Hobart Welding Products Hobart 300/300 Owner'S Manual Download Page 61

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OM-494 Page 57

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.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

Load (Watts)

600

350 (106)

225 (68)

137 (42)

100 (30)

840

400 (122)

250 (76)

150 (46)

100 (30)

62 (19)

1200

400 (122)

275 (84)

175 (53)

112 (34)

62 (19)

50 (15)

1800

300 (91)

175 (53)

112 (34)

75 (23)

37 (11)

30 (9)

2400

225 (68)

137 (42)

87 (26)

50 (15)

30 (9)

3000

175 (53)

112 (34)

62 (19)

37 (11)

3600

150 (46)

87 (26)

50 (15)

37 (11)

4200

125 (38)

75 (23)

50 (15)

4800

112 (34)

62 (19)

37 (11)

5400

100 (30)

62 (19)

6000

87 (26)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

Load (Watts)

1200

700 (213)

450 (137)

225 (84)

200 (61)

1680

800 (244)

500 (152)

300 (91)

200 (61)

125 (38)

2400

800 (244)

550 (168)

350 (107)

225 (69)

125 (38)

100 (31)

3600

600 (183)

350 (107)

225 (69)

150 (46)

75 (23)

60 (18)

4800

450 (137)

275 (84)

175 (53)

100 (31)

60 (18)

6000

350 (107)

225 (69)

125 (38)

75 (23)

7000

300 (91)

175 (53)

100 (31)

75 (23)

8400

250 (76)

150 (46)

100 (31)

9600

225 (69)

125 (38)

75 (23)

10,800

200 (61)

125 (38)

12,000

175 (53)

100 (31)

*Conductor size is based on maximum 2% voltage drop

Summary of Contents for Hobart 300/300

Page 1: ...n Dual OperatorEngine Driven Welding Generator OM 494 191 862F February 2001 Air Carbon Arc CAC A Cutting and Gouging TIG GTAW Welding Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Visit our website at www HobartWelders com ...

Page 2: ...rself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide which exact part you may need to fix the proble...

Page 3: ...ork Cable 20 4 10 Making Dual Operator CV Weld Connections W Separate Work Cables 21 4 11 Making Dual Operator CV Weld Connections W Common Work Cable 22 4 12 Making Dual Operator CC And CV Weld Connections W Separate Work Cables 23 4 13 Making Dual Operator CC And CV Weld Connections W Common Work Cable 24 4 14 Making Single Operator CC Weld Connections 25 4 15 Selecting Weld Cable Sizes 26 4 16 ...

Page 4: ......

Page 5: ...en not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit a...

Page 6: ...uch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations Shielding gas cylinders contain gas under hi...

Page 7: ...ammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other ac...

Page 8: ...eune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards...

Page 9: ...ovoquer une électrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des câbles usés endommagés de grosseur insuffisante ou mal épissés Ne pas enrouler les câbles autour du corps Si la pièce soudée doit être mise à la terre le faire directement avec un câble distinct ne pas utiliser le connecteur de pièce ou le câble de retour Ne pas toucher l électrode quand on est e...

Page 10: ...tection pour travailler sur un moteur chaud Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces récemment soudées LE BRUIT peut affecter l ouïe Le bruit des processus et des équipements peut affecter l ouïe Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimula...

Page 11: ...istance les produits inflammables de l échappement LES ÉTINCELLES À L ÉCHAPPEMENT peuvent provoquer un incendie Empêcher les étincelles d échappement du moteur de provoquer un incendie Utiliser uniquement un pare étincelles approuvé voir codes en vigueur 1 4 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser Utiliser l an...

Page 12: ...550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Règles de sécurité en soudage coupage et procédés connexes norme CSA W117 2 de l Associatio...

Page 13: ... Circuit Breaker Engine Oil Check Injectors Pump Check Valve Clearance Fuel Protective Earth Ground Positive Negative Certified Trained Mechanic Welding Arc A Amperes V Volts Panel Local Remote On Temperature Output Contactor Alternating Current Stick SMAW Welding TIG GTAW Welding MIG GMAW Welding 3 Three Phase Time h Hours s Seconds 1 Single Phase Read Operator s Manual ...

Page 14: ...ide CC DC 30 600 A 85 550 A at 30 Volts DC 40 Duty Cycle Single Phase 4 kVA kW 34 17 A 120 240 V AC Deutz F3L 912 Air Cooled Dual 2 CC DC 15 300 A 85 275 A at 31 Volts DC 40 120 240 V AC 50 60 Hz 4 kVA kW Shared By Air Cooled Three Cylinder 41 5 HP Diesel Engine 22 3 gal 84 4 L Dual Both Sides CV DC 10 32 V 49 Volts DC 40 Duty Cycle All Receptacles Engine 3 3 Dimensions Weights And Operating Angle...

Page 15: ... 0 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 0 40 0 21 0 62 0 83 1 25 1 04 1 46 1 70 1 98 0 95 2 84 3 78 5 67 4 73 6 62 7 57 U S GAL HR IMP GAL HR LITERS HR 3 5 AC Auxiliary Power 193 018 The ac power curve shows the aux iliary power in amperes available at the 120 and 240 volt receptacles 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOLTS 0 25 50 75 100 150 125 0 10 20 30 ...

Page 16: ...uty cycle before welding This unit has separate duty cycle ratings for each operating mode If the unit is operated in the dual oper ator mode the unit is rated at 40 duty cycle This means each side of the unit can be operated at 275 am peres at 40 duty cycle When the unit is operated in the single operator mode the Welder B side right is rated at 40 duty cycle 550 A at 40 duty cycle Dual Operator ...

Page 17: ... Curves of all other settings fall be tween the curves shown A CC DC Single Mode B CC DC Dual Mode C CV DC Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES DC VOLTS MIN MED MAX 0 20 40 60 80 100 0 50 100 150 200 250 300 350 400 450 500 DC AMPERES DC VOLTS MAX MED MIN 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES DC VOLTS MIN MED MAX ...

Page 18: ...ys ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire Be sure equipment con nected to the 240 V ...

Page 19: ...lls Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintainprop...

Page 20: ...nnecting The Battery Connect Cable Last 190 377 4 4 Installing Exhaust Pipe Stop engine and let cool 1 2 in Tools Needed exh_pipe2 4 96 154 089 A 154 611 190 377 Do not blow exhaust toward air cleaner or air intake Top View ...

Page 21: ...2 in 13 mm from top to allow room for expansion Open fuel shut off valve Do not run out of fuel or air enters fuel system and causes starting problems See engine manual to bleed air from fuel system Oil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label Engine stops if oil pressure is too low To improve cold weather starting ...

Page 22: ... at the same time ELECTRIC SHOCK can kill TWO TIMES NORMAL OPEN CIRCUIT VOLTS can exist between electrode holders of opposite polarity Do not touch electrode holders of opposite polarity at the same time Separate electrode holders of opposite polarity to prevent contact Consult ANSI Z49 1 for common grounding safe practices 4 7 Weld Output Terminals Ref 190 377 802 292 A 802 554 Stop engine 1 Nega...

Page 23: ...CEP connect work cables to Negative terminals and elec trode holder cables to CC terminals For Stick TIG Direct Current Electrode Negative DCEN connect work cables to CC terminals and electrode holder cables to Negative terminals If unit has the Polarity switch option con nect work cables to Work receptacles and electrode holder cables to Electrode recep tacles Be sure Process Selector switches ar...

Page 24: ...lectrode holder cables to Nega tive terminals If unit has the Polarity switch option con nect common work cable and work jumper cable to Welder B right Work receptacle Connect other end of work jumper cable to Welder A left Work receptacle Connect electrode holder cables to Elec trode receptacles Be sure Process Selector switches and optional Polarity switches are set correctly See Section 5 3 Too...

Page 25: ...nt Elec trode Negative DCEN connect work cables to CV terminals and wire feeder cables to Negative terminals If unit has the Polarity switch option con nect work cables to Work receptacles and wire feeder cables to CV receptacles Place optional Polarity switches in Re verse position when using CV weld re ceptacles There is no CV weld output when switch is in Straight position Be sure Process Selec...

Page 26: ...ble and work jumper cable to Welder B right Work receptacle Connect other end of work jumper cable to Welder A left Work receptacle Connect wire feeder cables to CV recep tacles Place optional Polarity switches in Re verse position when using CV weld re ceptacles There is no CV weld output when switch is in Straight position Be sure Process Selector and Polarity switches are set correctly See Sect...

Page 27: ...nt Electrode Positive DCEP connect work cable to Negative terminal and wire feeder cable to CV terminal For MIG and FCAW Direct Current Elec trode Negative DCEN connect work cable to CV terminal and wire feeder cable to Negative terminal For Stick TIG welding on units with Polarity switch option connect work cable to Work receptacle and electrode cable to Electrode receptacle For MIG FCAW welding ...

Page 28: ...Negative terminal If unit has the Polarity switch option connect common work cable and work jumper cable to Welder B right Work receptacle Con nect other end of work jumper cable to Weld er A left Work receptacle Connect electrode holder cable to either Electrode receptacle Connect wire feeder cable to CV receptacle on other side Place optional Polarity switch in Re verse position when using CV we...

Page 29: ...gh strain reliefs 2 Electrode Holder Cable 3 Work Cable For Stick TIG welding Direct Current Elec trode Positive DCEP connect work cable to Negative terminal and electrode hold er cable to CC terminal For Stick TIG Direct Current Electrode Neg ative DCEN connect work cable to CC terminal and electrode holder cable to Neg ative receptacle If unit has the Polarity switch option con nect work cable t...

Page 30: ...2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm2 equivalent weld cable sizes S 0007 E ether1 7 96 153 382 A 190 377 802 291 A Stop engine Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder Do n...

Page 31: ...4 volts ac contactor control circuit C Output to remote control 10 volts dc in CV 0 to 10 volts dc in CC REMOTE OUTPUT D Remote control circuit common CONTROL E 0 to 10 volts dc input command signal from remote control A V AMPERAGE VOLTAGE F H Current feedback 0 to 10 volts dc 1 volt per 100 amperes Voltage feedback 1 volts dc per 10 arc volts 115 VOLTS AC I J 115 volts 15 amperes 60 Hz ac Protect...

Page 32: ...ge 28 4 18 Remote 14 Receptacle Connections Single Operator Operation Dual Operator Operation OR OR OR A J B K I C L N H D M G E F 60 0 AM PS A J B K I C L N H D M G E F A J B K I C L N H D M G E F Ref 802 291 A ...

Page 33: ...trol 3 Ether Starting Aid Switch Optional Push switch up and release while cranking engine to release ether To Start Press button and use Ether switch if necessary Release button when engine starts If the engine does not start let engine come to a complete stop before attempt ing restart To Stop Pull control out and hold Release control when engine stops 4 Battery Charging Warning Light Light goes...

Page 34: ...OM 494 Page 30 5 2 Weld Controls See Section 5 3 Ref 191 848 8 9 7 5 6 3 4 2 60 0 AM PS 300 AMPS 300 AMPS 600 AMPS WELDER A Welder B Welder B 1 10 ...

Page 35: ...A Turn switch Off for TIG GTAW welding When switch is in On position higher short cir cuit amperage helps arc starting After arc starts the front panel or remote Amperage Voltage control setting determines weld am perage The hot start circuit does not function when constant voltage CV welding 5 Amperage Voltage Control When Process Selector switch is in the Stick TIG position turn control clockwis...

Page 36: ... or CB2 opens RC1 does not work 120 volts may still be present at RC1 If CB2 opens GFCI 1 does not work Press button to reset breaker CB3 and CB4 protect RC2 and GFCI 2 from overload If CB3 or CB4 opens RC2 does not work 120 volts may still be present at RC2 If CB4 opens GFCI 2 does not work Press button to reset breaker If a circuit breaker continues to open contact Factory Authorized Service Age...

Page 37: ...bels 250 h Check And Clean Spark Arrestor See Section 7 9 500 h Repair Or Replace Cracked Cables 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Drain Sludge From Fuel Tank FUEL SLUDGE Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Change Fuel Filters See Section 7 4 Check Valve Clearance 1 2 in 13 mm Check Belt Tension See Section 7 ...

Page 38: ...OM 494 Page 34 7 2 Maintenance Label ...

Page 39: ...l engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 7 Housing 8 Safety Element Optional 9 Primary Element 10 Dust Cap 11 Dust Ejector To clean air filter Wipe off...

Page 40: ... filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Bleed air from fuel system accord ing to engine manual Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank This procedure should only be done by a Factory Authorized Service Agent Remove Welder A left control...

Page 41: ...ver Turn screw in until screw touches lever Tighten lock nut on screw Close side door 3 8 in 1 3 2 4 Right Side 5 RPM 1850 Tools Needed Engine Speed No Load Weld Power 7 6 Servicing Optional Ether Starting Aid ether2 7 96 153 382 A Ref 190 377 S 0692 Stop engine Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder If engine does not st...

Page 42: ... 1 2 in 13 mm belt is okay If not okay adjust belt tension To adjust belt tension 4 Hex Nuts 2 5 Alternator Bracket Loosen nuts Pivot alternator until belt is tight Tighten nuts Recheck tightness of belt Readjust if necessary Replace belt if damaged or cracked To replace belt Loosen hex nuts and pivot alterna tor clockwise Remove belt Install new belt pivot alternator until belt is tight and tight...

Page 43: ...l to replace or tighten belt If belt breaks or becomes loose safety shutdown stops engine Correct problem then reset safety shutdown as follows 2 Rod 3 Stop 4 Bracket 5 Handle Pull handle towards front of unit un til stop snaps in position behind bracket Close door 1 3 8 in Right Side 5 2 3 4 Tools Needed Pull Handle To Reset Shutdown ...

Page 44: ...rk Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run several min utes to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fire proof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 2 1 3 8 in ...

Page 45: ... Weld er A left RC9 24 and 115 volt ac output stops Circuit Breaker CB6 protects the 24 volt and 115 volt ac output to Welder B right re mote receptacle RC8 If CB6 opens Weld er B right RC8 24 and 115 volt ac output stops Circuit Breaker CB7 protects field current regulator board PC4 If CB7 opens weld and auxiliary power output on both sides stops Circuit Breaker CB8 protects the generator field f...

Page 46: ...3 and replace if open see Section 7 10 Check position of Welder Selector switch Welder A left weld output stops when Welder Selector switch is placed in Welder B position see Section 5 1 Unit overheated High Temp Shutdown light goes on wait several minutes for thermostat s TP3 to reset see Section 7 10 Have Factory Authorized Service Agent check Welder A left contactor circuit No Welder B right we...

Page 47: ...V Control switch in Panel position or place switch in Remote position and connect remote control to remote receptacle RC8 or RC9 see Sections 4 17 and 5 3 Check connections to Remote receptacle RC8 and RC9 Have Factory Authorized Service Agent check control board PC1 or PC5 Wire feeder does not work either side Reset Welder A left circuit breaker CB5 or Welder B right circuit breaker CB6 see Secti...

Page 48: ...hutdown stops engine if belt is broken or loose see Section 7 8 Check engine charging system according to engine manual See engine manual Engine suddenly stops Check blower fan V belt according to engine manual Safety shutdown stops engine if belt is broken or loose see Section 7 8 See engine manual Battery discharges between uses Clean battery terminals and posts with baking soda and water soluti...

Page 49: ...OM 494 Page 45 Notes ...

Page 50: ...OM 494 Page 46 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Welding Generator ...

Page 51: ...OM 494 Page 47 ST 192 298 F ...

Page 52: ...ger than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run i...

Page 53: ...nect load bank to generator Welder B right weld output termi nals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals 350 Amps at 40 volts Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is load...

Page 54: ...size weld cables with cor rect connectors polarity is not im portant 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals 350 Amps at 40 volts Check generator and meters after first five minutes then every fifteen minutes to be sure generator...

Page 55: ...le Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI pro tected extension cord OR 1 2 Electrically bond generator frame to vehicle fra...

Page 56: ...sistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 A x 115 V 520 ...

Page 57: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP...

Page 58: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 59: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 10 9 How Much Power Can G...

Page 60: ...ge capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 7 Load Connections Customer supplied equipment is required if generator is to supply standby power during emergencies or power outages 120 240 Volt 6...

Page 61: ... 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200...

Page 62: ...nd not available unless listed 802 317 B 1 2 3 4 5 6 7 8 9 10 11 12 13 9 10 14 15 16 17 18 19 20 21 22 23 24 25 SEE FIG 11 4 26 9 10 27 28 29 30 31 32 33 34 35 36 37 38 83 84 85 86 87 88 89 90 91 92 SEE FIG 11 2 93 94 95 96 97 98 99 Figure 11 1 Main Assembly ...

Page 63: ...OM 494 Page 59 802 317 B 39 40 41 42 43 44 45 46 47 48 49 51 52 53 54 46 55 56 57 SEE FIG 11 3 58 59 60 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 37 36 78 SEE FIG 11 5 35 34 79 80 81 82 50 61 62 ...

Page 64: ...bg x 1 4NPT 2 28 083 859 BRACKET mtg fuel filter 1 29 192 331 ROD fuel shut off 1 30 083 553 BASE fuel filter w adapter 1 31 062 342 SEPARATOR fuel filter water 1 32 135 205 NUT 625 11 94 hex 76H stl pld 8 33 116 707 SUPPORT front engine 1 34 119 849 SCREW 625 11 x 4 00 hexhd pln gr 5 pld 4 35 071 731 WASHER flat stl 656 ID x 2 250 OD x 187thk 4 36 071 890 RETAINER mount eng gen 4 37 071 730 TUBIN...

Page 65: ...6 236 BAFFLE air outlet 1 81 CLAMP muffler included with engine 1 82 105 733 PIPE muffler extension elbow 1 875 OD 1 83 165 739 BASE 1 84 191 446 EXTRUSION rubber w adhesive 1 000 x 1 000 D order by ft 2 1ft 85 173 352 EXTRUSION rubber clamp bulb order by ft 2 4ft 86 192 305 TRAY base 1 87 176 167 NUT 250 20 acorn nylon 6 88 192 303 ANGLE mtg stabilizer 4 89 Z1 Z2 192 296 STABILIZER 2 90 192 304 P...

Page 66: ...ardware is common and not available unless listed 802 318 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 13 17 2 18 19 20 21 22 23 21 12 18 22 24 25 26 27 28 29 30 31 32 33 34 30 36 37 38 35 39 40 41 42 Figure 11 2 Front Panel ...

Page 67: ... 847 FUSE mintr cer slo blo 12A 250V 2 25 182 130 RIVET stl 125dia x 18 1 26 C1 087 110 CAPACITOR elctlt 240 1 27 087 111 CLAMP capacitor 1 375dia 1 28 SR1 035 704 RECTIFIER integ bridge 1 195 702 HARNESS wiring componet panel consisting of 1 188 512 SEAL wire univ 6P S 3 row 3 187 651 SEAL wire univ 9P S 3 row 3 RC13 21 116 045 HOUSING plugs and pins 2 PLG17 135 275 HOUSING plugs and pins 1 RC19 ...

Page 68: ...64 Hardware is common and not available unless listed 802 320 A 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 12 22 23 24 25 26 27 28 29 30 31 32 33 34 Figure 11 3 Side Control Panels Welder B Right Side Shown ...

Page 69: ...ng control box welder A left consisting of 1 CR2 000 770 RELAY encl 24VDC 3PDT 10A 120VAC 11 pin 1 GRD 185 011 STUD primary board brs 10 32 x 1 592 1 S3 6 7 011 609 SWITCH tgl SPDT 15A 125VAC on none on 3 R1 8 035 897 POTENTIOMETER cp std slot 1t 2w 1k linear 2 LS1 2 089 645 SWITCH lim 11A 125V 2 PLG18 131 056 CONNECTOR housing plug pins and sockets 1 187 651 SEAL wire univ 9P S 3 row 1 PLG19 168 ...

Page 70: ...4 735 CONNECTOR circ MS CPC 14skt 1 PC3 181 261 CIRCUIT CARD ASSEMBLY filter 1 PLG14 115 094 HOUSING plug and sockets 1 PLG6 168 847 HOUSING plug pins and sockets 1 PLG3 152 249 HOUSING plug pins and sockets 1 PLG13 135 556 HOUSING plug pins and sockets 1 188 512 SEAL wire univ 6P S 3 row 1 32 165 316 STAND OFF No 6 32 x 875 lg 312 hex nyl 6 145 217 SCREW K40 x 12 pan hd phl stl pld slftpg 6 33 05...

Page 71: ...3 177 317 HEAT SINK rect 4 4 025 248 STAND OFF insul 250 20 4 5 192 302 BRACKET mtg rectifier 2 6 166 667 CLAMP spring thyristor 6 7 TP3 TP4 185 679 THERMOSTAT NC open 211F C 2 8 192 308 ANGLE support rectifier 2 9 SCR1 6 148 091 THYRISTOR SCR 865 12 10 188 692 CLAMP thyristor rectifier 6 PLG1 PLG2 158 720 CONNECTOR SOCKETS 1 To maintain the factory original performance of your equipment use only ...

Page 72: ...OM 494 Page 68 Ref 048 456 E 1 3 4 5 7 6 9 10 11 8 12 13 15 14 Hardware is common and not available unless listed 2 Figure 11 5 Generator ...

Page 73: ...17 RING retaining external 1 10 053 390 BEARING ball 1 11 083 748 FAN rotor 1 12 013 367 LABEL warning moving parts 2 13 195 704 STATOR exciter aux pwr 120 240 1 14 173 068 ENDBELL generator consisting of 1 15 143 220 O RING 2 859ID x 139CS 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 193 5...

Page 74: ...Notes ...

Page 75: ...obart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warra...

Page 76: ...r To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact th...

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