Page 2 - From Hobart to You
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Hobart distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-877-Ho...
Page 3 - TABLE OF CONTENTS; CALIFORNIA; WARNING
The following terms areused interchangeablythroughout this manual: Stick = SMAW TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-130 098 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This...
Page 6 - BUILDUP OF GAS can injure or kill.; Engine Hazards; FUEL can cause fire or explosion.
OM-130 098 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion,...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance
OM-130 098 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting a...
Page 8 - Principal Safety Standards
OM-130 098 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qu...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-130 098 Page 5 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 procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un mess...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-130 098 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incen...
Page 11 - LIRE LES INSTRUCTIONS.
OM-130 098 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou br...
Page 13 - SECTION 2 – DEFINITIONS; Symbols And Definitions
OM-130 098 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/...
Page 14 - SECTION 3 – SPECIFICATIONS; Dimensions, Weights, And Operating Angles
OM-130 098 Page 10 SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC (Nominal) Auxiliary Power Rating Engine Fuel Capacity 400 A, 40 Volts DC, 40% Duty Cycle 40 – 400 95 (90) Single-Phase, 3 kVA/kW, 26 A,120 V A...
Page 16 - AC Auxiliary Power
OM-130 098 Page 12 3-5. AC Auxiliary Power The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacles. rsb3.1 2/92 – ST-109 365-C 3-6. Volt-Ampere Curves ST-183 882 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities o...
Page 17 - Optional AC Power Plant Curves
OM-130 098 Page 13 3-7. Optional AC Power Plant Curves rsb13.1 12/94 - ST-134 636-A / ST-134 637-A The ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt orthree-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 1...
Page 18 - SECTION 4 – INSTALLATION; Installing Welding Generator
OM-130 098 Page 14 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grou...
Page 19 - Activating The Dry Charge Battery
OM-130 098 Page 15 4-3. Activating The Dry Charge Battery drybatt1 2/96 – S-0886 Remove battery from unit. 1 Eye Protection – SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom of well (maximum)...
Page 22 - Selecting Weld Cable Sizes
OM-130 098 Page 18 4-8. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cyc...
Page 23 - Notes
Page 24 - SECTION 5 – OPERATING THE WELDING GENERATOR
OM-130 098 Page 20 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (See Section 5-2) Ref. ST-188 449 / ST-800 162-A / ST-800 159-D 14 15 1 2 12 13 5 3 4 6 7 10 11 8 9
Page 26 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT
OM-130 098 Page 22 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles Ref. ST-188 449 1 2 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord. Auxiliary power is not affectedby weld output. If a circuit breaker continues toopen, contact Fa...
Page 27 - Optional Auxiliary Power Receptacles
OM-130 098 Page 23 6-2. Optional Auxiliary Power Receptacles Ref. ST-188 449 / ST-174 408 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord. Auxiliary power is not affectedby weld output. If a circuit breaker continues toopen, contact Factory Autho-rized Service Agent. GFCI...
Page 28 - Connecting Optional Auxiliary Power Plant
OM-130 098 Page 24 6-3. Connecting Optional Auxiliary Power Plant Ref. S-188 059-A Stop engine. Power and weld outputs arelive at the same time.Disconnect or insulateunused cables. Have qualified person installaccording to circuit diagramand Auxiliary Power Guidelines(Section 10). Remove junction bo...
Page 29 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance
OM-130 098 Page 25 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label.Service engine more often if used in severe condi-tions. * To be done by Factory Authorized Service Agent. 8 h W...
Page 30 - NOTE; Maintenance Label
OM-130 098 Page 26 Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-2. Maintenance Label
Page 31 - Servicing Air Cleaner
OM-130 098 Page 27 7-3. Servicing Air Cleaner aircleaner4 9/99– 802 495 / Ref. S-0698-B Stop engine. 1 Air Cleaner 2 Service Indicator (Optional) 3 Window 4 Reset Button Service air cleaner element if redband appears in window. A greenband means air cleaner is okay.Press button to reset indicator. D...
Page 32 - Servicing Fuel And Lubrication Systems
OM-130 098 Page 28 7-4. Servicing Fuel And Lubrication Systems Ref. ST-801 739 / Ref. ST-188 449 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff Valve 8 Fuel Line 9 Sludge Drain Plug ...
Page 33 - Adjusting Engine Speed
OM-130 098 Page 29 7-5. Adjusting Engine Speed Ref. ST-801 179 / Ref. ST-801 739 / Ref. ST-800 161 After tuning engine, check engineno load speed with a tachometer(see table for no load speeds). Ifnecessary, adjust speed as follows: Start engine and run until warm.Turn Amperage/Voltage Control to100...
Page 35 - Inspecting And Cleaning Optional Spark Arrestor; Troubleshooting
OM-130 098 Page 31 7-8. Inspecting And Cleaning Optional Spark Arrestor ST-800 523 / Ref. ST-188 449 Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed toblow out cleanout hole. If nothin...
Page 37 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator
OM-130 098 Page 33 SECTION 8 – ELECTRICAL DIAGRAM SC-190 649-A Figure 8-1. Circuit Diagram For Welding Generator
Page 38 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking
OM-130 098 Page 34 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking 1 Welding Generator Run diesel engines near rated out-put during run-in period to properlyseat piston rings and prevent wets-tacking. See nameplate or ratinglabel to find rated output. Do not idle engine longer thannecessa...
Page 39 - Run-In Procedure Using Load Bank
OM-130 098 Page 35 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Load Bank Turn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall receptacle or genera-tor ...
Page 40 - Run-In Procedure Using Resistance Grid
OM-130 098 Page 36 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Resistance Grid Use grid sized for generator ratedoutput. Turn Off grid. 2 Welding Generator Place A/V range s...
Page 41 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame
OM-130 098 Page 37 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas t...
Page 42 - 0-3. Grounding When Supplying Building Systems
OM-130 098 Page 38 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1...
Page 43 - 0-5. Approximate Power Requirements For Industrial Motors
OM-130 098 Page 39 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts 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 140...
Page 44 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-130 098 Page 40 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts 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 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw ...
Page 46 - 0-10. Typical Connections To Supply Standby Power
OM-130 098 Page 42 10-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotecti...
Page 48 - SECTION 11 – PARTS LIST
OM-130 098 Page 44 SECTION 11 – PARTS LIST Figure 11-1. Main Assembly 3 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 82 83 84 85 86 87 88 89 90 91 92 94 93 95 96 97 98 99 100 101 102 103 104(Fig.11–2) 105 106 107 108 109 110 111 112 113 114 115 116 117 118 71(Includes 72–77) 72 73 74 75 76 77 78 79 80 81...
Page 53 - Optional Equipment
OM-130 098 Page 49 Optional Equipment Description Quantity Part No. 043 096 RECEPTACLE KIT, 120V GFCI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE PROTECTION PACKAGE, (consisting of) . . . . . . . . . . . . . . . . . . . ....
Page 59 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-877-HOBART1for your localHobart distributor. hobart standard 7/00 ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contact your distributor orcall 1-800-33...
Page 60 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA 2001 Hobart Welding Products. 1/01 Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equ...
