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Processes Description Stick (SMA W) W elding Engine Driven Welding Generator OM-498 197 849D December 2001 CHAMP 1435 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 ...
T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . ...
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OM-498 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-498 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-498 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-498 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-498 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-498 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-498 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-498 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-498 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Engine Choke Read Operator ’ s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds T ime Protective Earth (Ground) Circuit Breaker T emperature SECTION 3 – SPECIFICA TIONS This unit uses either a Kohl ...
OM-498 Page 10 3-2. Dimensions, W eights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) Width 22-3/4 in (577 mm) D Depth 31-1/4 in (793 mm) A 31-1/4 in (793 mm) B Do not exceed tilt angles or engine could be damaged or unit could tip. B 10-1/2 in (268 mm) Do not move or operate unit where it C 13-45/64 in (348 mm) could tip. ...
OM-498 Page 1 1 3-4. Fuel Consumption (Honda-Powered Units) 802 121 Continuous Welding 3-5. Duty Cycle 802 092 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 80 Amperes CC/DC 3 Minutes W elding 7 Minutes Resting 30% Duty ...
OM-498 Page 12 3-6. Auxiliary Power Curve 802 129 The ac auxiliary power curves show the auxiliary power available in amperes at the receptacles. 3-7. V olt-Ampere Curves 198 453 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 c ...
OM-498 Page 13 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 1/97 – 802 512-A / Ref. 151 556 / 158 936-A / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location 4-2. Grounding Generator T o T ruck Or T railer Frame install1 1/97* – Ref. 151 556 / S-0854 ...
OM-498 Page 14 4-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop, ...
OM-498 Page 15 4-5. Engine Prestart Checks (Honda-Powered Units) Ref. 802 099-A Full Full Gasoline 1/2 i n (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low . 1 Fuel V alve Open valve. Close fuel valve before moving unit or carburetor may fl ...
OM-498 Page 16 4-7. Connecting T o W eld Output T erminals 196 921 / 495 179 1 Positive (+) W eld Output T erminal 2 Negative ( – ) W eld Output T erminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( – ) terminal and electrode holder to Positive (+) terminal. For Direct Current Electrode nega- tive (DCEN), re ...
OM-498 Page 17 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Controls (Kohler-Powered Units) 802 512-A / 495 179 5 2 60 Hz 3 4 W eld and auxiliary power output stops if generator overheats or engine speed is too low . 1 Engine Switch Us e switch to open ignition circuit, and to stop engine. 2 Throttle Control Lever Us e lever to select e ...
OM-498 Page 18 5-2. Controls (Honda-Powered Units) (See Section 5-3) 802 099-A / 802 100-A / 953T-5-4 Recoil-Start Electric-Start 60 Hz 1 4 3 6 2 1 5 ...
OM-498 Page 19 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) W eld and auxiliary power output stops if generator overheats or engine speed is too low . 1 Engine Switch On models with recoil-start, use switch to open ignition circuit, and to stop engine. On models with electric-start, use switch to open ignition circuit, a ...
OM-498 Page 20 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT The welding generator provides power while welding and with the Current control in any position. However , under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under thes ...
OM-498 Page 21 6-2. Optional Auxiliary Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 Auxiliary Power Panel 495 315 (USA) Auxiliary Power Panel 495 279 (Canada) Auxiliary Power Panel 495 253 (South Africa) Auxiliary Power Panel 495 289 (Australia) If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Power may ...
OM-498 Page 22 6-3. Auxiliary Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. NOTE T otal power from generator NOT to exceed 3500 W atts (60 Hz) Receptacle Protected By Panel 495 218 (USA) Panel 495 315 (USA) Panel 495 298 (USA) Panel 495 279 (Canada- CSA) Panel 495 253 (S. Africa) ...
OM-498 Page 23 6-4. Wiring Instructions For Optional 120/240 V olt T wistlock Plug (NEMA L14-30P) plug3-1 1/99 – 802 527 1 Plug Wired For 120/240 V , 3-Wire Load When wired for 120 V loads, each d u - plex receptacle shares a load with one half of the 240 V receptacle. 2 Neutral (Silver) T erminal 3 Load 1 (Brass) T erminal 4 Load 2 (Brass) T erm ...
OM-498 Page 24 SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See Engine Manual and Maintenance Label. Service more often if used in severe conditions. * T o be done by Factory Authorized Service Agent. 8 h 20 h Wipe up spills. Check fluid levels. See Section 4-4 or 4-5. Check and c ...
OM-498 Page 25 Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-2. Maintenance Label Ref. S-175 679-A ENGINE MAINTENANCE 8 h 1.1 l (1.2 US qt, 1.94 lmp qt) Unleaded 86 + Octane 6.5 l (1.7 US Gal, 1 1.4 lmp pt) 50 h 100 h 10W -30 ° F +32 +59 +86 +30 +20 +10 0 +40 ° C +104 -10 ...
OM-498 Page 26 7-4. Adjusting Engine Speed (Kohler-Powered Units) 802 512-A / Kohler Dwg. After tuning engine, check engine speeds. See table for proper no load speeds. If necessary , adjust speeds as follows: Start engine and run until warm. W eld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (far right) posi ...
OM-498 Page 27 7-5. Adjusting Engine Speed (Honda-Powered Units) 802 101-A After tuning engine, check engine speeds. See table for proper no load speeds. If necessary , adjust speeds as follows: Start engine and run until warm. W eld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (far left) position. Turn screw ...
OM-498 Page 28 SECTION 8 – TROUBLESHOOTING 8-1. T roubleshooting A. Welding T rouble Remedy No weld output. Check Amperage control setting. Check weld connections. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor , stator , reactor L2, output rectifie ...
OM-498 Page 29 C. Engine T rouble Remedy Engine will not crank (Honda electric- start models only). Reset ignition circuit breaker (see Section 7-3). Check battery voltage. Check battery connections and tighten if necessary . Have Factory Authorized Service Agent check engine ignition circuit. Engine will not start. Check fuel level (see Section 4- ...
OM-498 Page 30 SECTION 9 – ELECTRICAL DIAGRAMS SC-495 297 198 016-D Figure 9-1. Circuit Diagram For Welding Generator ...
OM-498 Page 31 198 014-C Figure 9-2. Wiring Diagram For Welding Generator ...
OM-498 Page 32 201 026-A Figure 9-3. Wiring Diagram For Auxiliary Power Panels (1 Of 2) ...
OM-498 Page 33 201 026-A Figure 9-4. Wiring Diagram For Auxiliary Power Panels (2 Of 2) ...
OM-498 Page 34 SECTION 10 – AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 4/01 – 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-498 Page 35 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-498 Page 36 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-498 Page 37 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-498 Page 38 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-498 Page 39 10-10. T ypical Connections T o Supply Standby Power S-0405-A Have only qualified persons perform these connections according to all applicable codes and safety practices. 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 r ...
OM-498 Page 40 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-498 Page 41 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. P lace work clamp as close t o the weld as possi ...
OM-498 Page 42 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-498 Page 43 1 1-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End View of W ork Angle Side V iew of Electrode Angle End View of W ork Angle Side V iew of Electrode Angle 10 ° -30 ° 1 1-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater ...
OM-498 Page 44 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 VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo S mall Angle T oo Large Correc t Angle 1 1-9. Elec ...
OM-498 Page 45 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-498 Page 46 1 1-13. Weld 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. Possi ...
OM-498 Page 47 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-498 Page 48 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-498 Page 49 Notes ...
OM-498 Page 50 SECTION 12 – P ARTS LIST Hardware is common and not available unless listed. 802 513-A / 802 153-B 19 25 29 22 23 28 26 27 20 21 32 33 30 31 – Fig 12-2 34 35 37 36 1 6 24 3 5 4 7 8 2 18 17 16 15 14 13 12 9 11 10 38 39 40 41 42 43 44 Figure 12-1. Main Assembly ...
OM-498 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 495 096 LABEL, precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
OM-498 Page 52 Hardware is common and not available unless listed. 196 921 25 3 4 Auxiliary Power Panel 495 315 (USA) Auxiliary Power Panel 495 218 (USA) Auxiliary Power Panel 495 279 (Canada) Auxiliary Power Panel 495 253 (South Africa) Auxiliary Power Panel 495 289 (Australia) 6 7 8 9 10 11 12 13 14 15 16 18 17 17 19 19 20 21 22 23 Auxiliary ...
OM-498 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Auxiliary Power Panels (Figure 12-1, Item 31) Quantity Auxiliary Power Panel 495 298 (USA) 1 495 220 P ANEL, auxiliary power assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2 ...
OM-498 Page 54 Notes ...
Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 4/00 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 distribut ...
PRINTED IN USA 2001 Hobart Welding Products. 1/01 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 ...
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