current regulato[...]

OM-474 Page 33 T rouble Remedy Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board PC1. High output at optional auxiliary power plant. Check engine weld/power speed, and adjust if necessary (see Section 7-5). Have Factory Authorized Service Agent check field current regulator board PC1. C. Engine T [...]

OM-474 Page 34 Notes[...]

OM-474 Page 35 SECTION 8 – ELECTRICAL DIAGRAMS 193 981-A Figure 8-1. Circuit Diagram For Welding Generator For Standard Models[...]

OM-474 Page 36 Figure 8-2. Circuit Diagram For Welding Generator With Welders And Deluxe Package Options[...]

OM-474 Page 37 193 989-B[...]

OM-474 Page 38 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. W etstacking 1 W elding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output.  Do not idle engine longer than necessary . Piston rings seat faster if engine r[...]

OM-474 Page 39 9-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 Wel[...]

OM-474 Page 40 9-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output. Turn Of f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V cont[...]

OM-474 Page 41 SECTION 10 – AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 10-2. Grou[...]

OM-474 Page 42 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electric[...]

OM-474 Page 43 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running W atts 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 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850 3[...]

OM-474 Page 44 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts 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 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 3[...]

OM-474 Page 45 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

OM-474 Page 46 10-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 Circuit Breakers or Fused Disconnect Sw[...]

OM-474 Page 47 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

OM-474 Page 48 SECTION 1 1 – P ARTS LIST  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 10 9 12 13 17 14 10 11 19 20 21 22 23 24 25 26 27 79 80 81 88 89 90 91 92 99 105 108 11 3 109 11 2 11 7 11 8 11 9 120 107 Fig 1 1-4 93 100 104 106 78 11 0 111 87 86 85 84 83 82 11 15 16 18 68 77 94 95 96 97 98 101 103 102 11 6 11 4 11 [...]

OM-474 Page 49 ST-1 10 964-Q 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 49 50 51 57 43 56 58 59 60 61 62 63 64 65 66 67 70 71 72 Includes Fig 1 1-3 74 46 75 52 53 54 48 Items 58 – 68 55 73 69[...]

OM-474 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 089 517 STRAP , fuel tank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134 771 PLUG, protective .640sq 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-474 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 52 084 979 HOSE, radiator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 +197 825 GUARD, fan LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-474 Page 52 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 103 +181 841 P ANEL, front lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦ 042 421 SELECTOR SWITCH, plrt and AC (consisting of) 1 . . . . . . . . . . . . . . .[...]

OM-474 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box w/Components (Fig 1 1-4 Item 12) Quantity 1 CR1 044 588 RELA Y , encl 12VDC 3PDT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2R 2 ♦ 130 515 RESISTOR, board 1 . . . . . . . . . . . . . . . . . . . . . . [...]

OM-474 Page 54  Hardware is common and not available unless listed. 14 15 16 17 18 12 21 22 19 23 24 25 26 27 1 2 4 5 6 4 3 12 28 20 ST-1 10 922-E 13 7 8 9 10 11 Figure 1 1-3. Generator[...]

OM-474 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Generator (Fig 1 1-1 Item 70) Quantity 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-474 Page 56  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 18 20 21 22 23 13 27 28 29 30 31 32 33 34 35 36 37 24 25 26 Fig 1 1-2 3 ST-1 10 872-C 8 19 38 Figure 1 1-4. Panel, Front w/Components[...]

OM-474 Page 57 Description Part No. Dia. Mkgs. Item No. Figure 1 1-4. Panel, Front w/Components (Fig 1 1-1 Item 107) Quantity 1 010 647 PIN, spring CS .156 x 1.250 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 044 328 HANDLE, switch range 1 . . . . . . . . . . . . . . . . . . .[...]

Notes[...]

Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distrib[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]