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:MIG = GMAW, Wire WeldingTIG = GTAWStick = 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.; FUMES AND GASES can be hazardous.
OM-487 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 gro...
Page 6 - FLYING METAL can injure eyes.; BUILDUP OF GAS can injure or kill.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.
OM-487 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, ove...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; TILTING OF TRAILER can cause injury.
OM-487 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 as ne...
Page 8 - Principal Safety Standards
OM-487 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 qualif...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-487 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 message ...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-487 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 incendies...
Page 11 - LIRE LES INSTRUCTIONS.
OM-487 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 branch...
Page 13 - SECTION 2 – DEFINITIONS; Symbol Definitions; SECTION 3 – SPECIFICATIONS
OM-487 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil On Check Valve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire Stick (SMA...
Page 14 - Dimensions, Weights, And Operating Angles; Fuel Consumption
OM-487 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions A Height 33-1/2 in (851 mm) B C Width 18-3/4 in (476 mm) C Depth 48 in (1219 mm) D Do not exceed tilt angles or engine couldbe damaged or unit could tip. A 18 in (457 mm) G Do not move or operate unit where it couldtip. B 16-1/...
Page 15 - Auxiliary Power Curve; Duty Cycle
OM-487 Page 11 ST-189 268 The ac auxiliary power curveshows the auxiliary power availablein amperes at the receptacles. 3-4. Auxiliary Power Curve 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 0 120 80 40 200 160 280 240 AC POWER AMPERES AT 120V AC POWER AMPERES AT 240V 0 10 20 30 40 60 50...
Page 17 - SECTION 4 – INSTALLATION; Installing Welding Generator
OM-487 Page 13 SECTION 4 – INSTALLATION install1 10/00 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Boltunit down using holes pro-vided in base. Always securely fastenwelding generator ontotransport vehicle ...
Page 18 - Engine Prestart Checks
OM-487 Page 14 4-3. Engine Prestart Checks ST-801 939-C / ST-801 940 / ST-801 961 1/2 in (13 mm) Full Diesel Full Open Valve Full Check all fluids daily. Engine must becold and on a level surface. Unit isshipped with 10W30 engine oil. Enginestops if oil pressure is low or engine tem-perature is high...
Page 19 - Adding Coolant To Radiator; Connecting The Battery
OM-487 Page 15 4-4. Adding Coolant To Radiator ST-801 939-C / Ref. ST-187 602-A Stop engine and let cool. Check coolant level accordingto Section 4-3 before startingthis procedure. If coolant level is below bottom ofradiator filler neck, add coolant asfollows: 1 Thermostat Housing Plug Remove thermo...
Page 20 - Selecting Weld Cable Sizes; Remote 14 Receptacle Information; NOTE
OM-487 Page 16 4-7. Selecting Weld Cable Sizes Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 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) Weld Output Terminals Stop engine beforeconnecting to weld out...
Page 21 - Adjusting MIG Weld Puddle Consistency
OM-487 Page 17 4-9. Adjusting MIG Weld Puddle Consistency Ref. ST-801 944-B / Ref. ST-187 602–A Stop engine. Stabilizer DC-Z is factoryconnected to suit most MIG (WireWelding) applications. To change MIG weld puddle consis-tency, proceed as follows: Remove lower front panel and sidepanel. Starting f...
Page 22 - SECTION 5 – OPERATING WELDING GENERATOR; Front Panel Controls
OM-487 Page 18 SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls Ref. ST-187 602-A 1 DC Polarity/AC Switch Do not switch under load. Use switch to select AC weld output or polarityof DC weld output. 2 Process Select Switch Do not switch under load. Use switch to select output for wel...
Page 23 - Remote Amperage/Voltage Control
OM-487 Page 19 5-2. Remote Amperage/Voltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control toRC1 (see Section 4-8). 2 Remote Hand Control(Optional) 3 Remote Foot Control(Optional) Engine runs at weld/powerspeed whenever a device con-nected to the remote 14 recep-tacle is running....
Page 24 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Auxiliary Power Receptacles And Circuit Breakers
OM-487 Page 20 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Ref. ST-187 602-A 1 4 2 5 3 If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. 1 240 V 50 A AC ReceptacleRC1 RC1...
Page 25 - Optional Auxiliary Power Receptacles
OM-487 Page 21 6-2. Optional Auxiliary Power Receptacles If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. Combined output of all receptacleslimited to 8 kVA/kW rating of thegenerator. GFCI Receptacle Option 1 120 V 15 A A...
Page 26 - Wiring Optional 240 Volt Plug; Notes
OM-487 Page 22 6-3. Wiring Optional 240 Volt Plug ST-120 813-D The plug can be wired for a 240 V,2-wire load or a 120/240V, 3-wireload. See circuit diagram. 1 Plug Wired for 120/240 V,3-Wire Load When wired for 120 V loads, eachduplex receptacle shares a loadwith one half of 240 V receptacle. 2 Plug...
Page 27 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Maintenance Label
OM-487 Page 23 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Maintenance Label
Page 28 - Routine Maintenance
OM-487 Page 24 7-2. Routine Maintenance Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE Stop engine before maintaining. See also Engine Manual andmaintenance label. Service engine moreoften if used in severe conditions. * To be done...
Page 30 - Servicing Air Cleaner
OM-487 Page 26 7-3. Servicing Air Cleaner aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. The air cleaner primary element canbe cleaned...
Page 31 - Servicing Engine Cooling System; Servicing Optional Spark Arrestor
OM-487 Page 27 7-4. Servicing Engine Cooling System 801 939 / 802 727 Stop engine and let cool. 1 Radiator Cap 2 Radiator Drain Cock Drain engine coolant according toprocedure in engine manual. Add engine coolant according toprocedure in Section 4-4. 1 2 Stop engine and let cool. 1 Spark Arrestor Sc...
Page 32 - Servicing Engine Fuel And Lubrication Systems
OM-487 Page 28 7-6. Servicing Engine Fuel And Lubrication Systems Ref. ST-801 961 / ST-801 940 / Ref. ST-187 602-A / S-0842 Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord-ing to engine manual. Close valve and valve capbefore adding ...
Page 33 - Adjusting Engine Speed; A. Checking Fuel Solenoid
OM-487 Page 29 7-7. Adjusting Engine Speed If the engine does not start and stop properly, verify the fuel solenoid is installedproperly before adjusting engine speed (see Section A following). If the engine does not stay at idle speed, verify the throttle solenoid is installed andadjusted properly ...
Page 34 - B. Checking Throttle Solenoid
OM-487 Page 30 B. Checking Throttle Solenoid Ref. ST-801 961 / ST-802 649 Stop engine. If the engine does not stay at idlespeed, verify the the throttle sole-noid and linkage is installed proper-ly. Adjusting Throttle Solenoid 1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bolt 5 Throttle ...
Page 35 - C. Making Engine Speed Adjustments
OM-487 Page 31 C. Making Engine Speed Adjustments Ref. ST-801 961 / ST-801 963 Before adjusting engine speed, verifythrottle solenoid is installed properly(see Section B on previous page). Check engine speeds with a tachometer(see table). If necessary, adjust speeds asfollows: Start engine and run u...
Page 36 - Overload Protection
OM-487 Page 32 Stop engine. If a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedService Agent. 1 Circuit Breaker CB6 CB6 protects the 115 volt ac outputto Remote 14 receptacle RC1. IfCB6 opens, 115 volt ac output toRC1 stops. 2 Circuit Bre...
Page 40 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator
OM-487 Page 36 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator
Page 42 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking
OM-487 Page 38 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 thannecessary. ...
Page 43 - Run-In Procedure Using Load Bank
OM-487 Page 39 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 auxi...
Page 44 - Run-In Procedure Using Resistance Grid
OM-487 Page 40 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 switc...
Page 45 - SECTION 10 – AUXILIARY POWER GUIDELINES; Selecting Equipment; Grounding Generator To Truck Or Trailer Frame
OM-487 Page 41 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 this ...
Page 46 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?
OM-487 Page 42 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 2 U...
Page 48 - Approximate Power Requirements For Contractor Equipment
OM-487 Page 44 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 14 i...
Page 49 - Power Required To Start Motor; How Much Power Can Generator Supply?
OM-487 Page 45 10-8. Power Required To Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table tofind kVA/HP. If code is not listed,multiply running amperage by six tofind starting amperage. Step 2: Find Motor HP ...
Page 50 - 0-10. Typical Connections To Supply Standby Power
OM-487 Page 46 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 overcurrentprotection. ...
Page 52 - SECTION 11 – PARTS LIST
OM-487 Page 48 SECTION 11 – PARTS LIST ST-802 106-B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 30 31 19 32 33 37 34 35 36 38 39 40 41 42 43 44 46 48 50 51 52 53 54 55 56 – Fig.10 – 3 48 58 57 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 70 69 74 75 76 77 78 79 80 – Fig.1...
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 2000 Hobart Welding Products. 1/00 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...
