OM-477 116 508V July 2000 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging With Optional Equipment: TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Engine Driven Welding Generator Contractor 40G
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 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. 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. 1-2.
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 48-3/4 in (1238 mm) Width 24-5/8 in (625 mm) Depth 64-1/2 (1638 mm) A 62 in (1575 mm) B 59-1/8 in (1502 mm) C 46-1/4 in (1175 mm) D 34-3/4 in (883 mm) E 26-15/16 in (684) mm) F 9-1/2 in (241 mm) Engine End L Do not exceed tilt angles or engine could be damaged or unit could tip. Do not move or operate unit where it could tip.
3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle At 350 Amperes 6 Minutes Welding 4 Minutes Resting 100% Duty Cycle At 300 Amperes Continuous Welding rduty1 5/95 – SB-111 076-A 3-5. AC Auxiliary Power The ac power curve shows the auxiliary power in amperes available at the 120 and 240 volt receptacles. rsb3.
3-6. Optional AC Power Plant Curves The ac power curves show the auxiliary power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 8.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) 280 AC VOLTS 260 240 220 200 180 0 20 40 60 80 100 AC AMPERES B. 12.5 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) 280 AC VOLTS 260 240 220 200 180 0 10 20 30 40 50 60 70 AC AMPERES rsb13.
3-7. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. A. CC/DC (Standard) 100 Ranges: 190–Max 110–270 85–210 55–110 Min–65 DC Volts 80 60 40 20 0 0 100 200 300 400 500 600 700 DC Amperes B. CC/AC (Models with Optional Polarity/AC Selector Switch) 100 AC Volts 80 60 40 20 0 0 100 200 300 400 500 600 700 AC Amperes C.
SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Do Not Lift Unit From End Airflow Clearance Location 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in (460 mm) 18 in (460 mm) Grounding 3 1 Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 4 GND/PE 1 2 3 4 OR Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire.
4-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. 1/2 in (13 mm) This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Full Gasoline Full 1 2 Carburetor Heat Selector Pipe Manifold Turn pipe toward manifold in cold weather and away from manifold in warm weather. Capacity: 9 qt (8.
4-5. Connecting To Weld Output Terminals Open left side door. 1 Bracket Route cables through bracket. 3 2 2 Positive (+) Weld Output Terminal 3 Negative (–) Weld Output Terminal For Stick welding Direct Current Electrode Positive (DCEP), connect work cable to (–) terminal and electrode holder cable to (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections.
4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8) Socket* A B K Socket Information A 24 volts ac. Protected by circuit breaker CB4. B Contact closure to A completes 24 volts ac contactor control circuit. I 115 volts ac. Protected by circuit breaker CB3. J Contact closure to I completes 115 volts ac contactor control circuit. G Circuit common for 24 and 115 volts ac circuits. C 0 to +10 volts dc output to remote control. D Remote control circuit common.
SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) 3 4 5 1 2 6 17 7 16 15 14 13 11 10 9 8 () 12 Ref. ST-159 730-A / Ref.
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 output control returns to the R1 front panel or combination front panel/remote control setting. The Amperage/Voltage Adjust control adjusts amperage only when constant current (CC) welding and does not adjust open-circuit voltage.
5-3. Remote Control (Optional) Weld 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). 1 Example: Combination remote amperage control In Example: Range = 85 to 210 A DC Min = 85 A DC Percentage of Range = 50% Max = 148 A DC (50% of 85 to 210) OR Max (148 A DC) Min (85 A DC) Set switches Set range Set percentage Adjust optional remote control S-0774 / Ref.
SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt Duplex And Optional GFCI Receptacles If unit does not have GFCI receptacles, use GFCI-protected extension cord. 1 1 120 V 15 A AC Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 15 A AC GFCI Receptacles GFCI1 And GFCI2 (Optional) 2 Receptacles supply 60 Hz singlephase power at weld/power speed. 4 5 4 Circuit Breaker CB1 5 Circuit Breaker CB2 CB1 protects RC1/GFCI1 and CB2 protects RC2/GFCI2 from overload.
6-2. 240 Volt Duplex Receptacle (Optional) If unit does not have GFCI receptacles, use GFCI-protected extension cord. 1 Receptacle supplies 60 Hz singlephase power at weld/power speed. Maximum output is 3 kVA/kW. 2 Circuit Breaker CB1 1 3 2 240 V 15 A AC Receptacle RC1 3 Circuit Breaker CB2 CB1 and CB2 protect the receptacles from overload. If CB1 or CB2 opens, the 240 V receptacle and half of the 120 V receptacle does not work. 120 volts may still be present at the 240 V receptacle.
6-3. Connecting Optional Auxiliary Power Plant Stop engine. Power and weld outputs are live at the same time. Disconnect or insulate unused cables. Have qualified person install according to circuit diagram and Auxiliary Power Guidelines Booklet (M176 712). Place optional Process switch in Stick position when using optional auxiliary power plant. Front Remove junction box cover.
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 7-1. Routine Maintenance 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 Wipe up spills. Check fluid levels. See Section 4-4. OIL Full 50 h Clean air filter. See Section 7-3.
7-2.
7-3. Servicing Air Cleaner Stop engine. Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. 5 4 3 2 1 1 Dust Cap 2 Baffle 3 Element 4 Plastic Fins 5 Housing 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. Do not clean housing with air hose.
7-5. Changing Engine Oil And Filter 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 5 Oil Fill Cap Change filter according to engine manual. 1 Install optional remote oil filter if location makes it difficult to change standard filter. The remote oil filter requires extra oil to fill the hoses. Keep oil up to full mark on dipstick. 4 5 3 Tools Needed: 2 7/8 in Ref. ST-159 727-B / Ref.
7-6. Changing Fuel Filter Stop engine and let cool. 1 Fuel Shutoff Valve 2 Fuel Line 3 Fuel Filter To replace filter, close valve and remove clamps and filter. Install new filter and clamps. Inspect line and replace if cracked or worn. Wipe up any spilled fuel. Open valve. Start engine and check for leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Close door. 1 2 3 2 Tools Needed: Ref. ST-191 898 / Ref. ST-159 727-C 7-7.
7-8. Adjusting Engine Weld/Power Speed Governor sensitivity may require adjustment if engine speed is adjusted (see Section 7-10). 1850 rpm (max) 7 11 If linkage binds, loosen socket nuts and turn sockets until linkage works smoothly. Tighten nuts. After tuning engine, check engine no load speed with a tachometer (see table for no load speeds).
7-9. Adjusting Engine Idle Speed Start engine. Place Engine Control Switch in Run/Idle position. 2 5 1250 rpm 1 Solenoid Bracket Screws 2 Throttle Arm 3 Idle Speed Screw 4 Throttle Stop Loosen bracket screws and move arm so screw touches stop. Do not release arm. Turn idle speed screw to obtain 550 rpm. 5 Idle Mixture Screw Turn mixture screw counterclockwise until engine falters, then turn screw clockwise until engine runs smoothly.
7-11. Adjusting Optional High Altitude Carburetor A too lean air-fuel mixture can damage valves. Do not adjust main adjustment screw so air-fuel mixture is too lean. Carburetor can be equipped with an adjustable main jet for operation above 4000 ft (1219 m). Adjust carburetor as follows: Start engine and apply nearly full load to welding generator. 1 Main Adjustment Screw 2 Lock Nut Loosen nut. Turn screw in until engine falters (lean air-fuel mixture).
Trouble Low or high weld output. Remedy Check control settings. Place optional Process switch in correct position (see Section 5-1). Check engine weld/power speed, and adjust if necessary (see Section 7-8). Have Factory Authorized Service Agent check field current regulator board PC1. Low open-circuit voltage. Place optional Process switch in correct position. Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Trouble Remedy Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board PC1. High or low voltage at auxiliary power ac receptacles. Check engine weld/power speed, and adjust if necessary (see Section 7-8). Have Factory Authorized Service Agent check field current resistor R3. High output at optional auxiliary power plant. Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Notes OM-477 Page 34
SECTION 8 – ELECTRICAL DIAGRAMS 193 965-A Figure 8-1.
Figure 8-2.
193 967-A OM-477 Page 37
SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. 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 9-2. 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.
9-3. 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 9-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.
9-5.
9-7. 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.
9-8. 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.
9-10. 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 1 240 V 120/240 Volt 60 Hz Three-Wire Service Circuit Breakers or Fused Disconnect Switch Obtain and install correct circuit breakers or switch.
9-11. 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.
Notes OM-477 Page 45
SECTION 10 – PARTS LIST Hardware is common and not available unless listed. 4 3 5 2 1 18 6 17 116 115 49 114 113 112 65 111 16 11 110 9 109 7 10 12 8 66 15 67 68 14 69 108 13 107 106 105 70 104 103 Fig 10-3 102 101 71 100 72 99 98 97 81 90 80 73 74 89 91 92 93 94 96 75 88 87 86 85 84 82 76 83 79 78 77 95 Figure 10-1.
20 19 21 22 30 23 31 25 24 29 28 27 25 32 33 26 62 63 64 61 34 35 36 37 38 40 60 47 Includes Item 49 46 50 51 52 59 Fig 10-2 58 57 56 55 54 53 45 41 48 44 39 43 42 ST-115 004-P OM-477 Page 47
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . . . . 134 771 . . . PLUG, protective .640sq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . 184 677 . . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . 182 022 . . . . CAP, fuel large . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Continued) . . . 53 . . . . . . . . . . . . . . . . . . 113 658 . . . . LINKAGE, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . FS1 . . . . . . . . . . . . . . . . . . . . CARBURETOR, (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . 602 887 . . . . FITTING, pipe brs plug hexhd 1/4NPT . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Continued) . . 106 . . . . . . . . . . . . . . . . . . . 107 . . . . . R3 . . . . . . . . . . 108 . . . . . . . . . . . . . . . . . . . 109 . . . . . . . . . . . . . . . . . . . 110 . . . . . . . . . . . . . . . . . . . 111 . . . . . . . . . . . . . . . . . . . 112 . . . . . . . . . . . . . . . . . . . 113 . . . . . . . . . . . . . . . . . . . 114 . . . . TE4 . . . . . . . . ........................ . . 115 . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-2. Generator (Fig 10-1 Item 59) . . . 1 . . . . . . . . . . . . 106 426 . . . 2 . . . . . . . . . . . . 106 440 . . . 3 . . . SR3 . . . . 106 427 . . . 4 . . . . . . . . . . . . 048 420 . . . . . . . . . . . . . . . . . . 106 641 . . . 5 . . . . . . . . . . . . 037 957 . . . 6 . . . . . . . . . . . . 106 425 . . . 7 . . . . . . . . . . . . 173 066 . . . 8 . . . . . . . . . . . . 018 614 . . . 9 . . . . . . . . . . . . *151 299 . . 10 . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102) . . . 1 . . . . . . . . . . . . . . . . . . 010 647 . . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . 044 328 . . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102) (Continued) . . . 12 . . . . . . . . . . . . . . . . . . Fig 10-4 . . . CONTROL BOX w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . CB1,2 . . . . . . . 139 266 . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . 14 . . . . RC1,2 . . . . . . . 170 901 . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-4. Control Box w/Components (Fig 10-3 Item 12) . . . 1 . . . . . CR1 . . . . . . . 044 588 . . . . . . 2 . . . . . . R2 . . . . . . ♦130 515 . . . . . . 3 . . . . . . D1 . . . . . . . . 189 701 . . . . . . 4 . . . . . . 2T . . . . . . . . 116 005 . . . . . . 5 . . . . . . 1T . . . . . . . . 129 939 . . . . . . 6 . . . . . . . . . . . . . . . . . . 130 608 . . . . . . 7 . . . . . . . . . . . . . . . . . . 603 107 . . . . . . 8 . . . . . . . . .
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.