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Hobart Welding Products OM-478 manual

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Table of contents for the manual

  • Page 1

    Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMA W) W elding MIG (GMA W) W elding Flux Cored (FCA W) W elding Engine Driven Welding Generator OM-478 120 240V August 2000 TIG (GT AW ) W elding With Optional Equipment: Battery Charging PowerPak  Visit our website at www.HobartWelders.com[...]

  • Page 2

    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[...]

  • Page 3

    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 defects, and other reproductive harm. T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ B[...]

  • Page 4

    [...]

  • Page 5

    OM-478 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[...]

  • Page 6

    OM-478 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[...]

  • Page 7

    OM-478 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[...]

  • Page 8

    OM-478 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[...]

  • Page 9

    OM-478 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[...]

  • Page 10

    OM-478 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[...]

  • Page 11

    OM-478 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. ?[...]

  • Page 12

    OM-478 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 ?[...]

  • Page 13

    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 Operator ’ s Manual Certified/T rained Mechanic Engin[...]

  • Page 14

    OM-478 Page 10 SECTION 3 – SPECIFICA TIONS 3-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open-Circuit V oltage (Nominal) Auxiliary Power Rating 5 kV A/kW Auxiliary Power Plant (Optional) 15 kV A/kW Auxiliary Power Plant Engine Fuel T ank Capacity CC/DC 50 – 500 A 400 A, 36 V olts DC[...]

  • Page 15

    OM-478 Page 1 1 3-4. Fuel Consumption The curve shows typical fuel use under weld or auxiliary power loads. ST-188 312 0.00 2.00 U.S. GAL/HR. IMP . 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 4.54 1.00 1.20 5.30 1.17 1.40 6.06 1.33 1.60 6.[...]

  • Page 16

    OM-478 Page 12 3-6. Air Compressor Output Curve SB-121 490-A The air output curve shows the vol- ume and pressure of air available from the air compressor . 0 10 20 30 40 50 60 70 80 90 100 1 10 120 130 0 10 20 30 40 50 60 70 80 90 100 11 0 P .S.I.G. S.C.F .M. 3-7. AC Auxiliary Power ST-109 365-C Th e ac power curve shows the aux- iliary power in a[...]

  • Page 17

    OM-478 Page 13 3-8. V olt-Ampere Curves ST-188 21 1 / ST-188 212 / ST-188 220 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. For AC Mode B. For Constant Current (CC) DC Mode C. For Constant V oltage (CV) DC Mod[...]

  • Page 18

    OM-478 Page 14 3-9. Optional AC Power Plant Curves ST-188 214 / ST -188 213 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. 10 KV A/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 15 KV A/KW Thre e-P hase Auxiliary Power Plant (No W eld Load) 0 180 A[...]

  • Page 19

    OM-478 Page 15 3-10. Optional Battery Charging Output Curve ST-188 221 The battery charging curves show th e charging amperage and voltage output of the welding generator . As battery voltage nears the charg- ing voltage, charging current de- creases. 0 0 DC AMPERES DC VOL TS 100 200 300 400 500 600 700 10 20 30 40 50 MAX MIN[...]

  • Page 20

    OM-478 Page 16 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 electric[...]

  • Page 21

    OM-478 Page 17 4-3. Installing Precleaners, Exhaust Pipe, And Rain Cap  Stop engine and let cool.  Do not blow exhaust toward air cleaner or air intake. Remove rear , left side panel. 1 Air Cleaner 2 Precleaner Remove tape from air cleaner openings. Install precleaners on air cleaners. 3 Exhaust Pipe 4 Muf fler Extension Remove tape from exte[...]

  • Page 22

    OM-478 Page 18 4-5. Connecting T o W eld Output T erminals 2 3 1 Access Door 2 W ork W eld Output T erminal 3 Electrode Weld Output T erminal 4 T orch Cable Adapter Adapter connects power and water to torch and cooling system or drain.  Use only a proper torch cable adapter positioned so it does not hit frame, hardware, or door during operation.[...]

  • Page 23

    OM-478 Page 19 ether1 7/96 – ST-153 382-A / ST -180 933  Stop engine.  Improper handling or expo- sure to ether can harm your health. Follow manufactur- er ’ s safety instructions on cylinder .  Do not use Ether Starting Aid while e n g i n e i s r u n n i n g . Open side door(s). 1 Ether Cylinder 2 Nozzle Remove cover and clean cylind[...]

  • Page 24

    OM-478 Page 20 4-9. T erminal Strip 3T Connections Ref. ST-121 578-F / Ref. S-184 781-A  Stop engine. If remote control plug does not fit in receptacle RC3, wire cord directly to terminal strip 3T .  Do not connect to Remote 14 receptacle RC3 and terminal strip 3 T at the same time. Use only one remote control method. Open lower front door . [...]

  • Page 25

    OM-478 Page 21 Notes[...]

  • Page 26

    OM-478 Page 22 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Front Panel Controls (See Section 5-2) 20 19 18 ST-184 780-C / Ref. ST -121 578-F 23 12 12 4 5 6 7 8 9 1 0 1 1 14 15 21 22 13 3 16 17 24[...]

  • Page 27

    OM-478 Page 23 5-2. Description Of Standard Controls (See Section 5-1)  This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the front panel or remote control setting. The Amperage/voltage Control adjusts amperage only when weldi[...]

  • Page 28

    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 ( 9 0 A DC/CC) Max (140 A DC/CC) 2 In Example: Min = 90 A DC/CC Percentage of Range = 50 % Max = 140 A DC/CC (50% of 90 to 190)[...]

  • Page 29

    OM-478 Page 25 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt GFCI Duplex Receptacles Ref. ST-184 781-A 1 1 120 V 15 A AC GFCI Receptacle GFCI1 2 120 V 15 A AC GFCI Receptacle GFCI2 Receptacles supply 60 Hz single- phase power at weld/power speed. 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects GFCI1 and CB2 pro- tects GFCI2 [...]

  • Page 30

    OM-478 Page 26 120V AC 6-3. Optional 5 kV A/kW Power Plant Receptacles 1 240 V 13 A AC Duplex Receptacle RC1 2 120 V 15 A AC GFCI Receptacle GFCI2 RC 1 and GFCI2 supply 60 Hz sing- le-phase power at weld/power speed. 3 Circuit Breaker CB1 And CB2 CB1 and CB2 protect RC1 from overload. CB2 also protects GFCI2 from overload. If CB1 or CB2 open, the r[...]

  • Page 31

    OM-478 Page 27 6-4. Connecting Auxiliary Power Plant Ref. S-160 620C  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 Section 1 2 – Auxiliary Power Guide- lines.  Place CC/CV switch in CC position when using auxiliary p[...]

  • Page 32

    OM-478 Page 28 SECTION 7 – OPERA TING OPTIONAL BA TTER Y CHARGER Follow jump starting procedure to quickly start equipment having a weak or dead battery . 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 or jump start a battery which has l[...]

  • Page 33

    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. Us e switch to select weld or battery charge/jump start output. Output automatically stops when terminal voltage is 15 to 25 percent above required battery voltage. Move switch to weld position when done charging/jump star[...]

  • Page 34

    OM-478 Page 30 7-4. Battery Charging Procedure Ref. ST-184 780-C / S-1 15 587-B Stop Engine. Connect Cables (Observe Correct Polarity). Set Battery V oltage Switch. Set Charge/Jump Start Switch T o Charge. Set Amperage/V oltage Switch T o Panel And Out- put (Contactor) Switch T o Remote. T urn Of f Remote Devices. + – Start Engine. If Battery Lig[...]

  • Page 35

    OM-478 Page 31 7-5. Jump Starting Procedure Ref. ST-184 780-C  Charge battery for 10 minutes before 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 MInutes (See Section 7-4). Press Remote Momentary [...]

  • Page 36

    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 often if used in severe conditions. * T o be done by Factory Authorized Service Agent. 8 h Check Fluid Levels. See Section 4-4. Wipe Up Spills. OIL Full Drain W ater From Fuel Sys[...]

  • Page 37

    OM-478 Page 33 1000 h Change Fuel Filters. See Section 8-4. Drain Sludge From Fuel T ank. See Section 8-4. FUEL SLUDGE Blow Out Or V acuum Inside. During Heavy Service, Clean Monthly . OR Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Check V alve Clearance.* 1/2 in. (13 mm) Check Belt T ension. See Sect[...]

  • Page 38

    OM-478 Page 34 -3. Maintenance Label DEUTZ F4L912 DIESEL ENGINE Check + S-120 629-G Spark Arrestor Inspection And Service 250 operating hours – . . . . . . . . . . see Owner ’ s Manual Fuel Capacity 19 gal (72.8 L) . . . . . . . . . Fuel Grade 1-D or 2-D Cetane No. 45 min. . . . . . . . . . . . Primary Fuel Filter/ W ater Separator MILLER 062 3[...]

  • Page 39

    OM-478 Page 35 8-4. Servicing Engine Fuel And Lubrication Systems Ref. ST-153 653-A / Ref. ST -184 780-C  Stop engine. 1 Fuel Filter Se e engine manual for fuel filter r e - placement procedure. 2 Oil Filter 3 Oil Drain See engine manual for oil change procedure. 4 Fuel/W ater Separator 5 Petcock T o drain water from fuel system, put metal conta[...]

  • Page 40

    OM-478 Page 36 8-6. Adjusting Engine Speed  Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer . See table for proper no load speeds. If necessary , adjust speeds as follows: Idle Speed Adjustment 1 Throttle Solenoid 2 Adjustment Rod 3 Throttle Rod Disc[...]

  • Page 41

    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 fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Circuit Breaker CB3 CB3 protects the 1 15 volts ac out- p u t to Remote 14 recep[...]

  • Page 42

    OM-478 Page 38 8-8. Checking And Replacing Engine Belt Ref. ST-121 577-B / Ref. ST -184 781-A  Stop engine. A V -belt drives the engine cooling fan and alternator . T o check tightness of belt, proceed as follows: Remove rear panel and guard from engine pulley . 1 Fan Pulley 2 Alternator Pulley 3 Engine Belt Position straight edge along top of p[...]

  • Page 43

    OM-478 Page 39 8-10. T roubleshooting A. Welding T rouble Remedy No weld output. Check position of Ampere Range and Output Selector switches. Place Output/Contactor Control switch in On position, or place switch in Remote position and connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-8 and 4-9). Disc[...]

  • Page 44

    OM-478 Page 40 Min or max CV weld output only . Check position of Amperage/voltage control and Amperage/V oltage Control switch. Repair or replace remote control device. Have Factory Authorized Service Agent check optional CV regulator board PC2. Tungsten electrode oxidizing and not remaining bright at end of weld. Shield weld zone from drafts. Inc[...]

  • Page 45

    OM-478 Page 41 Engine remains at weld rpm when En- gine Control switch is in the Run/Idle p o - sition and load is removed. Check fuse F1 1, 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 continuity and connections of current transforme[...]

  • Page 46

    OM-478 Page 42 SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator[...]

  • Page 47

    OM-478 Page 43 194 053-A[...]

  • Page 48

    OM-478 Page 44 Figure 9-2. Circuit Diagram For W elding Generator With Optional Battery Charger[...]

  • Page 49

    OM-478 Page 45 194 061-A[...]

  • Page 50

    OM-478 Page 46 Figure 9-3. Circuit Diagram For W elding Generator With Optional 5 kV A/kW Auxiliary Power Plant[...]

  • Page 51

    OM-478 Page 47 194 062-A[...]

  • Page 52

    OM-478 Page 48 SECTION 10 – RUN-IN PROCEDURE run_in1 6/96 10-1. 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[...]

  • Page 53

    OM-478 Page 49 10-2. 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 We[...]

  • Page 54

    OM-478 Page 50 10-3. 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 con[...]

  • Page 55

    OM-478 Page 51 SECTION 1 1 – AIR COMPRESSOR T ABLES 1 1-1. Flow Of Free Air (CFM) Through Orifices Of V arious 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 0.607 1.36 2.43 5.42 9.74 3 0.046 0.188 0.471[...]

  • Page 56

    OM-478 Page 52 1 1-2. Approximate Air Consumption (Cubic Feet) T o Operate Pneumatic Equipment At 70-90 P .S.I.G. Drill, 1/18 ” to 3/8 ” 3.75 6.25 8.75 25 Burring T ool, Large 3.6 6.0 8 .4 24 Drill, 3/8 ” to 5/16 ” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13 Screwdriver , #2 to #6 Screw 1 .8 3 .0 4. 2 12 Rammers, Medium 5.1 8.5 1 1.9 [...]

  • Page 57

    OM-478 Page 53 SECTION 12 – AUXILIAR Y POWER GUIDELINES 12-1. 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 12-2. Grou[...]

  • Page 58

    OM-478 Page 54 12-3. 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[...]

  • Page 59

    OM-478 Page 55 12-5. 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[...]

  • Page 60

    OM-478 Page 56 12-7. 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[...]

  • Page 61

    OM-478 Page 57 12-8. 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[...]

  • Page 62

    OM-478 Page 58 12-10. 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[...]

  • Page 63

    OM-478 Page 59 12-1 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[...]

  • Page 64

    OM-478 Page 60 SECTION 13 – SELECTING AND PREP ARING TUNGSTEN ELECTRODE gtaw 7/97 For additional information, see your distributor for a handbook on the Gas T ungsten Arc Welding (GT AW) pr ocess. Wear clean gloves to prevent contamination of tungsten electrode. NOTE 13-1. Selecting T ungsten Electrode Amperage Range - Gas T ype ♦ - Polarity El[...]

  • Page 65

    OM-478 Page 61 13-2. Preparing T ungsten For AC Or DC Electrode Positive (DCEP) Welding Ref. S-0161 1 T ungsten Electrode 2 Balled End  Understand and follow safety symbols at start of Section 14-1 before pre- paring tungsten. Ball e n d o f tungsten before welding by applying either an ac amperage slightly higher than what is recom- mended for [...]

  • Page 66

    OM-478 Page 62 SECTION 14 – GUIDELINES FOR TIG WELDING (GT A W) 14-1. Positioning The T orch ST-161 892  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp as close t o the weld as possible. 1 W orkpiece Make sure workpiece is clean before welding. 2 W ork Clamp [...]

  • Page 67

    OM-478 Page 63 14-3. Positioning T orch T ungsten For V arious W eld 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

    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 42 43 44 45 46 47 48 49 31 32 21 50 51 52 53 54 31 32 55 56 57 58 60 59 31 32 55 56 61 31 62 63 64 25 65 66 68 67 69 70 [...]

  • Page 69

    OM-478 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Part 1 Of 2) Quantity 1 Z1 186 907 REACTOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 049 525 NUT , speed push-on-type .312-18 U type 8 . . . . . . . . . . . . . . . . . .[...]

  • Page 70

    OM-478 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Part 1 Of 2) (Continued) Quantity 47 159 012 HOSE, oil drain 1 1.000 3/4 swivel fem 1/2MNPT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 159 013 FITTING, pipe stl elbow M 1/2tbg x .500NPT 1 . . . . . . . . . . . . . . . . . . . [...]

  • Page 71

    OM-478 Page 67 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Part 1 Of 2) (Continued) Quantity 96 149 541 HOLDER, fuse crtg 60A 250V 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 F1-3 *012 625 FUSE, crtg 45A 250V 3 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 72

    OM-478 Page 68 ST-121 286-J (Part 2 0f 2) Figure 15-2. Main Assembly (Part 2 of 2) 1 2 3 4 5 6 7 9 11 12 13 14 15 10 Includes Item 16 16 17 18 19 20 21 22 62 24 25 26 27 28 29 30 31 9 32 33 34 9 31 30 29 35 36 37 38 39 40 42 Includes Item 41 43 44 45 46 47 48 47 49 50 51 52 53 54 – Fig 15-6 55 41 56 57 58 59 60 61 62 63 64 65 66  Hardware is c[...]

  • Page 73

    OM-478 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 15-2. Main Assembly (Part 2 Of 2) (Continued) Quantity 24 138 098 HOSE, sst 20.750 lg 3/4NPT M ftg & 3/4NPT M inv 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 089 973 BOL T , U stl .250-20 x 1.125 wide x 2.250 deep 1 . . . . . . . . . . . . . . . . . [...]

  • Page 74

    OM-478 Page 70 ST-121 288-D  Hardware is common and not available unless listed. 32 1 2 3 1 4 5 6 7 8 9 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 23 24 27 28 26 29 16 15 14 30 31 31 31 Figure 15-3. Panel, Front w/Components[...]

  • Page 75

    OM-478 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 15-3. Panel, Front w/Components (Fig 15-1 Item 84) Quantity 1 086 706 SP ACER, range switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 S3 1 19 850 SWITCH, range/changeover 1 . . . . . . . . . . . . . . . [...]

  • Page 76

    OM-478 Page 72 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front Lower w/Components (Fig 15-1 Item 85) Quantity 1 039 047 TERMINAL, pwr output (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 601 880 NUT , hex jam .500-13 2 . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 77

    OM-478 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front Lower w/Components (Fig 15-1 Item 85) (Continued) Quantity 13 PC30 150 415 CIRCUIT CARD, connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG6-8 165 668 CONNECTOR & SOCKETS 3 . . . . . . . . . . . . . [...]

  • Page 78

    OM-478 Page 74 ST-140 459-A 1 2 3 5 6 4 7 8 9 10 11 12 13 14 15 9 17 18 16  Hardware is common and not available unless listed. Figure 15-5. Control Box[...]

  • Page 79

    OM-478 Page 75 Description Part No. Dia. Mkgs. Item No. Figure 15-5. Control Box (Fig 15-1 Item 71) Quantity 1 2T 129 939 BLOCK, term 10A 19P 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 216 CONNECTOR, blk 15A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 80

    OM-478 Page 76 Ref. ST-143 803-B 10 9 8 7 6 5 4 3 2 1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 37 36 35 34 33 32 31 30 29 28  Hardware is common and not available unless listed. Figure 15-6. Compressor , Air[...]

  • Page 81

    OM-478 Page 77 Description Part No. Item No. Figure 15-6. Compressor , Air Quantity 1 066 133 HOUSING INSERT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 066 134 GRIPPING DEVICE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 82

    OM-478 Page 78 Description Part No. Item No. Figure 15-7. Generator (Fig 15-2 Item 54) Quantity 1 173 066 BRACKET , mtg brush holder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 018 614 BRUSH SET , (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 83

    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[...]

  • Page 84

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Product s An I l li noi s T ool Works Company 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 o[...]