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Hobart 3225DX User's Manual

1. Valve Open 8 Tools Needed Tom 7 7 16 11 16 in A Stop engine and let cool 1 Oil Filter 2 Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter Fuel Water Separator Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line oo ON O OC Sludge Drain Plug To change oil and filter See engine manual To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove 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 Put metal container under drain and remove sludge drain plug Re install plug when done A After servicing start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe up Spilled fuel Close doors Ref ST 801 739 Ref ST 188 449 OM 130 098 Page 28 7 5 Adjusting Engine Speed 2 Pa AW F a Fa CI 1850 rpm U A 1250 rpm Standard Models Tools Needed 3
2. 240 V 120 240 Volt Y 60 Hz i V Three Wire Service aay A Ki 2 3 z 240 V i YO Y 120V Load lt U 1 i 120 V SY A OO 7 CB 5 Es or NT F1 6 240V EE a 120 240 Volt Y 120V Single Phase L Three Wire 120 V Generator Output A Connection Ground i power output circuit S 0405 A OM 130 098 Page 42 10 11 Selecting Extension Cord Use Shortest Cord Possible A Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Aas Load Watts 4 6 8 10 12 14 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 87 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 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 A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Peb Load Wa
3. Stop engine Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle gt gt 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals 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 rated generator output see nameplate Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed After one hour minimum place A V control in minimum position then turn off load bank to remove load Run engine several minutes at no load A Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0683 OM 130 098 Page 35 9 3 Run In Procedure Using Resistance Grid A A CL w Su Stop engine
4. 1 eee OE tet ie pe 145 283 HOSE fuel 10 000 1 4 swivel both ends 1 KON PA eae uk 188 250 4 BASE 13 54 HA shine heh aed De lieth da crite Sad a ee P cte 1 a 010 146 CLAMP nyl 625 clamp dia 1 3 EE OE 123 794 EDGE TRIM order by ft 1ft 85 TEI 2 038 621 BLOCK term 30A 4P 1 ai AA 038 620 LINK jumper term blk 30A 2 THUS PLG7 135 556 CONNECTOR 8 SOCKETS 1 86 CR98 CR99 090 104 RELAY encl 12VDC SPST 2 87 Idle mod 142724 MODULE pull to idle 5 pin 1 ee OO qu exse 176775 BRACKET mtg comp panel auto idle 1 pr BG weeds F4 073429 FUSE mintr gl slo blo 15A 32V 1 EER init 046 432 HOLDER fuse mintr 250 x 1 250 panel mtg 1 in Oli kal 053 967 INSULATION rectifier 1 u eae a bet amp 081 499 BRACKET mtg strip terminal 1 DEC RS T 113 932 GUARD panel rcpt consisting of 1 ES RE ESE 113 730 LABEL warning stop engine before 1 95 SR1
5. e 3 8 7 16 in After tuning engine check engine no load speed with a tachometer see table for no load speeds If necessary adjust speed as follows Start engine and run until warm Turn Amperage Voltage Control to 100 Standard Models 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut Turn screw until engine runs at 1850 rpm Tighten nut Models With Automatic Idle Optional 3 Throttle Rod 4 Locknut Loosen locknuts Place engine control switch in Run ldle position Turn throttle rod until engine runs at idle speed Tighten locknuts 5 Engine Speed Adjustment Screw 6 Locknut Place engine control switch in Run position Loosen locknut Turn screw until engine runs at weld power speed Tighten locknut A Stop engine Ref ST 801 179 Ref ST 801 739 Ref ST 800 161 OM 130 098 Page 29 7 6 Overload Protection ES O 7 ar A Stop engine AN t3 EF When a fuse opens it usually indicates a more serious prob lem exists Contact a Factory Authorized Service Agent 1 Magnetic Shutdown Switch MS1 Optional 2 Fuse F See Parts List Fuse F protects magnetic shut down switch MS1 If fuse F opens the engine stops 3 Throttle Solenoid Fuse F4 Optional Fuse F4 protects the throttle sole noid from overload on models with automatic idle option If fuse F4 opens the engine does not run at idle speed Check fuses and replace if op
6. 2 mibi 6 005000 CONTACT ASSEMBLY movable consisting of 3 NE 7 222222 011076 SPRING pressure d Ian aa 011953 ius GONTAGT 3c cane a a e ci ca Ga atc ora e C t c sabad Danae 1010074 sis SPRING pressures 1 104 2 0 a KANA ana RD eres etes A EM 10 011 644 CONTACT stationary 15 bata 11 004999 CONTACT BOARD stationary 2 ee 12 011 012 SHIM guide contact board 8 Ninos 13 100623 GUIDE contact board movable 8 5 6 sa Includes 8 9 Item 7 9 Ts h e y A N A S 77 Je SB 011 273 gt SB 011 100 Figure 11 4 Switch Range BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 130 098 Page 54 Warranty Questions Call 1 877 HOBART1 for your local Hobart distributor Service You 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 distributor and Hobart is there to help you every step of the way HOBART WARRANTY Effective January 1 2000 Equipment with a serial num
7. 24 7 5 Adjusting Engine Speed 25 756 Overload Protections oo eed Ug cea e ser pede t 26 7 7 Servicing Optional Ether Starting Aid 26 7 8 Inspecting And Cleaning Optional Spark Arrestor 27 7 95 Troubleshooting E er Pee Baha a ie eel UT de Ae 27 SECTION 8 ELECTRICAL DIAGRAM 29 SECTION 9 RUN IN PROCEDURE eie ee ee ee Ge ee e ee ee ee ee ee ee ee ee 30 9 1 Wetslacking ie RE BE Eie da Ra Botte KA AE DE EE Ye De Ei ER ER 30 9 2 Run In Procedure Using Load Bank 31 9 3 Run In Procedure Using Resistance Grid 32 SECTION 10 AUXILIARY POWER GUIDELINES 33 SECTION 11 PARTS LIST SEE egte me er sea 40 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the relat
8. 1 Iss unas nein 125687 HOSE nprn SAE 125 ID x 343 OD order by ft 1ft c 125 704 FITTING hose brs splice 1 8tbg 1 me ee 097 507 STRIP rbr adh back 1 125 x 1 000 x 20 500 2 ww p 188 235 UPRIGHT base center 1 il OE RD NGA ane 017 479 SEAL weather lift eye 1 Seine NE a 111352 BATTERY stor 12V 380crk 80rsv 1 RE ca eae the 108 081 TERMINAL PROTECTOR battery post mtg 2 Se aa 124941 CABLE bat pos 1 Ca a EE E E 089914 BOLT L stl 312 18 x 10 000 1 c 124 668 HOLD DOWN battery 1 ee One 010460 STUD stl 312 18x 10 000 1 A Rah He 032 453 CABLE bat neg nn devine Pei Wee da 1 RE 049 026 SCREW M10 1 5 x 25mm hexhd 1 ms 124 766 COVER top 1 Ca OE 134 792 LABEL warning general precautionary 1 MP 9 ER set acus 107 990 LABEL use diesel fuel only 1 nexa ER ES 035 968 WASHER flat rbr 3 625 ID x 5 875 OD x 062thk 1 AE N EE 108 487 LABEL war
9. zur UN CHOC ELECTRIQUE peut tuer Un simple contact avec des pieces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment la En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e Siisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l ent
10. 2 Items furnished by Hobart but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s option 1 repair or 2 replacement or where authorized in writing by Hobart in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart authorized service facility as determined by Hobart Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE
11. Ed Delet d RE OR er EE ee N RE N EE 010 863 CLAMP hose 2 062 3 000clp dia 1 u EE N sem us 124 985 HOSE air cleaner to engine 1 xod ee ER OLSEN 010862 CLAMP 1 812 2 500clp dia 1 is ETE 010089 FITTING pipe brs coupling 1 8NPT 1 AS sae hou ies 046 545 RESTRICTION INDICATOR 2222200 ane 1 Ca en ES 175465 FITTING pipe brs adapter extender 1 8 x 1 8 120 1 a ADs en et 158 610 LABEL warning electric shock and moving parts 2 pang AO ce 08 1336 LATCH cen rer ea aka Lesern 2 rn 173908 1 1 9 G B linia eee Meier he ae Ree d ina 1 abe Seay AE EE 010 736 TUBING stl 625 OD x 12ga wall x 625 1 a ee NE 173910 WEATHERSTRIPPING se se ed ee ee ee ee ee ee eee 1 p 173903 ENGINE Deutz dsl elec 1 Es PLG5 124346 HOUSING plug nyl 8 contact d AA 128287 STUD adjusting throttle d B ns 127648 CLEVIS throttle 1 No Mkgs No Description Quantity Figure 11 1 Main Assembly Continued ER RED 127 994 BALL JOINT 250 28 1 TEE 17 5936 ROD throttle e etii ere OY
12. If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 130 098 Page 1 NG WELDING can cause fire or explo TAS sion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can 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 be sure the area is safe before doing any welding e Protect yourself and others from flying spark
13. e Do not block or filter airflow to unit STATIC ESD can damage PC boards 4 e Puton grounded wrist strap BEFORE handling ASS boards or parts Eo e Use proper static proof bags and boxes to store move or ship PC boards IN TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer Re READ INSTRUCTIONS e Use only genuine MILLER replacement parts e Perform engine maintenance and service according to this manual and the engine manual OM 130 098 Page 3 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 5 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune R
14. Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 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 File a claim for loss or damage during shipment 2001 Hobart Welding Products 1 01 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 WELDING PRODUCTS
15. 174008 BRACKET mtg switch and output terminals zx MO es OE 174010 SWITCH polarity RS AE e 059 773 HANDLE switch 111 R23 128862 RESISTOR WW adj 375W 50 ohm ARE AR 085 656 STRIP mtg resistor 1 I RE PES Ve 188 237 UPRIGHT base front 114 an 108 163 FRAME mtg reactor 8 fuel tank WAS castes er 110069 FITTING brs flrd elbow M 1 4tbg x 1 4NPT NG anis 010314 VALVE shut off fuel ma PAPA EES Mae aw be 070010 BOLT J stl 250 20 x 2 750 ix A 089517 xx STRAP TT N TT cc ee jadal daki te ei Pahang NG m ad aa a mal nag 179 919 JI label A a dha ea eS Deal me When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts OPTIONAL BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 130 098 Page 48 Part ut No Description Quantity Optional Equipment DE EI nU dats 043 096 RECEPTACLE KIT 120V GFCI d EE EE rad ENGINE PROTECTION PACKAGE consisting of EE HI a 042 318 AUTOMATIC S
16. contact your local Hobart distributor Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local to receive the latest full line catalog or sul T banana e can also su ou wit individual catalog sheets To locate your nearest Welding ee Manuals such as SMAW GTAW distributor or service agency call 1 877 Hobart1 GMAW and GMAW P WELDING PRODUCTS 4 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 4 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The following terms are used interchangeably throughout this manual Stick SMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage s s don dy uA KAGALAKANG AR ge Mend aes RR NAA 1 1 2 Arc Welding Hazards ee
17. lt haters acs 106 425 INSULATOR aa RS ER E Racer ate ha eo eB Ee 2 A BA ren 173 066 BRACKET mtg brushholder 1 nde TE 018614 BRUSH SET consisting of 3 OD RA ee A 151 299 BRUSH CONTACT a ER EE ee MG ate a went econ en 1 Ak NO A 600 270 HOLDER brush 1 d SM co 152 044 CAP brushholder 1 END 013 367 LABEL warning moving parts can cause serious injury 2 E 124 855 GUARD starter 1 stat TA ee maires 174 002 STATOR gen consisting of 1 wae dd ERES 1e 140 100 STATOR gen consisting of 1 At De ks 039 207 BAFFLE air gen 2 1 in AO same 089 736 ROTOR gen consisting of 1 Sb TR Een 024 617 RING retaining external 0 0c ccna 1 i Orne 053 390 BEARING ball eiii pes ea teh ioe na 1 EE keda 089 797 c FAN r0l r t is iela tes metal alal er he ee ER Eile 1 WERDE te ad Re 095 776 KEY 375 375 X 21000 EER ba ac babel rer Dee na las I toh BQO isses 044 374 STATOR excitor 1 EE FREE 173 068 ENDBELL gen consisting of 1 L
18. AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax 115 Vs 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 130 098 Page 38 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 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 10 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De lcer 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 A
19. Add fresh diesel fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 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 2 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 7 To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather Ref ST 801 739 OM 130 098 Page 16 4 6 Installing Ether Cylinder Optional Ether Starting Aid FR lt KZA A Stop engine A Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder A Do not use Ether Starting Aid while engine is running Open side door s 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle 3 Clamp 4 Fitting 5 Cap 6 Valve Remove cap and clean fitting Install cylinder on fitting Tighten clamp x After installing cylinder wait at least 10 minutes before using to let ether particles settle and
20. HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 130 098 Page 40 10 8 Power Required To Start Motor A AG MOTOR 1 Motor Start Code 2 2 Running Amperage IN VOLTS 230 AMPS 254177 nun SE 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage Cup 1 4 PHASE 1 To find starting amperage Step 1 Find code and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motor s running amperage 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 kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 10 54 Staring th t ires 12 2 7 290 7 1a arting the motor requires 12 2 amperes onis 10 9 How Much Power Can Generator Supply 1 LimitLoad To 90 Of Generator Output Always start non resistive motor loads in order from largest
21. ee agian wes 1 o Od at cx 126388 NUT 250 28 LH 1 TE mcr 194 036 BRACKET arm throttle 1 EE EE UE Rep e 010021 CLAMP stl cush 562dia x 343mtg hole 1 BR ER MA t SE 072082 BUSHING stl 265 ID x 499 OD x 593 lg 2 partos quiete deua 118679 SCREW M 6 1 0 x30 2 put lt lt ih Meaty naka basahang 125 663 1BA L JOINT 250 28 EH ie matid eret eem ED GR ei rr sed 1 86 TS1 124974 SOLENOID 12VDC 202 ena 1 LO Lean el een 175 937 BRACKET support solenoid 1 Lau DO EE sa des 188246 BRACKET mtg engine RH 1 LO cd esteem RER 601 945 SCREW cap stl hexhd 625 18 x 4 000 4 EE US 071 731 WASHER flat stl 656 ID x 2 250 OD x 187thk 4 ee Od isle ues 071890 RETAINER mount eng gen 4 DA ED C LE wt 071 730 TUBING stl 875 OD x 12ga wall x 2 375 4 diu Ospite aus 072848 TUBING nprn 875 ID x 2 500 OD x 2 000 4 EE SIR OE remus 173 929 BRACKET mtg solenoid 1 na oo N Figure 11 3 GENERATOR ee se a cee eee eh K 1 66 SHUNT 030084 SHUNT m
22. in 0 3 mm Exhaust 0 020 in 0 5 mm Have only trained technician maintain injection pump and injectors AIR WATER or GASOLINE will harm the injection system Injectors should be checked annually 250 operating hours See Owner s Manual 173 847 E OM 130 098 Page 26 7 3 Servicing Air Cleaner Blow Inspect Stop engine Air Cleaner Service Indicator Optional Window Reset Button BOD K Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to reset indicator A Do not run engine without air cleaner or with dirty element Clean or replace element if dirty or damaged Replace element yearly or after six cleanings 5 Dust Ejector Dust Cover Element Safety Element Optional Body To clean air filter ON o Wipe off cover and body Remove cover and dump out dust Wipe dust from inside cover and body with damp cloth Remove element s and reinstall cover A Do not clean housing with air hose Clean element s with compressed air only Keep nozzle at least 1 in 25 mm from inside of element Max air pressure 100 psi 690 kPa Replace element s if it has holes or damaged gaskets Reinstall element s and cover dust ejector down aircleaner4 9 99 802 495 Ref S 0698 B OM 130 098 Page 27 7 4 Servicing Fuel And Lubrication Systems DUR efor
23. niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 130 098 Page 5 TE LE SOUDAGE peut provoquer un in NEAR cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de Parc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et
24. prevent atomizer plugging Put cap on fitting when cylinder is removed ether1 12 96 ST 153 382 A Ref ST 188 449 PE Jl gy Tools Needed EP 3 4 in Open left side door 1 Bracket Route cables through bracket 2 Positive Weld Output Terminal 3 Negative Weld Output Ter minal For Stick welding Direct Current Electrode Positive DCEP con 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 cable to Electrode terminal and work cable to Work terminal For FCAW welding connect work cable to terminal and wire feeder cable to terminal Close door Ref ST 800 162 A OM 130 098 Page 17 4 8 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding wating CEE BS aS can BS hea 60 Ede Duty 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 Weld cable size AWG is based on either a 4
25. rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles 1 5 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Weld ing Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 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 LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interference maintenir les c bles de souda ge aussi courts que possible
26. sea 604 103 RECEPTACLE str dx grd 2P3W 15A 250V 1 AE EE AE 025 234 PLUG str grd 2P3W 15A 250V 1 8 AG2 ese 170 901 RECEPTACLE str dx grd 2P3W 15A 125V 1 ucc uda e REED 073 690 PLUG str grd 2P3W 15A 125V Arrow Hart 5965V Dis bison 601 836 NUT brs hex 250 20 jam hvy 3 Mo 083 030 STUD brs grd 250 20 x 1 750 1 EE EE ML DE EE rere PLATE ident control rating order by model and serial number 1 aan eda se EE 046 559 METER amp DC 50MV 0 500 1 pu oed ere 046 654 METER volt DC 0 100 1 n NA sail a e 021 385 BOOT toggle switch lever 1 EER Sans 129 860 GAUGE oil pressure 1 M fata 128829 KIT oil line 44 000 in 1 8NPT x 10mm 1 CR AERE ERR e ach e128 633 FITTING pipe brs adapter 1 8NPT x 12mm 1 Is MO sc tee tres 129 837 GAUGE engine pressure 1 as E ne 119014 LEVER switch black 1 er RD 082 788 HOLDER light ind 2 19 PL12 048 155 BULB incand flg base 12V
27. to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 130 098 Page 41 10 10 Typical Connections To Supply Standby Power A CL P Fx Customersupplied equipment is required if generator is to supply standby power during emergencies or power outages 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double Pole Double Throw Transfer Switch Obtain and install correct switch Switch rating must be same as or greater than the branch overcurrent protection 4 Circuit Breakers or Fused Disconnect Switch Obtain and install correct switch 5 Extension Cord Select as shown in Section 10 11 6 Generator Connections Connect terminals or plug of ade duate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all eguipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and freguency 7 Load Connections D Item 4 is not necessary if circuit protection is already present in welding generator auxiliary
28. volts or less drop or a current density of at least 300 circular mils per ampere Contact your dis tributor for the mm equivalent weld cable sizes S 0007 E OM 130 098 Page 18 Notes OM 130 098 Page 19 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Controls See Section 5 2 120 240 99 s o pas 55 120 6 TTS MIN 70 120V 15A A N CI C E 1 0 11 60Hz 210 3 Ref ST 188 449 ST 800 162 A ST 800 159 D OM 130 098 Page 20 5 2 Description Of Front Panel Controls See Section 5 1 This unit has a max OCV control circuit that resets the Amperage Voltage Con trol to maximum when the arc breaks When an arc is struck weld output control returns to the front panel or remote con trol setting The Amperage voltage Con trol adjusts amperage only when welding and does not adjust open circuit voltage 1 Ampere Range Switch Use switch to select weld amperage range For most welding applications use lowest amperage range possible to prevent arc out ages A Do not switch under load 2 Amperage Voltage Control Control adjusts amperage within range selected by Ampere Range switch Weld out put would be 140 A DC with controls set as shown 50 of 90 to 190 A 3 DC Voltmeter Optional 4 DC Am
29. 2 ELIT 082 789 lt LENS lightind red s i vaatada KA KALA PIA GA PLA PNG nen 2 21 HM 145 247 METER hour 4 40VDC 1 RS NANA AG LANG 148 723 KNOB pointer 1 DO etas EED us 019 754 HANDLE switch range 1 mad sd noises lo NAMEPLATE order by model and serial number 1 22b cce ruris 176 606 SWITCH ignition 4posn 1 na MO deri ER E 127618 PANEL front upper 1 OL sev Y 189404 4 SPACER nylon Passe teu setae M eris RENEE EG P RI ranged ete px 1 OPTIONAL Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 130 098 Page 51 ST 110 922 D Figure 11 3 Generator OM 130 098 Page 52 Item Dia Part 23 No Mkgs No Description Quantity Figure 11 3 Generator Fig 11 1 Item 65 ge oe Cn MG 106 426 INSULATOR 4 NRT mn 4 ORAE EON 106 440 BUS BAR rectifier anea 2 8 SR3 106 427 DIODE ASSEMBLY reverse polarity consisting of 1 Sana JE EE 048 420 CAPACITOR rectifier EE EE Gee Ee Ge ee ee eek ee ee ee 2 PIE ee 106 641 CAPACITOR ee T DA RER Es 037 957 DIODE rect 275A 300V RP 3 uus
30. 2 4 035 704 RECTIFIER integ 40A 800V 3 n2 JO kll en 173982 PANEL mtg components 1 I ree IT pana 038 621 BEOCK term 30A AP en RA gu ERR ae NG SR DEEG ERROR ale 4 1 98 D8 192307 KIT diode w washers 1 99 D1 C1 D9 C9 189 701 DIODE CAPACITOR BOARD ee ee ee ee ee ee nennen 2 100 C8 170674 CAPACITOR BOARD 222222220002 1 101 R6 030844 RESISTOR WW fxd 25W 25 ohm 1 OM 130 098 Page 47 Rp La DR EE ees 4173 317 PANEL front lower Item Dia Par No Mkgs No Description Figure 11 1 Main Assembly Continued 103 CR2 044588 RELAY encl 12VDC SPDT 104 Figure 11 2 PANEL front w components 105 CT1 4105370 TRANSFORMER current 106 Zl kawan 129 044 REACTOR sti aida carios ie 107 Neg 097 416 TERMINAL pwr output black consisting of 108 Pos 097 421 TERMINAL pwr output red consisting of mie 601 879 NUT stl hex full fluxh 500 13 ia EE tans ES LE ER e 601 880 NUT stl hex jam 500 13 zs 109 c ra x
31. CILITIES ACCESSORY COO U D C B A Na D C B K LI TE TEI HE X qe mE A n i E en ceil B y E 2 42 vor 42 BRITISH d rh 7 rh OR N RCI El uem RCI z L OPTION 24 1 OPTION 240v Pr E UM RE lt lt lt LH 5 38 F a GFCI OPTION 2 o 85 o TEI SR ol cl 4 aly al 4 vL 8 set TE TT cB2 E 7 ee ct A cd Y Y Yun 201 ay ci Kp L b 680 poh bee et Ho N E 102 Z i ES 240V 6 V Na t GND YAN 4 fOr y N j A BC D AAA IM a m 102 42 D4 27 D5 E ALS a A OR 1 5 43 45 103 Si A ENE E GR w GR C4 SR3 CS 2 S1 PLG1 2 a WHEN MS1 OPTION IS USED RUNNING m gj E 3 gt q REMOVE LEAD 49 ON HM THAT COMES N PL67 3 aar WL jip 7 EIE B SS 10 bie RAN FROM PL2 amp INSTALL ON LOOSE LEAD 49 a 2 47 IN HARNESS INSTALL LOOSE LEAD 44 IN 3 c6 c7 7 x gt HARNESS TO HM 2 VRI 3 3 X gt 49 w T Ger d N 0 Lo VX MS1 HOLD IN 45 79 130 a PLA PL SHUNT IS CONNECTED IN X CLOSED TO B Mm A F LIQ START B 6 gt SERIES WITH LINE 19 NPL67 2 17 I 8 S clcormonan DLE Ra A PLe7 1 MODULE rt co Y os 60 4 Y LT o oz tle el ETHER START P 46 OL c E L at Lo SHUNT El 8 OPTIONAL TEMPERATURE 2 PLG5 2 V PLG5 6 Y E mM LII 9 eo Y Y 61 04 P H 9 Tw 75 4 NI 7 SE 98 WELD METERS L A r pa BEG AL N PL65 7 amp 5 OPTIONAL Es PRESSURE 76 m POLARITY SWITCH V
32. Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables gt gt 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 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 rated generator output see nameplate Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed After one hour minimum place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 130 098 Page 36 SECTION 10 AUXILIARY POWER GUIDELINES 10 1 Selecting Equipment 1 Auxiliary Power Receptacles Neutral Bonded To Frame 2 3 Prong Plug From Case Grounded Equipment 3 2 Prong Pl
33. E IE LE 143 220 O RING 2 859 ID x 189CS 1 ERES 173323 2 BARREL rectifier mm ae Ree E ERE MERERI en 1 24 SR3 106430 DIODE ASSEMBLY consisting of 1 BO as 048 420 CAPACITOR rectifier 2 tang amas tached 106641 CAPACITOR Santa eres Toss fade er etes toe tees 1 a A eue 106 425 INSULATOR aa iaa e a a TT 1 MO hae s 037 956 DIODE rect 275A 300V SP 3 28 VR1 R4 046819 SUPPRESSOR 422 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered Part of 042 358 Optional 10 7 5kVA Auxiliary Power BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 130 098 Page 53 Item Part WE No No Description Quantity 114 193 Figure 11 4 Switch Range Fig 11 2 Item 1 bay 1 114 285 BRACKET mtg switch consisting of d SON 2 010671 SPRING ext x 312 OD x 042 wire x 1 875pld 1 v e eaten 017428 2 LOCATOR quadrant code rar Nee SEE RE nee A apa 4 004998 CONTACT BOARD ASSEMBLY switch range consisting of 1 el 5 011 980 CONTACT BOARD movable switch
34. F2 And F3 F1 F2 and F3 protect each load line from overload Set Engine Control switch to Run when using auxiliary power Tools Needed I EB Esi a Ref S 188 059 A OM 130 098 Page 24 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 7 1 Routine Maintenance ey eb y 7 we KA A Stop engine before maintaining L See also Engine Manual and Maintenance Label engine Service engine more often if used in severe condi fluids tions To be done by Factory Authorized Service Agent 8h Check Fluid FUEL Rial Water QqUEA Levels See WATER un Section 4 5 ystem See Section 7 4 50h Mes Clean And ee A ren Wot ee Sectio si y Terminals O 100 h Clean Cooling System Clean And Check air Tighten cleaner hoses Battery for cracks and Connections loose clamps M Replace Unreadable Labels Check And TSN Clean Spark Fe Arrestor See Section 7 8 Change Oil ED Change Oil See Filter See Cracked Section 7 4 Section 7 4 Cables Blow Out Or Service Welding Vacuum Inside Change Fuel Generator Brushes During Heavy Filters See And Slip Rings Service Section 7 4 Service More Often Clean Monthly In Dirty Conditions Drain Sludge Check From Fuel Check Belt Tank See Valve Tension Section 7 4 Clearance 3000 h C
35. GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator 1 3 Engine Hazards 7 k FUEL can cause fire or explosion dl o Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames e Do not overfill tank allow room for fuel to expand e Do not spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container OM 130 098 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine e Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemak ers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully e Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks an
36. HUTDOWN low oil pres hi oil temp see Figure 11 2 1 ET Oke any 043 088 AUTOMATIC IDLE see Figure 11 1 1 E ER ROLE 041 671 SERVICE INDICATOR KIT see Figure 11 1 1 a WELDER S PACKAGE includes Engine Protection Package consisting of E E CU 042 235 WELD METERS see Figure 11 2 1 EE EE od 041 966 POLARITY SWITCH see Figure 11 1 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 130 098 Page 49 1 Fig 11 3 ST 801 652 B Front w Components Figure 11 2 Panel OM 130 098 Page 50 Item Dia Part No Mkgs No Description Quantity Figure 11 2 Panel Front w Components Fig 11 1 Item 104 panded da SS eost 114 193 SWITCH range Fig 11 3 se ee eee eee 1 LP Gabo RT sies 605 960 RHEOSTAT WW 300W 34 ohm 1 3 MS 011072 SWITCH magnetic consisting of 1 EE F 048317 FUSE mintr gl 14A 32V 1 Hate res BAM are 011609 SWITCH tgl SPDT 15A 125V 1 Ds kp eee he 032 897 RECEPTACLE twlk grd 2P3W 15A 125V 1 6 CB1 2 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 eed rm Od
37. O Visit our website at www HobartWelders com WELDING PRODUCTS OM 130 098V August 2000 Processes Stick SMAW Weldin Ka TIG GTAW Welding pa Air Carbon Arc CAC A Cut ting And Gouging With Optional Equipment Flux Cored FCAW With ike Voltage Sensing Wire Feeder Description D a NG Contractor 3225DX OWNER S MANUAL 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 MA 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 proper maintenance And if for some reason the unit Hobart is registered to the needs repair there s a Troubleshooting section nn Penn Quality System 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 problem Warranty and service information for your particular model are also provided REGISTERED QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products
38. PLG7 4 K S7 E Fei x OPTIONAL 12 VOLT OIL PLG7 6 Y WITH THE POLARITY SWITCH STARTER PRESSURE OPTION LEADS 19 amp 30 GO TO Ts THE POLARITY SWITCH RATHER 1 2 THAN THE OUTPUT STUDS THE AUTOMATIC PLes 8 AUTOMATIC OUTPUT STUDS ARE LABELED IDLE CONTROL 42 IDLE CONTROL ELECTRODE AND WORK OPTIONAL 42 42 42 OPTIONAL 2 NEGATIVE POSITIVE mM m 11 HT IA m m les EE a zl ELECTRODE WORK For Welding Generator it Diagram Ircul Figure 8 1 C OM 130 098 Page 33 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 properly seat piston rings and prevent wets tacking See nameplate or rating label to find rated output Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is 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 in procedures See the engine manual for addition al engine run in information OM 130 098 Page 34 9 2 Run In Procedure Using Load Bank A A CL w
39. RES IN 120V MODE COMBINED LOADS 31 AMPERES PER LINE MAXIMUM B 10 KVA KW Three Phase Auxiliary Power Plant No Weld Load 300 PF 250 0 8 PF n 200 O 150 ds L 100 50 F 0 O 10 20 30 40 50 AC AMPERES The ac power curves show the aux iliary power in amperes available at the single phase 120 240 volt or three phase 240 volt terminals rsb13 1 12 94 ST 134 636 A ST 134 637 A OM 130 098 Page 13 SECTION 4 INSTALLATION 4 1 Installing Welding Generator Movement Airflow Clearance Location A Do Not Lift Unit From End OR Grounding 1 3 4 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal OR ie 4 Grounding Cable PA RN Use 10 AWG or larger insulated L copper wire D If unit does not have GFCI re Electrically bond generator frame to C uz A ceptacles use GFCI vehicle frame by metal to metal T protected extension cord 2 contact 2 install1 3 96 Ref ST 800 652 Ref ST 800 477 A ST 158 936 A S 0854 4 2 Installing Muffler Pipe A Stop engine and let cool A Do not blow exhaust toward ce air cleaner or air intake O I Top View Tools Needed JOINT 1 2 in exh_pipe2 12 96 ST 154 089 A ST 154 611 Ref S
40. SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province HOBART A WELDERS hobart standard 7 00 Owner s Record
41. Soyez vigilant Il y a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixerle c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apres avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre ap
42. T 188 449 OM 130 098 Page 14 4 3 Activating The Dry Charge Battery GE Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill battery cells 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 A 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 EF When electrolyte is low add only distilled water to cells to maintain proper level 5 A For 30 Minutes OR N 30 A For 12 Minutes Tools Needed drybatt1 2 96 S 0886 OM 130 098 Page 15 4 4 Connecting The Battery Tools Needed IZ 1 2 in A Connect Negative Cable Last ST 156 011 A Ref ST 188 449 S 0756 4 5 Engine Prestart Checks Valve Open Check all fluids daily Engine must be cold and on a level surface Follow run in procedure in engine manual If unburned fuel and oil col lect in exhaust pipe during run in see Section 9 1 Fuel A Do not use gasoline Gaso line will damage engine
43. anels covers and guards closed and securely in place e Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall panels or guards and close doors when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while working on generator components BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE EXHAUST GASES can kill e Use equipment outside in open well ventilated areas e If used in a closed area vent engine exhaust outside and away from any building air i
44. ber preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart must be notified in writing within thirty 30 days of such defect or failure at which time Hobart will provide instructions on the warranty claim procedures to be followed Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output r
45. ch does not work 5 3 Remote A V Control PA Pa A V i 1 A V Control Switch Use switch to select front panel or remote amperage control 2 Remote A V Receptacle RC3 Connect optional remote control to RC3 Example Combination Remote Amperage Control Set Switch gt AIN In Example Range 90 to 190 A Percentage Of Range 50 Max 140 A DC 50 of 90 to 190 Max 140 DC Min 66 DC Set Range Set Percentage gt Adjust Optional Remote Control S 0774 OM 130 098 Page 21 SECTION 6 OPERATING AUXILIARY EQUIPMENT 6 1 120 Volt And 240 Volt Duplex Receptacles Ww 120V 15A 240V 13A A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord F7 Auxiliary power is not affected by weld output If a circuit breaker continues to open contact Factory Autho rized Service Agent 1 240V 15 A AC Receptacle RC1 2 120 V 15A AC Receptacle RC2 Receptacles supply 60 Hz single phase power at weld power speed 3 Circuit Breakers CB1 And CB2 CB1 and CB2 protect the receptacles from overload If CB1 or CB2 opens RC1 and half of RC2 does not work 120 volts may still be present at RC1 Maximum output from each duplex receptacle is 1 8 KVA KW and 3 kVA kW from a
46. che avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste iU Iss A e Laisser l quipement refroidir respecter le facteur de LES CHARGES ELECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effecteur la maintenance et la mise en service d apr s le manuel et celui du moteur OM 130 098 Page 7 LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf
47. curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon N DES ORGANES MOBILES peuvent provoquer des blessures Ng e Ne pas approcher les mains des ventilateurs cour roies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d entretien et de d pannage Pour emp cher tout d marrage accidentel pendant les travaux d entre tien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des or ganes mobiles Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le mo
48. d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de Parc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise e
49. d Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 130 098 Page 4 ARC WELDING can cause interf
50. d arcs e Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no overflow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap d MOVING PARTS can cause injury e Keep away from fans belts and rotors Ng e Keep all doors p
51. ectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Hobart Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear
52. ed instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away Ka ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power accord
53. ee ee ee ee ehm 1 1 3 Engine Hazards ie tinti ne ER cote idee A es 2 1 4 Additional Symbols for Installation Operation and Maintenance 3 1 5 Principal Safety Standards 4 1 6 EMF Information rex er nr ni E Uer E an De 4 SECTION2 DEFINITIONS ere arar Re ERE Rx sn ex ee aR Re 5 251 Symbols And D finitions 2r na xi a RESET RE A AERE S RU RSEN S 5 SECTION 3 SPECIFICATIONS ee eke BE EER EE EE EER RE RR ERG ee ea nnn 6 3 1 Weld Power And Engine Specifications 6 3 2 Dimensions Weights And Operating Angles 6 3 3 Fueli CONSUMPTION 225208 28 0 e pee OS SE EER N DE EE Oe DE EE BANGA LAM 7 3 4 Duty Cycle And Overheating EE EG GE EE EE EE ee ee ee ee ee ee ee 7 3 5 AC Auxiliary POWE as aaa cone see AE ER ER ERA RERE RUPEM lan 8 3 6 VolitAmpere Eu rves sux EES awe gads remain RE AR aa RS RS ERN 8 3 7 Optional AC Power Plant Curves 422 2 9 SECTION 4 INSTALLATION 0 ee ee ee Se ee Gee SG Ge SG EE ee eens 10 4 1 Installing Welding Generator EE EE EE Ee ee ee ee ee ee ee ee ee ee ee 10 4 2 Installing Muffler Pipe ie 0 ER ee RS ee Re de Re ee Re ee Re de Re ee ek ed ee 10 4 3 Activating The Dry Charge Battery 11 4 4 Connecting The Ba
54. en Tools Needed u R a Ref ST 156 199 B ST 801 740 Lay A A Stop engine y cal C A Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder If engine does not start in cold weather check ether cylinder as follows Remove cylinder from valve 1 Ether Cylinder 2 Valve 3 Scale Weigh cylinder to see if it is empty Be sure atomizer is not plugged and valve fitting is clean Replace cylinder according to Section 4 6 ether2 7 96 ST 153 382 A S 0692 OM 130 098 Page 30 7 8 Inspecting And Cleaning Optional Spark Arrestor A Stop engine and let cool 1 Spark Arrestor Tools Needed 22 3 8 in 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material A Stop engine and let cool Reinstall cleanout plug ST 800 523 Ref ST 188 449 7 9 Troubleshooting ap M Wer A Welding Trouble Remedy No weld output Check position of Ampere Range switch Check position of
55. er CB1 and or CB2 see Section 6 1 or 6 2 Disconnect equipment from auxiliary power receptacles during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high output at auxiliary power receptacles Check engine speed and adjust if necessary see Section 7 5 Low output at optional auxiliary power junction box Check engine speed and adjust if necessary see Section 7 5 If optional remote device is being used set A V Control switch in Remote position and remote device at maximum see Section 5 3 If optional remote device not being used set A V Control switch in Panel position see Section 5 3 Check and replace fuses F1 F2 and or F3 if necessary see Section 7 3 Have Factory Authorized Service Agent check brushes and slip rings No output from optional auxiliary power plant weld output and standard auxiliary power receptacle output okay Check connections to auxiliary power plant see Section 7 3 Check fuses F1 F2 and F3 and replace if necessary see Section 7 3 C Engine Trouble Remedy Engine does not start Check fuel level Open fuel valve see Section 4 5 Check optional Magnetic Shutdown switch fuse F and replace if open see Section 7 6 Check battery and replace if necessary Check connections to Engine Control switch Check oil level Optional automatic s
56. erence e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area 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 Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not co
57. es de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 130 098 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant to
58. eter 50MV 600A 1 AO pra 188239 BRACKET mtg engine LH 1 nd OB ate Denne nee key 109591 CLAMP muffler 1 750dia 1 OI Ren SA enr 124 866 PIPE muffler extension elb 1 O LE rt 087 341 BUMPER door 1 000 OD x 750 high 4 ap 188 359 BASE filter fuel standard models includes items 72 thru 77 1 EE Br 190 926 BASE filter fuel models w 7 5 10 KVA opt incl items 72 thru 77 1 rado ect roce p ee 110069 FITTING flrd brs elbow M 1 4 1 SR MER ES 106 394 FITTING flrd brs conn M HD 1 4 tbg x 1 4 NPT 7 5 10 KVA option 1 pox Duce eror edi 080389 SCREW 312 18 x 1 000 cap hexhd 2 M MA RM MEE 124 607 STRIP mtg separator fuel 1 MRT Cash in fate 1 2 684 3x NUT 312 16 X 50 NOX 4 ioci esie ae 2 in Lancet 179 661 BASE filter w adapter and vent 1 ER EE bagan 145 282 FITTING hose brs barbed elb M 5 16tbg x 1 4NPT 1 nine ed E AE ter 134 835 HOSE SAE 312 ID x 560 OD order by ft 2ft Hr eh EE EN 010323 CLAMP hose 250 625clp dia 2 mp T 106 467 FILTER fuel spin on
59. hutdown system stops engine if oil pressure gets too low or oil temperature gets too high See engine manual Have Factory Authorized Service Agent check engine charging system Engine suddenly stops Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil temperature gets too high Check optional Magnetic Shutdown switch fuse F and replace if open see Section 7 6 Engine slowly stopped unable to restart engine Check fuel level Open fuel valve see Section 4 5 Engine does not stop when Engine Con trol switch is placed in Off position Use manual shutoff lever to stop engine see Section 5 1 Check connections to Engine Control switch Have Factory Authorized Service Agent check engine fuel solenoid Engine remains at idle speed when Engine Control switch is placed in Run Idle position and an arc is struck models with automatic idle option only Have Factory Authorized Service Agent check Engine Control switch and idle module Engine will not run at idle speed models with automatic idle option only Check throttle solenoid fuse F4 and replace if open see Section 7 6 Have Factory Authorized Service Agent check Engine Control switch and idle module Battery discharges between uses Make sure Engine Control switch is in Off position when unit is shut down Clean battery terminals and posts with baking soda and water solutio
60. il or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 Signification des symboles A ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit A L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particulierement les enfants
61. ing to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual rom nd 11 98 AF This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with g
62. ionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires e Utiliser un quipement de levage de capacit suffi sante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil N gt LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance inflammable LE SURCHAUFFEMENT peut endom mager le moteur lectrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il ya lieu N L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT marche nominal e R duire le courant ou le facteur de mar
63. lean Set Injectors OM 130 098 Page 25 NOTE Follow the storage procedure in the engine owner s manual if the unit will not be 7 used for an extended period 7 2 Maintenance Label DEUTZ F3L1011F DIESEL ENGINE See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts 22 31 ay 1 Only with engine oil preheating Recommended Oil API Service Classification CC SE CC SF CD SE CD SF or better or better Oil Change amp Filte dirty conditions 250 hours 375 hours normal conditio 500 hours 750 hours Oil Filter MILLER 067 265 Deutz 116 4626 Fram PH46 Oil Capacity 5 8 qt 5 5 L or 6 2 qt 5 9 L with filter change Fuel Capacity 11 3 gal 42 8 L Fuel Grade 1 D or 2 D Cetane No 45 min Primary Fuel Filter Water Seperator MILLER 192744 Donaldson P550587 Fram P1145A Secondary Fuel Filter MILLER 066 217 Deutz 117 4696 Fill filter with clean fuel before installing read instructions on filter Air Filter Service 50 hours or less see Owner s Manual Air Filter Element MILLER 197676 Donaldson P821575 WIX 46438 Air Filter Element Safety Opt MILLER 197679 Donaldson P822858 E ig Blower Belt Gates 7435 Deutz 117 9565 ed PIS Avoid recirculation of air from hot air exit to blower intake Diesel Battery BCI Group 55 Cranking Performance at 0 F 18 C 500 Amps Valve Clearance Cold Intake 0 012
64. les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas dinterferences apr s avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 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 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les cabl
65. les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ou
66. ll receptacles Auxiliary power is not affected by weld output EXAMPLE If 10 A is drawn from RC1 only 10 Ais available at RC2 240 V x 10 A 120 Vx 5 A 3 0 kVA KW Ref ST 188 449 OM 130 098 Page 22 6 2 Optional Auxiliary Power Receptacles 240V 13A 1 60Hz 240V 13A 1 60Hz 240V 13A 17 60Hz A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord 7 Auxiliary power is not affected by weld output If a circuit breaker continues to open contact Factory Autho rized Service Agent GFCI Receptacle Option 1 120V 15A AC GFCI Receptacle GFCI1 Auxiliary power output and circuit breaker protection is the same as standard receptacles see Section 6 1 If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check for faulty tools plugged in receptacle Press button to reset 7 At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly Australian British And South African Receptacle Options 2 240V 10A AC Australian Re ceptacle RC1 3 240 Volt 13 AC South African Receptacle RC1 4 240 Volt 13 A AC British Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maxi mum output from receptacle is 3 kVA kW 5 Ci
67. meter Optional 5 Remote A V Switch And Receptacle See Section 5 3 6 Magnetic Shutdown Switch Optional Use switch during start up to bypass optional engine shutdown system System stops en gine if oil pressure is too low or oil temperature is too high 7 Engine Control Switch To Start turn switch to Start while pressing Shutdown switch Release switches when engine starts If the engine does not start let engine come to a complete stop before attempt ing restart In Run position engine runs at weld power speed In Run ldle position optional engine runs at idle speed at no load and weld power speed with load applied To Stop turn switch to Off position 8 Battery Charging Warning Light Light goes on when battery is not charging 9 Oil Pressure Warning Light Light goes on if oil pressure is too low If unit has automatic shutdown option light also goes on if oil temperature is too high A Stop engine and fix trouble if either light goes on 10 Ether Starting Aid Switch Optional Push switch up and release while cranking engine to release ether A Do not use Ether if engine is running 11 Engine Hour Meter 12 Oil Temperature Gauge Switch Optional 13 Oil Pressure Gauge Switch Optional 14 Polarity Switch Optional Place switch in Straight position for electrode negative or Reverse position for electrode positive 15 Manual Shutoff Lever Use lever to stop engine if engine control swit
68. mm Ng 7 S 1 A 23 1 4 in 591 mm M 1 B 24 5 8 in 625 mm NA BE 1 C 11 16 in 17 mm L D 2 7 8 in 73 mm d 1 1 K E 4 1 2 in 114 mm e h J F 22 9 16 in 573 mm G H G 27 i M 1 1 F in 686 mm D H 30 3 8 in 772 mm ht let Le EN J 41 1 4 in 1048 mm A K 51 1 8 in 1299 mm B ee et L 54 in 1372 mm M 21 32 in 16 7 mm Dia 4 Holes N 1 2 in 12 7 mm Dia 10 Holes Weight 1475 Ib 670 kg A A Do not exceed tilt angles or engine could be damaged or unit could tip A Do not move or operate unit where it could tip angles 4 96 OM 130 098 Page 10 3 3 Fuel Consumption i The curve shows typical fuel use Re ee G under weld or power loads co 23 7m D 5 5 7 57 1 67 2 00 6 81 1 50 180 6 06 1 33 160 f 5 30 1 17 140 F 4 54 1 00 120 F 3 79 0 83 100 3 03 0 67 080 F 2 27 0 50 O60 1 51 0 33 0 40 0 76 0 17 0 20 0 00 0 00 0 00 i i l l L L l O 50 100 150 200 250 300 350 400 450 500 IC WELD AMPERES AT 100 DUTY CYCLE SB 137 487 A 3 4 Duty Cycle And Overheating par a 1000 AMPERES gt 40 Duty Cycle At 400 Amperes Puno Ow O O L C WEI 15 100 N a 4 Minutes Welding 6 Minutes Resting 20 08 Duty Cycle is percentage of 10 min utes that
69. n rinse with clear water Periodically recharge battery approximately every three months Replace battery Engine uses oil during run in period wetstacking occurs Dry engine see Section 9 See engine manual OM 130 098 Page 32 SECTION 8 ELECTRICAL DIAGRAM o 3 amp WARNING e Do not touch live electrical parts e un 7 e Disconnect input power or stop 5 engine before servicing eo Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit RC3 WHE siS 703 ci y I STD Y PLG8 9 S gt Ruas Mm GR mm 6 BLK 18 R gt A REMOTE CONTROL REMOTE CONTROL FA
70. n mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES f P peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter
71. ning falling equipment can cause serious injury 2 p 004 130 BRACKET support door 2 TL D 173847 LABEL diesel engine maintenance 1 N EE ep 124 687 DOOR side RH ee ee ee ee ee ee ee e 1 EE EN 124 685 DOOR side LH 0 cette 4 Site EE Mace GER 168 385 LABEL warning battery explosion can blind 1 Modes EE 173 028 RIVET nyl 250dia x 1 000 lg 6 Paba DO eg 178 763 su PANEL fear 1 E 162 741 GUARD belt 1 Pain ENE EN 146 994 LABEL warning moving parts can cause serious injury 1 TE nern 107343 GROMMET rbr neck 1 cu 197 614 La AIRBOX ci e e ELA RED eased SERS 1 OT nasse 197613 AIR CLEANER intake consisting of 1 ta BG ieu aac etus 197675 DUST EJECTOR air cleaner 1 Stet DO EN E 197 677 COVER ASSY air cleaner 1 NL d 197 676 ELEMENT air cleaner 1 2 3 GE epe Rotate dies 6197 679 ELEMENT air cleaner safety 1 REDDER REO 197829 BRACKET mig air cleaner 2 RL ET 197 678 BODY alrcleanef 23 cicada wid ei A ee a 1
72. ntakes ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e 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 e Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable i OVERUSE can cause OVERHEAT ING z EE A e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again
73. ood metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes e If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases
74. optional Polarity switch Place A V control switch in Panel position or place switch in Remote position and connect Remote Am perage control to Remote A V receptacle RC3 see Section 5 3 Check and secure connections to Remote A V receptacle RC3 Remove excessive coils from weld cables Disconnect equipment from auxiliary power receptacles during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Use dry properly stored electrode Be sure connection to work piece is clean and tight Check and tighten connections both inside and outside unit Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high weld output Check control settings Check engine speed and adjust if necessary see Section 7 5 Low open circuit voltage Check engine speed and adjust if necessary see Section 7 5 Have Factory Authorized Service Agent check integrated rectifier SR2 Amperage Voltage control R1 and resistor R2 Maximum weld output only in each am pere range Have Factory Authorized Service Agent check Amperage Voltage control R1 capacitor C8 diode D8 integrated rectifier SR4 and control relay CR2 OM 130 098 Page 31 B Auxiliary Power Trouble Remedy No output at receptacles auxiliary power Reset circuit break
75. propri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le
76. rcuit Breaker CB1 CB1 protects RC1 from overload If CB1 opens RC1 does not work Press button to reset breaker Ref ST 188 449 ST 174 408 OM 130 098 Page 23 6 3 Connecting Optional Auxiliary Power Plant PANNE 93 91 90 92 AC CV Single Three Output Volts 120 240 240 Amps 31 24 KVA KW 7 5 10 Frequency 60 Hz Engine Speed 1850 RPM Max Fuse Size 35 Amperes Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory A Stop engine A Power and weld outputs are live at the same time Disconnect or insulate unused cables IS Have qualified person install according to circuit diagram and Auxiliary Power Guidelines Section 10 Remove junction box cover 1 Lead 93 2 Lead 92 3 Lead 91 4 Lead 90 Neutral 5 Lead 42 Circuit Grounding Lead Lead 42 connects to front panel Ground stud 6 Grounding Terminal 7 Jumper Lead 42 8 Isolated Neutral Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be dis connected from neutral to meet applicable electrical codes 9 User Supplied Leads 10 Load Terminals Connect leads to terminals 11 Fuses F1
77. retien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine rom nd fre 11 98 APA Ce groupe de symboles signifie Mise en garde
78. s and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes Elo e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet a BUILDUP OF
79. teur avant de d brancher ou de brancher les c bles de batterie Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau LES GAZ D CHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels e Utiliser l quipement l ext rieur dans des zones ou vertes et bien ventil es e En cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distance des entr es d air dans les b ti ments LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES A L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur 1 4 Dangers suppl mentaires en relation avec l installation le fonct
80. ttery EE EE EE EE ee Ee ee ee ee ee ee ee ee ee ee ee 12 4 5 Engine Prestaft GhOCKS nena Yeas ean ER BEG ep ul Mee Pee GEE re 12 4 6 Installing Ether Cylinder Optional Ether Starting Aid 13 4 7 Connecting To Weld Output Terminals 13 4 8 Selecting Weld Cable Sizes 14 SECTION 5 OPERATING THE WELDING GENERATOR 16 5 1 Controls See Section 5 2 16 5 2 Description Of Front Panel Controls See Section 5 1 17 5 9 Remote A V Control anii herded e oan ur eee CES let 17 SECTION 6 OPERATING AUXILIARY EQUIPMENT 18 6 1 120 Volt And 240 Volt Duplex Receptacles 18 6 2 Optional Auxiliary Power Receptacles 19 6 3 Connecting Optional Auxiliary Power Plant EE EE EE EE EE Ee ee ee ee ee ee ee 20 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 21 7 1 Routine Maintenance ie ees ses K K ee RE K K teen eee a rh ehh rn rr nn ne 21 7 2 Maintenance Label i s oe cit e e e EE RE ee ARR RE e GR Re ER DE EN su 22 7 3 Servicing Air Cleaner e siey EE EE aa Re e 23 7 4 Servicing Fuel And Lubrication Systems
81. tts 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 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 130 098 Page 43 SECTION 11 PARTS LIST 71 Includes 72 77 Figure 11 1 Main Assembly OM 130 098 Page 44 9 60 N 22 ST 801 653 F OM 130 098 Page 45 Item Dia Part WE No Mkgs No Description Quantity Figure 11 1 Main Assembly Ld socer aem 134771 PLUG protective 640sq 2 EE RE co 107 972 TANK fuel consisting of 1 EES RT EO carts 115 000 CAP fuel large ie iia NA ER GE Ee ER alee er Bae NANG 1 EE A 605 288 FITTING pipe galv plug sqhd 250NPT 1 Ca Ee 020185 FITTING pipe brs elbow st 1 8NPT 1 ares lt Pad ra NT EN 073 432 FITTING brs barbed M 3 16tbg x 1 8NPT
82. ug From Double Insulated Equipment Be sure equipment has this symbol and or wording aux pwr 2 99 Ref ST 159 730 ST 800 577 10 2 Grounding Generator To Truck Or Trailer Frame e 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord GND PE ENTM a Electrically bond generator H 2 frame to vehicle frame by metal to metalcontact OR S 0854 OM 130 098 Page 37 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 1 2 2 Grounding Cable GND PE E 4 Use 10 AWG or larger insulated 6 copper wire 3 Ground Device A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 3 1 Resistive Load kes us A light bulb is a resistive load and 4 Hz 60 requires a constant amount of pow er 2 Non Resistive Load Equipment with 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 6 OW
83. ugers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 130 098 Page 39 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 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 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 Floor Polisher 3 4 HP 16 in 4500 1400 1
84. unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty 10 15 20 25 30 40 50 6 80 100 DUTY CYCLE rduty1 5 95 SB 070 999 B OM 130 098 Page 11 3 5 AC Auxiliary Power 150 125 100 AC VOLTS B a N a 300 250 200 150 100 50 3 KW A AMPERES IN 240V MO die 20 10 Al AMPERES IN 120V MO 30 40 25 50 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 3 6 Volt Ampere Curves DC VOLTS 100 80 60 40 20 100 RANGES MIN 70 95 120 90 190 120 240 200 MAX 200 DC AMPE 400 200 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown ST 183 882 OM 130 098 Page 12 3 7 Optional AC Power Plant Curves A 7 5 KVA KW Single Phase Auxiliary Power Plant No Weld Load 150 300 L 1 0 PF 125 250 F 08 PF y 100 200 L E 0 0 PF a 5 75 150 m L lt sp wo 25 50 0 0 l l O 10 20 30 40 5 AC AMPERES IN 240V MODE O 20 40 50 80 10 AC AMPE
85. ut consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Symbols And Definitions KI Stop Engine Fast S Slow Idle Start Engine Fast Slow n lt gt Run ldle Battery Engine Circuit Breaker Engine Oil Check Valve Protective Earth While Welding Check Injectors Fuel Pump Clearance Ground i Positive Negative Ker oe Welding Arc A Amperes Volts Panel Local Remote Read Operator s b A Manual Engine Temperature Output NU ering Time Hours Seconds Current DO Natanto Single Phase 3 Three Phase Ether Starting Aid Engine Coolant Temperature OM 130 098 Page 9 SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Maximum Open Circuit Rated Welding Amperage Voltage DC Auxiliary Power Engine Fuel Capacity Output Range Nominal Rating 400 A Single Phase EE eta 40 Volts DC 40 400 95 90 3 KVA KW 26 A 11 3 gal 42 8 L 40 Duty Cycle 120 V AC 60 Hz Three Cylinder 29 HP Diesel Engine 3 2 Dimensions Weights And Operating Angles Dimensions Height 40 1 2 in 1029 mm Width 24 5 8 in 625 mm Depth 56 in 1422 N ep in
86. vrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 1 3 Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro a voquer un incendie ou une explo sion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge OM 130 098 Page 6 LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autre ment dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e Mettre des lunettes de s

Hobart 3225DX User's Manual

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