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OM-474 108 848X
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 40D
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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. With Hobart you can count on years of reliable service with
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause par
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Fast/Slow Battery (Engine) Glow Plug Engine Oil (Run/Idle) Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes Volts Panel/Local Remote 14 14 A V Read Operator’s Engine Coolant G Engine Temperature 1 Manual Temperature Alternating Time Hours Seconds Current h s Do Not Switch Single Phase Three Pha
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3-2. Dimensions, Weights, And Operating Angles Dimensions Height 48-3/4 in (1238 mm) Width 24-5/8 in (625 mm) Engine End L Do not exceed tilt angles or engine could Depth 64-1/2 in (1638 mm) be damaged or unit could tip. A 62 in (1575 mm) D Do o not move or operate unit where it could not move or operate unit where it could tip. B 59-1/8 in (1502 mm) C 46-1/4 in (1175 mm) B D 34-3/4 in (883 mm) E 26-15/16 in (684 mm) A C F 9-1/2 in (241 mm) 33° G 2-7/8 in (73 mm) E 33° ° D 20° H 7/8 in (22
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3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle At 350 Amperes 100% Duty Cycle At 300 Amperes 6 Minutes Welding 4 Minutes Resting Continuous Welding rduty1 5/95 – SB-111 076-A 3-5. AC Auxiliary Power The ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. rsb3.1 2/92 – ST-109 365-C OM-474 Page 11
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3-6. Optional AC Power Plant Curves The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or A. 8.5 KVA/KW Single-Phase Auxiliary Power Plant three-phase 240 volt terminals. (No Weld Load) 280 260 240 220 200 180 0 2040 6080 100 AC AMPERES B. 12.5 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) 280 260 240 220 200 180 0 102030 40506070 AC AMPERES rsb13.1 12/94 - ST-111 118-D / ST-112 449-B OM-474 Page 12 AC VOLTS AC VOLTS
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3-7. Volt-Ampere Curves The volt-ampere curve shows the A. CC/DC (Standard) minimum and maximum voltage 100 and amperage output capabilities of the welding generator. Curves of all other settings fall between the Ranges: 190–Max curves shown. 110–270 80 85–210 55–110 Min–65 60 40 20 0 400 0 100 200 300 500 600 700 DC Amperes B. CC/AC (Models with Optional Polarity/AC Selector Switch) 100 80 60 40 20 0 0 100 200 300 400 500 600 700
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding Always ground generator frame to vehicle frame to pre- vent electric shock and static 3 electricity hazards. 1 4 GND/PE 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding OR Terminal 4 Grounding Cable Use #10 AWG or larger insulated copper wire. Electrically bond generator
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4-3. Installing Muffler Stop engine and let cool. Do not blow exhaust toward air cleaner or air intake. Tools Needed: 1/2 in muff1 4/96 – ST-154 088-B / Ref. ST-191 898 4-4. Engine Prestart Checks 1/2 in (13 mm) Full Full Diesel Capacity: 9 qt (8.5 L) Valve Open Full Ref. ST-155 331-B / Ref. ST-154 954 Check all fluids daily. Engine must be cold After fueling, check oil with unit on level sur- Keep radiator, air intake, and cooling fins and on a level surface. face. If oil is not up to full
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4-5. Connecting To Weld Output Terminals Open left side door. 1 Bracket Route cables through bracket. 2 Positive (+) Weld Output Terminal 3 Negative (–) Weld Output Ter- 3 minal For Stick welding Direct Current Electrode Positive (DCEP), con- 2 nect work cable to (–) terminal and electrode holder cable to (+) terminal. For Direct Current Electrode Nega- tive (DCEN), reverse cable connections. If equipped with optional polarity switch, connect electrode holder Left Side cable to Electrode (–) ter
