OM-492 190 603J August 2000 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Contractor 3025 Visit our website at www.HobartWelders.
From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 12 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 12-1. Symbol Usage Means Warning! Watch 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 Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 12-2.
WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can 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 be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal.
MOVING PARTS 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 maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (–) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts.
H.F. RADIATION 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. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once.
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 procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie.
DES ORGANES MOBILES peuvent provoquer des blessures. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LE SOUDAGE À L’ARC risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.
SECTION 2 – DEFINITIONS 2-1.
3-2. Dimensions, Weights, and Operating Angles Dimensions Height 36 in (914 mm) Width 24 in (610 mm) Depth 59 in (1499 mm) A 19-7/8 in (505 mm) B 18 in (457 mm) C 1 in (25 mm) A B C Do not exceed tilt angles or engine could be damaged or unit could tip. D G 4 Holes Do not move or operate unit where it could tip. E F D 15-5/8 in (397 mm) E 26-3/8 in (679 mm) F 58-3/4 in (1492 mm) G 13/32 in (10 mm) Dia. 20° 20° 20° 20° Weight 925 lb (420 kg) Front Panel End 800 426 3-3.
3-4. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. A. CC Mode ARC CONTROL B.
3-5. Fuel Consumption 7.57 1.70 2.00 6.62 1.46 1.75 5.67 1.25 1.50 4.73 1.04 1.25 3.78 0.83 1.00 2.84 0.62 0.75 1.98 0.40 0.50 3600 RPM IDLE 0.95 0.21 0.25 0 U.S. GAL./HR. IMP. GAL./HR. LITERS/HR. 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 193 458 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.
4-2. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Full Capacity w/Overflow Tank 6.4 qt (6 L) Full 1/2 in (13 mm) Full Diesel Full 802 330-B Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure is too low or engine temperature is too high. This unit has a low oil pressure shut- down switch. However, some conditions may cause engine damage before the engine shuts down.
4-3. Adding Coolant To Radiator Stop engine and let cool. Full 1 Capacity w/Overflow Tank 6.4 qt (6 L) Check coolant level according to Section 4-2 before starting this procedure. If coolant level is below bottom of radiator filler neck, add coolant as follows: 1 Radiator Air Bleed Screw Remove radiator air bleed screw. Add coolant to radiator until coolant is at bottom of filler neck. This ensures all air is purged from the system. Reinstall screw and radiator cap.
4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: 1/2 in 802 173-B / Ref. 189 438-A 4-6. Connecting To Weld Output Terminals 1 2 Positive (+) Weld Output Terminal Negative (–) Weld Output Terminal For MIG welding, connect work cable to Negative (–) terminal and wire feeder cable to Positive (+) terminal.
4-7.
Notes OM-492 Page 17
SECTION 5 – OPERATING WELDING GENERATOR 5-1. Controls (See Section 5-2) 2 3 4 5 6 7 8 10 9 1 14 11 12 13 15 Ref.
5-2. Description Of Controls (See Section 5-1) The fan motor is thermostatically controlled and only runs when cooling is needed. Engine Lights 1 Battery Charging Light Light goes on if engine alternator is not charging battery. Engine continues to run. Stop engine and fix trouble if Battery Charging light goes on. 2 Engine Temperature Light Light goes on and engine stops if engine temperature is too high. Stop engine and fix trouble if Engine Temperature light goes on.
5-3. Meter Functions NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle V Scratch Start TIG Lift-Arc TIG Meter Reading While Welding A 80.0 85 Actual Volts Actual Amps V A V A 7.0 85 85 Preset Amps Actual Volts Actual Amps V A V A Blank Preset Amps Actual Volts Actual Amps V A V A 24.5 250 Preset Volts Blank Actual Volts Actual Amps V A V A 10.3 85 PPP PPP 24.
5-5. Lift-Arc TIG Procedure With Mode Switch in the Lift-Arc TIG position, start an arc as follows: 1 “Touch” 1–2 Seconds 2 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.
SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1.
6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. 1 3 1 4 Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle.
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Stop engine before maintaining. Recycle engine fluids. See also Engine Manual and Maintenance Label. Service engine more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8h Full Wipe Up Spills. Check Fluid Levels. See Section 4-2.
500 h Replace fan belt. Drain sludge from fuel tank. Flush radiator. FUEL SLUDGE Repair or replace cracked cables. 800 h Check valve clearance.* 1000 h Blow out or vacuum inside. During heavy service, clean monthly. OR Service welding generator brushes and slip rings. Service more often in dirty conditions.* 2000 h Replace fuel lines and clamps. See Section 7-5. Replace radiator coolant and hoses. See Section 7-6.
7-2.
7-3. Servicing Air Cleaner Stop engine. 4 3 1 2 Do not run engine without air cleaner or with dirty element. 1 Evacuator Valve 2 Dust Cap 3 Element 4 Housing Open evacuator valve weekly to remove dust. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. To Clean air filter: Wipe off cap and housing. Remove cap and dump out dust. Wipe dust from inside cap and housing with damp cloth. Remove element and reinstall cap.
7-5. Servicing Engine Lubrication And Fuel Systems 4 FLOW 5 4 1 6 7 3 8 Tools Needed: 2 9/16 in Ref. 189 438-A / 802 330-B / S-0842 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Valve 3 4 5 1/2 ID x 12 in Hose Fuel Line Primary Fuel Filter To drain water from fuel system: To change coolant: Open secondary fuel filter petcock and drain water into metal container. Close petcock when water-free fuel flows. Change coolant according to engine manual.
7-6. Servicing Engine Cooling System Stop engine and let cool. 1 Radiator Draincock 2 Radiator Cap 3 Radiator Air Bleed Screw Change coolant according to engine manual. Add coolant according to Section 4-3). Run engine until engine reaches normal operating temperature. Loosen air bleed screw to remove air from cooling system. Tighten screw. Check coolant level in recovery tank.
7-7. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2450 ± 100 rpm 3750 Max Start engine and run until warm. Turn V/A control to max. Adjusting Idle Speed Turn Engine Control switch to Run/ Idle position. 1 2 3 Throttle Solenoid Idle Speed Jam Nut Idle Speed Screw Loosen nut and turn screw clockwise to increase idle speed. Turn screw counterclockwise to decrease idle speed. Tighten nut.
7-8. Overload Protection Stop engine. Tools Needed: 3/8 in 1 2 When a circuit breaker opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Circuit Breaker CB12 CB12 protects the 115 volt ac output to Remote 14 receptacle RC5. If CB12 opens, 115 volt ac output to RC5 stops. 2 Circuit Breaker CB11 CB11 protects the 24 volt ac output to Remote 14 receptacle RC5. If CB11 opens, 24 volt ac output to RC5 stops. Press button to reset breaker.
7-9. Voltmeter/Ammeter Help Displays V A 1 V A HE.L P–5 V A HE.L P–6 V A HE.L P–7 V A HE.L P–8 V A HE.L P–9 6 HE.L P–0 V A 2 7 HE.L P–1 V A 3 8 HE.L P–2 V A 4 9 HE.L P–3 V A 5 10 HE.L P–4 802 174-E Use the voltmeter/ammeter help displays to help determine the cause of no weld output. When a help display is shown, the inverter module weld output has stopped but the engine continues to run. Correct the problem before resuming operation.
7-10. Troubleshooting A. Welding Trouble No weld output. Remedy Check control settings. Check weld connections. Disconnect equipment from auxiliary power receptacles during start-up. Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, interconnecting board PC2, and control board PC1. If using remote control, be sure mode switch is in a position that provides output control at Remote 14 receptacle (see Sections 4-8 and 5-1).
Trouble Remedy Remote contactor control does not activate contactor. Check and tighten connections to Remote 14 receptacle RC5 (see Section 4-8). Lack of high frequency; difficulty in establishing Gas Tungsten Arc Welding arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.). Check cables and torch for cracked or deteriorated insulation or bad connections.
C. Engine Trouble Engine will not crank. Remedy Reset circuit breaker CB8 (see Section 7-8). Check battery voltage. Check battery connections and tighten if necessary. Have Factory Authorized Service Agent check Engine Control switch S1. Engine cranks, but does not start. Check fuel level (see Section 4-2). Open fuel valve (see Section 4-2). Check oil level (see Section 4-2). Engine will not start if oil pressure is low. Reset circuit breaker CB10 (see Section 7-8).
Trouble Engine does not go to low (idle) speed with Engine Control switch in Run/Idle position. Remedy Be sure Engine Control switch S1 is in Run/Idle position. Remove all weld and auxiliary power loads. Turn off remote device connected to Remote 14 receptacle RC5 (see Section 4-8). Check for obstructed movement of throttle solenoid linkage. Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer CT1. Reset circuit breaker CB9 (see Section 7-8).
Notes OM-492 Page 37
SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-2.
200 955 OM-492 Page 39
SECTION 9 – RUN-IN PROCEDURE run_in4 6/99 9-1. Wetstacking 1 Welding Generator Run diesel engines near rated output during run-in period to properly seat piston rings and prevent wetstacking. See nameplate or rating label to find rated output. 2 2 Do not idle engine longer than necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in.
9-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. 2 4 2 Welding Generator 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors. Observe correct polarity.
9-3. Run-In Procedure Using Resistance Grid 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 Off grid. 2 6 1 2 Welding Generator 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connectors (polarity is not important).
SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 1 2 3 Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment 1 2 3 Be sure equipment has this symbol and/or wording. OR aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 10-2. Grounding Generator To Truck Or Trailer Frame 1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire.
10-3. Grounding When Supplying Building Systems 1 1 2 2 GND/PE Equipment Grounding Terminal Grounding Cable Use #10 AWG 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. Use ground device as stated in electrical codes. 2 3 ST-800 576-B 10-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.
10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6.
10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec.
10-8. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage.
10-10. Typical Connections To Supply Standby Power 1 2 3 Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 4 1 5 120 V 6 Generator Connections Connect terminals or plug of adequate amperage capacity to cord. Follow all applicable codes and safety practices.
10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
SECTION 11 – PARTS LIST 15 Hardware is common and not available unless listed. 16 14 13 12 11 8 10 9 7 17 3 6 4 5 2 10 18 20 19 21 23 110 24 25 26 22 28 112 1 27 109 108 111 – Fig. 11-3 104 105 107 106 103 102 101 91 90 97 100 99 98 96 – Fig 11-2 93 95 94 Figure 11-5.
42 44 43 41 40 39 45 38 14 37 36 32 14 35 34 33 46 47 48 30 50 31 53 52 51 49 29 – Fig.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-5. Main Assembly . . 1 . . . . . . . . . . . . +198 157 . . PANEL, generator left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . +198 155 . . COVER, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . +♦198 871 . . COVER, generator stainless . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-5. Main Assembly (Continued) . . 55 . . . . . . . . . . . . 192 475 . . 56 . . . . . . . . . . . . 192 476 . . 57 . . . . . . . . . . . . 118 829 . . 58 . . . . . . . . . . . . 194 127 . . 59 . . . . . . . . . . . . 145 675 . . 60 . . . . . . . . . . . . 192 196 . . 61 . . . . . . . . . . . . 192 663 . . 62 . . . . . . . . . . . . 047 234 . . 63 . . . . . . . . . . . . 047 236 . . 64 . . . . . . . . . . . . 047 235 . . 65 . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-5. Main Assembly (Continued) . . . . . . . . . . . . . . . . . . 197 535 . . . . . . . . RC15 . . . . 158 466 . . . . . . . PLG27 . . . 192 170 . . . . . . . PLG36 . . . 192 169 . . . . . . . PLG28 . . . 192 171 . . . . . . . PLG37 . . . 192 168 . . . . . . . PLG11 . . . 092 670 . . . . . . . . . . . . . . . . . . 192 167 . 107 CB9,CB10 . . 139 266 . 108 . . CB8 . . . . 115 427 . 109 . . CB7 . . . . 147 658 . 110 . . CR3 . . . . 197 325 . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-6. Front Panel (Figure 11-5, Item 96) . . 1 . . . . . . . . . . . . . 198 049 . . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . +191 737 . . PANEL, front louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 182 761 . . LABEL, warning general precautionary CSA . . . . . .
Hardware is common and not available unless listed. 44 35 34 36 28 5 27 18 37 39 26 33 29 25 32 24 40 23 30 38 22 31 21 20 19 18 15 41 17 42 16 43 10 14 13 9 8 7 5 6 4 3 2 12 11 1 802 326-A Figure 11-7.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-7. Inverter Assembly (Figure 11-5, Item 111) . . 1 . . . PC2 . . . . 196 148 . . 2 . C3,C4,C5 . . 174 980 . . 3 . . . . C1 . . . . . 186 015 . . 4 . . . . . . . . . . . . . 025 248 . . 5 . . . . . . . . . . . . . 179 276 . . 6 . . . . . . . . . . . . . 175 140 . . 7 . . . . . . . . . . . . . 181 197 . . 8 . . . L3,L4 . . . . 175 482 . . 9 . . . . . . . . . . . . . 109 056 . . 10 . . . . . . . . . . . . 185 731 . . 11 . . . . . . . . . . . .
Hardware is common and 9 not available unless listed. 7 8 6 5 2 4 3 1 10 11 12 13 14 15 16 17 802 338-A Figure 11-8. Generator Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-8. Generator Assembly (Figure 11-5, Item 29) . . 1 . . . . . . . . . . . . . 160 943 . . ENDBELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 2 . . . . . . . . . . . . . 192 581 . . ROTOR, generator (consisting of) . . . . . . . . .
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Contact your Distributor for: Welding Supplies and Consumables Call 1-877-Hobart1 or visit our website at www.HobartWelders.