Hobart Welding Products OM-493 manual

OM -493 191 021C January 2000 Champion 8500 Processes Descrip tio n Non-Critical TIG (GT AW) W elding Stick (SMA W) W elding Engine Driven Welding Generator  Visit our website at www.HobartWelders.com[...]

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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . .[...]

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OM-493 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-493 Page 2 W elding on closed containers, such as tanks, drums, o r 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 [...]

OM-493 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-493 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-493 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-493 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-493 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-493 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-493 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator ’ s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check V alve Clearance Do not switch while welding W ork Connection Positive Negative Alternating Current[...]

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 (1 164 mm) D  Do not exceed tilt angles or engine could be damaged or unit could tip. A 18 in (457 mm) G  Do not move or operate unit where it could tip. B 16-1/2 in (419 mm) 4 Holes tip. C 3/4 in[...]

OM-493 Page 1 1 3-4. Fuel Consumption SB-191 556 Continuous Welding 3-5. Duty Cycle SB-191 554 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 100% Duty Cycle at 210 Amperes CC/DC[...]

OM-493 Page 12 3-6. V olt-Ampere Curve ST-191 555 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 12/99 – Ref. ST-800 652 / Ref. ST-800 477-A[...]

OM-493 Page 13 4-2. Engine Prestart Checks Full Full Gasoline Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.  Follow run-in procedure in engine manual.  This unit has a low oil pressure shutdown switch. However , some conditions may cause engine damage before the en- gine shuts down[...]

OM-493 Page 14 4-3. Activating The Dry Charge Battery (If Applicable) Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minute[...]

OM-493 Page 15 4-4. Connecting the Battery Ref. ST-192 519-A / Ref. ST -802 212 3/8, 1/2 in T ools Needed: + –  Connect negative ( – ) cable last. 4-5. Installing Exhaust Pipe Ref. ST-802 212 / Ref. ST -192 519-A  Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. T ools[...]

OM-493 Page 16 4-6. Connecting to Weld Output T erminals 1 Negative ( – ) W eld Output T erminal 2 Positive (+) Weld Output T erminal For Direct Current Electrode Positive (DCEP), connect work cable to Negative ( – ) terminal and electrode holder to Positive (+) terminal. For Direct Current Electrode negative (DCEN), reverse cable connections. [...]

OM-493 Page 17 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Front Panel Controls Ref. ST-192 519-A 5 1 Engine Control Switch Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs a t weld/power speed. 2 Engine Choke[...]

OM-493 Page 18 SECTION 6 – OPERA TING AUXILIAR Y 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 as weld current increases. S et Fine Adjust control R1 at 10 for full auxiliary power. 1 240 V 30 A AC Receptacle RC1 RC1 supplies 6[...]

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 as weld current increases. S et Fine Adjust control R1 at 10 for full auxiliary power. Combined output of all receptacles limited to 8.5 kVA/kW rating of the gene[...]

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 a n extended period. Note Recycle engine fluids.  Stop engine before maintaining.  Se e Engine Manual and Maintenance Label. Ser- vice more often if used in severe conditions. * T o b[...]

OM-493 Page 21 7-2. Maintenance Label[...]

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 ai r cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into wrapper . Squ[...]

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 21 1 / S-0842  Stop engine and let cool. 1 Oil Drain V alve 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 cap before adding oil and running engine.[...]

OM-493 Page 24 7-6. Adjusting Engine Speed ST-800 397 / Ref. ST -802 21 1 After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Turn Fine Adjust control to 10. Remove top cover to access speed adjustments. Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting[...]

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. Replace spark arrestor if screen wires are broken or missing. 1/4 in 1 T ools Needed:[...]

OM-493 Page 26 SECTION 8 – TROUBLESHOOTING A. Welding T rouble 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 check brushes, slip rings, and integrated rectif[...]

OM-493 Page 27 C. Engine T rouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 7-4). Check battery voltage. Check battery connections and tighten if necessary . Check plug PLG4 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine will not start. Check fuel level. Ch[...]

OM-493 Page 28 SECTION 9 – ELECTRICAL DIAGRAM ST-191 080-A Figure 9-1. Circuit Diagram For Welding Generator[...]

OM-493 Page 29 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-493 Page 30 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-493 Page 31 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts 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 [...]

OM-493 Page 32 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-493 Page 33 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-493 Page 34 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-493 Page 35 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-493 Page 36 SECTION 1 1 – STICK WELDING (SMA W) GUIDELINES 1 1-1. Stick Welding Procedure stick 12/96 – ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possibl[...]

OM-493 Page 37 1 1-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTR[...]

OM-493 Page 38 1 1-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of W ork Angle Side View of Electrode Angle End V iew of W ork Angle Side View of Electrode Angle 10 ° -30 ° 1 1-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crate[...]

OM-493 Page 39 1 1-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRA V EL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 1 1-9. Elect[...]

OM-493 Page 40 1 1-10. Butt Joints S-0662 1 T ack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with oxy- ace[...]

OM-493 Page 41 1 1-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 1 1-14. T roubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets i n weld metal. Poss[...]

OM-493 Page 42 1 1-16. T roubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prop[...]

OM-493 Page 43 1 1-19. T roubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 1 1-20. T roubleshooting – W avin[...]

OM-493 Page 44 SECTION 12 – P ARTS LIST ST-802 214-B  Hardware is common and not 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 54 10 12 33 35 34[...]

OM-493 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 181 881 GROMMET , neck filler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 147 601 CAP , tank screw-on w/vent 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-493 Page 46 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 44 177 136 CLAMP , capacitor 1.375dia clip 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 C1 176 719 CAP ACITOR, elctlt 100uf 75VDC 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-493 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 42) Quantity 1 NAMEPLA TE (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 185 161 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-493 Page 48 Description Part No. Item No. Figure 12-3. Generator (Figure 12-1 Item 22) Quantity 1 +194 621 HOUSING, Generator Front (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 183 419 O – Ring, 1.984 Id X .139 Cs 70 Duro Viton 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y ou 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 distribu[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding Produc ts An I l li noi s T ool Works Company 600 West M ain S treet Troy , OH 45373 U SA For Technical Assi stance: Call1-800-332-3281 For Lit erat ure Or Nearest Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to ori[...]