Hobart Arcstar 300D NT User guide

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OM-487 187 558K

August 2000

Processes

MIG (GMAW) Welding Flux Cored (FCAW) Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Engine Driven Welding Generator

Arcstar 300D NT

Visit our website at

www.HobartWelders.com

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you

protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit

Hobart is registered to the ISO 9001 Quality System Standard.

needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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 & Safety Code Section

25249.5 et seq.)

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: MIG = GMAW, Wire Welding TIG = GTA W Stick = SMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISA TION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers existant en relation avec le moteur 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbol Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Weld, Power, And Engine Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions, Weights, And Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Fuel Consumption 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Auxiliary Power Curve 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Duty Cycle 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Volt-Ampere Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Exhaust Pipe 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Engine Prestart Checks 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Adding C o o lant To Radiator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting The Battery 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting To Weld Output Terminals 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Selecting Weld Cable Sizes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Remote 14 Receptacle Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Adjusting MIG Weld Puddle Consistency 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING WELDING GENERATOR 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Front Panel Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Remote Amperage/Voltage Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – OPERATING AUXILIAR Y EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Auxiliary Power Receptacles And Circuit Breakers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Optional Auxiliary Power Receptacles 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Wiring Optional 240 Volt Plug 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Maintenance Label 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Servicing Air Cleaner 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Servicing Engine Cooling System 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Servicing Engine Fuel And Lubrication Systems 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Adjusting Engine Speed 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Overload Protection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Servicing Optional Spark Arrestor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – ELECTRICAL DIAGRAM 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – RUN-IN PROCEDURE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Wetstacking 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Run-In Procedure Using Load Bank 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Run-In Procedure Using Resistance Grid 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – AUXILIARY POWER GUIDELINES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 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 related 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.

 Only qualified persons should install, operate, maintain, and

repair this unit.

 During operation, keep everybody, especially children, away.

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.

 Do not touch live electrical parts.  Wear dry, hole-free insulating gloves and body protection.  Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

 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.  If AC output is required, use remote output control if present on

unit.

 Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 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.

 When making input connections, attach proper grounding conduc-

tor first – double-check connections.

 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.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

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 good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 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.

 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 of f from t h e weld.

 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 Z49.1 and Z87.1 listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

 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.  If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

 If ventilation is poor, use an approved air-supplied respirator.  Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

 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.

 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-487 Page 1

WELDING can cause fire or explo-

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.

 Protect yourself and others from flying sparks and hot metal.  Do not weld where flying sparks can strike flammable material.  Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.  Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 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).

 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.

 Do not use welder to thaw frozen pipes.  Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use ap-

proved air-supplied respirator.

HOT PARTS can cause severe burns.

 Allow cooling period before maintaining.  Wear protective gloves and clothing when

working on a hot engine.

 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.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.  Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

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.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

 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.

 Turn face away from valve outlet when opening cylinder valve.  Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

FUEL can cause fire or explosion.

 Stop engine and let it cool of f before checking or

adding fuel.

 Do not add fuel while smoking or if unit is near

any sparks or open flames.

 Do not overfill tank – allow room for fuel to expand.

 Do not spill fuel. If fuel is spilled, clean up before starting engine.

 Dispose of rags in a fireproof container.

OM-487 Page 2

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

 If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.  Turn cap slightly and let pressure escape slowly before completely

removing cap.

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative ( –) battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator

components.

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 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.

 Do not tip battery.  Replace damaged battery.  Flush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated

areas.

 If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.  Use approved engine exhaust spark arrestor in

required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

 Wear a face shield to protect eyes and face.  Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.  Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Use only genuine MILLER replacement parts.  Perform engine maintenance and service

according to this manual and the engine manual.

OM-487 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

 If notified by the FCC about interference, stop using the

equipment at 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 Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting 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 Protection Association, Batterymarch Park, Quincy, MA 02269.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

 Be sure all equipment in the welding area is

electromagnetically compatible.

 To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according t o this manual.

 If 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.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic 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 committee’s 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:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil 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 possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-487 Page 4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT

UTILISATION

rom _nd_fre 11/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

 Identifie un message de sécurité particulier.

 Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

 Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant e t suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes ces normes de sécurité.

 L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

 Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.  Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

 S’isoler de l a p i èce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

 Couper l ’alimentation ou arrêter le moteur avant de procéder à l’installation,

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer q ue

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée fixer d’abord le conducteur de

mise à la terre approprié et contre-vérifier les connexions.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

 Ne pas enrouler les câbles autour du corps.  Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.

 Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou

une électrode provenant d’une autre machine.

internes de l’appareil sont également sous tension à ce

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.  Maintenir solidement en place tous les panneaux et capots.  Fixer le c âble de retour de façon à obtenir un bon contact métal-métal avec

la pièce à souder ou la table de travail, le plus près possible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des composants.

LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

 Porter u n casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

 Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

des rayons visibles et invisibles intenses (ultraviolets et

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.  À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

 T ravailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

OM-487 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

 Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

 Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.  Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

 Brancher l e c âble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.  En cas de non utilisation, enlever la baguette d’électrode du porte-électro-

de ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des gants

en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

DES PARTICULES VOLANTES peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

 Prévoir u n e p ériode de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

 Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

 Porteurs d e stimulateur cardiaque, restez à distance.  Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser .

 Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.  Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

 Ne jamais souder une bouteille pressurisée – risque d’explosion.  Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

 Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité.

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une sour-

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

ce d’étincelles ou d’une flamme nue.

OM-487 Page 6

 Toujours vérifier le niveau de liquide de refroidissement dans le vase

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme

 Mettre des lunettes de sécurité et des gants, placer un torchon sur le

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures.

 Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter de se brûler.

d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).

bouchon du radiateur.

d’enlever le bouchon.

DES ORGANES MOBILES peuvent provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.  Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de d épannage.

 Pour e m p êcher tout démarrage accidentel pendant les travaux d’entre-

tien, débrancher le câble négatif (–) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-

ganes mobiles.

 Remettre en place les panneaux ou les dipositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.

 Avant d’intervenir , déposer les bougies ou injecteurs pour éviter la mise

en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-

hicules de démarrage rapide.

 Observer la polarité correcte (+ et –) sur les batteries.  Débrancher l e c âble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

L’ACIDE DE LA BATTERIE peut provoquer des br ûlures dans les YEUX et sur la PEAU.

 Ne pas renverser la batterie.  Remplacer une batterie endommagée.  Rincer immédiatement les yeux et la peau à l’eau.

LES GAZ D’ÈCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.

 Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

 En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti- ments.

LA CHALEUR DU MOTEUR peut provoquer un incendie.

 Ne pas placer l’appareil sur, au-dessus ou à proximité

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé –

voir codes en vigueur.

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires.

 Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.



En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie – éloigner toute substance

inflammable.

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter l e facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.  Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

OM-487 Page 7

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Effectuer régulièrement le contrôle et l’entretien de l’installation.  Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

1-5. Principales normes de sécurité

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 Cutting of Containers That Have Held Hazardous Substances, norme A WS

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 Protection Association, Batterymarch Park, Quincy, MA 02269.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

 L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de souda-

ge aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, 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.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFP A 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur , il est alors recommandé de respecter les consignes ci–dessus.

OM-487 Page 8

2-1. Symbol Definitions

SECTION 2 – DEFINITIONS

Stop Engine

Start Engine Panel/Local Temperature Fuel

Engine Oil On

Engine

MIG (GMAW),

Wire

Positive Negative

Time

Fast

(Run, Weld/Power)

Read Operator’s

Manual

Stick (SMAW) TIG (GTAW) Circuit Breaker

Hours

Fast/Slow (Run/Idle)

Check Valve

Clearance

Amperes

Alternating Current

(AC)

Seconds

Slow (Idle)

Battery (Engine)

Volts

Output

Protective Earth

(Ground)

Do not switch while

welding

Wire Feed

Remote 14

Receptacle

Electrode

Positive

SECTION 3 – SPECIFICATIONS

3-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/AC

CC/DC

CV/DC

Rated

Welding

Output

200 A, 25 V ,

60% Duty

Cycle

280 A, 25 V ,

100% Duty

Cycle

290 A, 25 V ,

100% Duty

Cycle

Maximum

Open-Circuit

Voltage

75 40 – 200 A

80 40 – 280 A

50 – –

Amperage

Range In CC Mode

Voltage Range In CV Mode

10 – 42 V

Work Connection Glow Plug

Electrode Negative High Temperature

Auxiliary

Power Rating

Continuous: 8 kVA/kW,

66.6/33.3 A,

120/240 V AC, 60 Hz,

Single-Phase,

Peak: 9 kVA/kW

(w/Weld Contactor Off)

Fuel

Capacity

10 gal (38 L)

Tank

Engine

Kubota D722

Water-Cooled,

Three-Cylinder,

Four-Cycle, 18.8

HP Diesel Engine

OM-487 Page 9

3-2. Dimensions, Weights, And Operating Angles

Dimensions

Height 33-1/2 i n (851 mm)

Width 18-3/4 i n (476 mm) Depth 48 in (1219 mm)

A 18 in (457 mm) B 16-1/2 i n (419 mm) C 3/4 in (19 mm) D 3-1/8 in (79 mm) E 32-3/4 i n (832 mm) F 48 in (1219 mm) G 13/32 in (10 mm) Dia.

Weight

740 lb (336 kg)

3-3. Fuel Consumption

 Do not exceed tilt angles or engine could

4 Holes

Engine End

ST-800 426

be damaged or unit could tip.

 Do not move or operate unit where it could

tip.

20°

20° 20°

20°

OM-487 Page 10

ST-189 283

3-4. Auxiliary Power Curve

140

280

120

240

100

200

160

120

AC POWER VOLTS

20 40 60 80 100 120 140 160

AC POWER AMPERES AT 120V

10 20 30 40 6050 70 80

AC POWER AMPERES AT 240V

The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles.

ST-189 268

3-5. Duty Cycle

300

275

250

225

200

WELD AMPERES

175

100% Duty Cycle at 290 Amperes DC

Continuous Welding

Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.

 Exceeding duty cycle can

damage unit and void warranty.

DC/CV

DC/CC

AC/CC

150

20 30 40 50 60

% DUTY CYCLE

70 80

100

ST-189 274

OM-487 Page 11

3-6. Volt-Ampere Curves

80 70

60 50

A. CC/AC Mode

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown.

40 30

AC VOLTS

MIN

50 100 150 200 250 300 350

MAX

400

AC AMPERES

B. CC/DC Mode

80 70

60 50

40 30

DC VOLTS

MIN

MAX

DC VOLTS

OM-487 Page 12

50 100 150 200 250 300 350

DC AMPERES

400

C. CV/DC Mode

DC AMPERES

ST-189 278 / ST-189 280 / ST-189 282-A

SECTION 4 – INSTALLATION

4-1. Installing Welding Generator

Movement Airflow Clearance

 Do not lift unit from end.

18 in

(460 mm)

18 in

(460 mm)

Location

Grounding

18 in

(460 mm)

GND/PE

18 in

(460 mm)

18 in

(460 mm)

 Do not weld on base. Weld-

ing on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

 Always ground generator

frame t o vehicle frame to prevent electric shock and static electricity hazards.

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-

protected extension cord.

4-2. Installing Exhaust Pipe

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

install1 8/99 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

 Do not blow exhaust toward

rear of unit or air cleaner will require frequent service.

 If unit is truck or trailer

mounted, point pipe away from direction of travel.

Tools Needed:

1/2 in

ST-801 681 / Ref. ST-187 602-A

OM-487 Page 13

4-3. Engine Prestart Checks

1/2 in

(13 mm)

Diesel

Full

Check radiator coolant

level when fluid is low in

recovery tank.

Capacity: w/Overflow

Tank 6.9 qt (6.5 L)

Open Valve

Full

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure is low or engine temperature is high.

 This unit has a low oil pressure shut-

down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level.

Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 9.

Fuel  Do not use gasoline. Gasoline will

damage engine.

Add fresh diesel fuel before starting engine the first time (see maintenance 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.

Oil

After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

 Engine may use oil and wetstack-

ing may occur during run-in. Check oil several times daily during run-in.

Coolant

Check coolant level in radiator before starting unit the first time. Add coolant if below bottom of filler neck (see Section 4-4 for radiator filling instructions).

Check coolant level in recovery tank daily. If coolant is below Cold Full level, add coolant until level in tank is between Cold Full and Hot Full levels. If recovery tank coolant level was low , check coolant level in radiator (see Section 4-4).

Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. Do not use 100% antifreeze or severe damage will occur.

Keep radiator and air intake clean.

 Incorrect engine temperature can

damage engine. Do not run engine without a properly working thermostat and radiator cap.

 T o improve cold weather starting:

Coolant Recovery

Tank

OM-487 Page 14

Full

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 information.

Use correct grade oil for cold weather.

ST-801 939-C / ST-801 940 / ST-801 961

4-4. Adding Coolant To Radiator

4-5. Connecting The Battery

Capacity: w/Overflow

Tank 6.9 qt (6.5 L)

Tools Needed:

8 mm

Full

 Stop engine and let cool.

 Check coolant level according

to Section 4-3 before starting this procedure.

If coolant level is below bottom of radiator filler neck, add coolant as follows:

1 Thermostat Housing Plug Remove thermostat housing plug.

Add coolant to radiator until coolant is at bottom of filler neck and coolant trickles out of thermostat housing plug hole. This ensures all air is purged from the system.

Reinstall plug and radiator cap. Check coolant level in recovery tank (see Section 4-3).

Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. D o not use 100% antifreeze or severe damage will occur.

ST-801 939-C / Ref. ST-187 602-A

Tools Needed:

3/8, 1/2 in

4-6. Connecting To Weld Output Terminals

 Connect negative (–)

cable last.

Ref. ST-801 965 / Ref. ST-187 602-A / Ref. S-0756-D

 Do not connect to CC and CV

terminals at the same time.

1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld Output

Terminal

3 Wire (CV) Weld Output

Terminal

For MIG welding, connect work cable to Work terminal and wire feeder cable to Wire (CV) terminal.

321

For Stick/TIG welding, connect work cable to Work terminal and electrode holder cable to Stick/TIG (CC) terminal.

–

OM-487 Page 15

4-7. Selecting Weld Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Welding

Amperes

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

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E

100 ft (30 m) Or Less

10 – 60%

Duty Cycle

60 – 100% Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 – 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

4-8. Remote 14 Receptacle Information

NOTE

Engine runs at weld/power speed whenever a device connected to the remote 14 receptacle is running.

Socket* Socket Information

A 24 volts ac.

24 VOLTS AC

115 VOLTS AC

A/V

AMPERAGE

VOLTAGE

GND

ST-801 941-A

B Contact closure to A completes 24 volt ac contac-

tor control circuit. Protected by circuit breaker CB5.

I 115 volts ac.

J Contact closure to I completes 115 volt ac contac-

tor control circuit. Protected by circuit breaker CB6.

C 0 to +10 volts dc output to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control.

G Circuit c om m on f or 2 4 a n d 115 volt ac circuits.

K Chassis common.

OM-487 Page 16

*The remaining sockets are not used.

4-9. Adjusting MIG Weld Puddle Consistency

 Stop engine.

Stabilizer DC-Z is factory connected to suit most MIG (Wire Welding) applications.

To change MIG weld puddle consistency, proceed as follows:

Remove lower front panel and side panel.

Starting from center of DC-Z, the three leads 79 will be referred to as inner, middle, and outer.

1 Stabilizer DC-Z 2 Inner Lead 79 3 Middle Lead 79

4 Outer Lead 79 5 Wire (CV) Weld Output

Terminal

Middle lead 79 is connected to Wire (CV) weld terminal at the factory. Disconnect middle lead 79 from terminal.

To wet out weld puddle:

Remove insulation sleeve from inner lead 79. Connect inner lead 79 to Wire (CV) terminal, reusing hardware.

To stiffen weld puddle:

Remove insulation sleeve from outer lead 79. Connect outer lead 79 to Wire (CV) terminal, reusing hardware.

Slide sleeves over unused leads 79, and secure with cable ties. Reinstall panels.

Tools Needed:

3/8, 7/16 in

234

Ref. ST-801 944-B / Ref. ST-187 602–A

OM-487 Page 17

SECTION 5 – OPERATING WELDING GENERATOR

5-1. Front Panel Controls

1 2 3

Glow Plug Time

0 s 10 s 20 s

70°F (21°C)

–4°F (–20°C)

32°F (0°C)

6 7

1 DC Polarity/AC Switch

 Do not switch under load.

Use switch to select AC weld output or polarity of DC weld output.

2 Process Select Switch

 Do not switch under load.

Use switch to select output for weld process. 3 A/V Control Use control to select weld voltage or

amperage. Control may be adjusted while welding.

4 Engine Hour Meter 5 High Engine Temperature Light Light goes on and engine stops if engine tem-

perature is too high.

 Do not run engine until trouble is fixed.

6 Low Oil Pressure Light Light goes on and engine stops if engine oil

pressure is too low.

 Do not run engine until trouble is fixed.

7 Glow Plug Switch

OM-487 Page 18

If necessary, push switch up before start-up (see table above).

 Do not use glow plugs longer than 20

8 Engine Control Switch Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs at weld/power speed.

11 10

seconds.

 Place switch in Run position to operate

most GMAW equipment.

9 Idle Lock Switch Use switch to lock engine in idle speed during

start-up. In Start position and Engine Control switch in Run or Run/Idle, engine is locked in idle speed. In Run/Idle position and Engine Control switch in Run/Idle, engine runs at idle speed at n o load and weld/power speed under load.

To start: move idle lock switch and engine control switch to Start. Release engine control switch when engine starts.

Ref. ST-187 602-A

 If the engine does not start, let the engine

come to a complete stop before attempting restart.

To Stop: turn Engine Control switch to Off position.

 Close fuel valve to stop engine if Engine

Control switch does not work (see Section 4-3).

10 Output (Contactor) Switch Use switch to control remote contactor if con-

nected to remote 14 receptacle RC1 (see Section 5-2). Place switch in Remote 14 position if using remote contactor.

 Weld output terminals are energized

when Output (Contactor) switch is in On position and engine is running.

11 Remote Amperage/Voltage Switch Use switch to select front panel or remote am-

perage/voltage control (see Section 5-2). 12 Remote 14 Receptacle RC3 Use receptacle to connect remote control (see

Sections 4-8 and 5-2).

5-2. Remote Amperage/Voltage Control

1 Remote 14 Receptacle RC1 Connect optional remote control to

RC1 (see Section 4-8). 2 Remote Hand Control

(Optional)

3 Remote Foot Control

(Optional)

 Engine runs at weld/power

speed whenever a device connected to the remote 14 receptacle is running.

In Example:

Process = Stick (SMAW)

Min = 40 A CC/DC

Max = 180 A CC/DC

Set Remote Control

Switches

Set Polarity Switch

Set Process and

A/V Control

Max (180 A DC)

Min (40 A DC)

Adjust Remote Control

(Stick Welding Only)

ST-801 941-A / ST-187602–A / S-0769 / S-0774

OM-487 Page 19

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

6-1. Auxiliary Power Receptacles And Circuit Breakers

Simultaneous Welding And Auxiliary Power

Output

Weld Current

Amperes

250 225 200 150 100

Watts

3500 4260 5140 6700 8000 8000 8000

120 V

Receptacle

Amperes

31 39 46 60

62.4

240 V

Receptacle

Amperes

15.5 19 23 30

31.2

 If unit does not have GFCI re-

ceptacles, use GFCIprotected extension cord.

 Auxiliary power decreases as

weld current increases.

1 240 V 50 A AC Receptacle

RC1

RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 8 kVA/kW.

2 120 V 20 A AC Duplex

Receptacle RC2

3 120 V 20 A AC Duplex

Receptacle RC3

RC2 and RC3 supply 60 Hz singlephase power at weld/power speed. Maximum output from RC2 or RC3 is

2.4 kVA/kW. 4 Circuit Breakers CB1 and CB2 CB1 and CB2 protect RC1 from over-

load. I f CB1 or CB2 opens, RC1 and one of the 120 volt receptacles does not work. 120 volts may still be present at RC1.

5 Circuit Breaker CB3 6 Circuit Breaker CB4 CB3 protects RC2 and CB4 protects

RC3 from overload. If a circuit breaker opens, the receptacle does not work.

 Press button to reset circuit

breaker. If breaker continues to open, contact Factory Authorized Service Agent.

Combined output of all receptacles limited t o 8 k VA/kW rating of the generator.

EXAMPLE: If 20 A is drawn from each 120 V duplex receptacle, only 13 A is available at the 240 V receptacle:

2 x (120 V x 20 A) + (240 V x 13 A) = 8 kVA/kW

OM-487 Page 20

Ref. ST-187 602-A

6-2. Optional Auxiliary Power Receptacles

Simultaneous Welding And Auxiliary Power

Output

 If unit does not have GFCI re-

ceptacles, use GFCIprotected extension cord.

 Auxiliary power decreases as

weld current increases.

Combined output of all receptacles limited to 8 kVA/kW rating of the generator.

GFCI Receptacle Option

1 120 V 15 A AC GFCI Recep-

tacles GFCI2 and GFCI3

GFCI2 and GFCI3 supply 60 Hz single-phase power at weld/power speed. Maximum output from GFCI2 or GFCI3 is 2.4 kVA/kW. Circuit breaker protection is the same as standard receptacles.

If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc. connected t o the receptacle. Press button to reset receptacle and resume operation.

 At least once a month, run

engine at weld/power speed

and press Test button to verify GFCI is working properly.

Australian Receptacle Option

2 240 V 15 A AC Australian Re-

ceptacles RC1, RC2, and RC3

Receptacles supply 60 Hz singlephase power at weld/power speed. Maximum output from each receptacle is 3.6 kVA/kW.

3 Circuit Breakers CB1, CB2,

CB3

CB1, CB2, and CB3 protect RC1, RC2, and RC3 from overload. If a circuit breaker opens, the receptacle does not work.

4 Circuit Breaker CB4 CB4 protects all the receptacles

from overload. If CB4 opens, none of the receptacles work.

 Press button to reset circuit

breaker . I f breaker continues to open, contact Factory Authorized Service Agent.

Weld Current

Amperes

250 225 200 150 100

Watts

3500 4260 5140 6700 8000 8000 8000

120 V

Receptacle

Amperes

31 39 46 60

62.4

240 V

Receptacle

Amperes

15.5 19 23 30

31.2

Ref. ST-187 602-A / Ref. ST-172 782

OM-487 Page 21

6-3. Wiring Optional 240 Volt Plug

Current Available in Amperes

240 V

Receptacle*

20 15 10

5 0

*One 240 V load or two 120 V loads.

Each 120 V Duplex

Receptacle

5 10 15 20

V x A = Watts

120V

240V

120V

240V

The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram.

1 Plug Wired for 120/240 V ,

3-Wire Load

When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle.

2 Plug Wired for 240 V , 2-Wire

Load 3 Neutral (Silver) Terminal 4 Load 1 (Brass)Terminal 5 Load 2 (Brass) Terminal 6 Ground (Green) Terminal 7 Amperes Available using

120/240 V Plug

Tools Needed:

ST-120 813-D

OM-487 Page 22

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING

7-1. Maintenance Label

OM-487 Page 23

7-2. Routine Maintenance

NOTE

Check fluid levels. See Section 4-3. OIL

Check fuel lines and connections.

used for an extended period.

Full

Check and clean optional spark arrestor screen. See Section 7-8.

Follow the storage procedure in the engine owner’s manual if the unit will not be

Recycle engine

8 h

Wipe up spills.

20 h

50 h

Clean an d tighten weld terminals.

fluids.

 Stop engine before maintaining.

 See also Engine Manual and

maintenance label. Service engine more often if used in severe conditions.

* To be done by Factory Authorized

Service Agent.

Service air filter element (see Section 7-3).

Check belt tension.

Change oil. See Section 7-5 and maintenance label.

Check air cleaner hoses for cracks and loose clamps.

5/16 in.

(8 mm)

Change oil filter. See Section 7-5 and maintenance label.

75 h

100 h

Clean an d tighten battery connections.

Clean secondary fuel filter.

150 h

OM-487 Page 24

200 h

Check radiator hoses and clamps.

Replace fan belt.

Repair or replace cracked cables.

Replace primary fuel filter. See Section 7-5.

Replace unreadable labels.

400 h

Replace secondary fuel filter (see Section 7-5).

500 h

Flush radiator.

Service welding generator brushes and slip rings. Service more often in dirty conditions.*

Replace fuel lines and clamps.

Check valve clearance.*

Blow out or vacuum inside. During heavy service, clean monthly.

800 h

1000 h

2000 h

Replace radiator coolant and hoses (see Section 7-4).

OM-487 Page 25

7-3. Servicing Air Cleaner

 Stop engine.

 Do not run engine without air

cleaner or with dirty element.

1 Evacuator Valve 2 Dust Cap 3 Element 4 Housing Open ev a cuator valve weekly to re-

move dust. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings.

To Clean air filter:

Wipe off cap and housing. Remove cap and dump out dust. Wipe dust from inside cap and housing with damp cloth. Remove element and reinstall cap.

 Do not clean housing with air

hose.

Clean element with compressed air. Max. air pressure: 100 psi (690 kPa). Replace element if it has holes or damaged gaskets.

Reinstall element and cap

Blow

Inspect

7-4. Servicing Engine Cooling System

Ref. ST-187 602-A / ST-801 964

 Stop engine and let cool.

1 Radiator Cap 2 Radiator Drain Cock Drain engine coolant according to

procedure i n engine manual. Add engine coolant according to

procedure in Section 4-4.

OM-487 Page 26

801 939 / 802 727

7-5. Servicing Engine Fuel And Lubrication Systems

 Stop engine and let cool.

1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord-

ing to engine manual.

 Close valve and valve cap

before adding oil and running engine.

Fill crankcase with new oil to full mark on dipstick (see Section 4-3).

4 Fuel Lines Replace fuel lines if cracked or

worn. 5 Primary Fuel Filter Install new filter as shown. 6 Secondary Fuel Filter Replace filter according to engine

manual. Wipe up any spilled fuel. Start engine, and check for fuel

leaks.

 Stop engine, tighten connec-

tions as necessary, and wipe up fuel.

Tools Needed:

Ref. ST-801 961 / ST-801 940 / Ref. ST-187 602-A / S-0842

OM-487 Page 27

7-6. Adjusting Engine Speed

NOTE

A. Checking Fuel Solenoid

If the engine does not start and stop properly, verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following).

If the engine does not stay at idle speed, verify the throttle solenoid is installed and adjusted properly before adjusting engine speed (see Section B following).

If the engine runs properly but the speeds are incorrect, do not adjust the solenoids. Adjust the engine speed according to the instructions in Section C.

 Stop engine.

Tools Needed:

7/16 in

10, 14 mm

Verify mounting bracket is recessed from edge of engine.

Tighten mounting screws when solenoid is in correct position.

If the engine does not start and stop when using the Engine Control switch, check the position of the fuel solenoid.

Adjusting Fuel Solenoid Position

1 Fuel Solenoid 2 Stop Screw 3 Fuel Solenoid Mounting Screws

 Stop screw is factory-set and should

not be adjusted.

When properly adjusted, the solenoid bracket is slightly recessed from the edge of the engine block and the solenoid linkage easily travels between the stop screw and the fuel solenoid internal stop.

If adjustment is necessary, loosen the solenoid mounting screws and push the solenoid bracket back toward engine as far as possible.

Continue pushing on solenoid bracket in a clockwise direction while tightening mounting screws.

4 Shutdown Lever 5 Stop screw 6 Stop Screw Jam Nut 7 Fuel Solenoid Jam Nut 8 Plunger

 Stop screw is factory-set and should

not be adjusted.

Hold throttle solenoid in idle (energized) position. If shutdown l e v e r i s t ouching or within 1/16 in of stop screw, fuel solenoid is properly adjusted.

If lever is more than 1/16 in. from stop screw, check for clearance between jam nut and fuel solenoid. If there is clearance

between jam nut and solenoid, loosen nut and turn plunger clockwise until lever touches stop screw. Retighten nut.

If there is no clearance between jam nut and solenoid, loosen the solenoid mounting screws and reposition the solenoid as described at the beginning of this section.

OM-487 Page 28

Ref. ST-801 961 / ST-802 649

B. Checking Throttle Solenoid

1 2 3

1/2 in

(13 mm)

 Stop engine.

If the engine does not stay at idle speed, verify the the throttle solenoid and linkage is installed properly.

Adjusting Throttle Solenoid

1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bolt 5 Throttle Lever 6 Solenoid Rod 7 Throttle Solenoid Mounting

Screw Loosen jam nut, remove shoulder

bolt, and remove link from throttle lever . Install link 1/2 in (13 mm) on solenoid rod. Reconnect link to

shoulder bolt and throttle lever. Push solenoid rod into idle (ener-

gized) position and check for nonbinding lateral movement of throttle link at throttle lever. If link binds, loosen solenoid mounting screws. Move the solenoid slightly until the link moves freely with solenoid in relaxed and energized positions. Tighten screws.

Tighten jam nut. Go to Step C.

Tools Needed:

Check for non-binding movement of link with solenoid in energized position.

Check for non-binding movement of link with solenoid in relaxed position.

3/8, 7/16 in

5/32 in

Ref. ST-801 961 / ST-802 649

OM-487 Page 29

C. Making Engine Speed Adjustments

Be sure throttle link

is parallel with

throttle lever.

Do not twist solenoid boot while adjusting engine speed.

Idle

Weld/Power

2450 ±100 rpm

3750 Max

 Before adjusting engine speed, verify

throttle solenoid is installed properly (see Section B on previous page).

Check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows:

Start engine and run until warm. T urn A/V control to max.

Adjusting Idle Speed

Turn Engine Control switch to Run/Idle position.

1 Throttle Solenoid 2 Idle Speed Jam Nut 3 Plunger 4 Throttle Link 5 Throttle Lever Loosen jam nut. While holding throttle link

with a 3/8 in wrench, turn plunger clockwise to increase idle speed or counterclockwise to decrease idle speed.

 After adjusting idle speed, verify the

throttle link is parallel with the throttle lever. If necessary, loosen the idle speed jam nut and reposition the throttle link.

 Do not twist solenoid boot while ad-

justing engine speed.

Tighten jam nut.

Adjusting Weld/Power Speed

Start engine and run until warm. Turn A/V control to max.

6 Weld Speed Jam Nut 7 Adjustment Screw Turn Engine Control switch to Run posi-

tion. Loosen nut and turn screw counterclockwise to increase speed. Turn screw clockwise to decrease speed. T ighten nut.

OM-487 Page 30

Tools Needed:

3/8, 7/16 in

10, 14 mm

Ref. ST-801 961 / ST-801 963

7-7. Overload Protection

Tools Needed:

3/8 in

 Stop engine.

 If a circuit breaker or fuse

opens, it usually indicates a

more serious problem exists.

Contact a Factory Authorized

Service Agent.

1 Circuit Breaker CB6 CB6 protects the 1 15 volt ac output

to Remote 14 receptacle RC1. If CB6 opens, 115 volt ac output to RC1 stops.

2 Circuit Breaker CB5 CB5 protects the 24 volt ac output

to Remote 14 receptacle RC1. If CB5 opens, 24 volt ac output to RC1 stops.

Press button to reset breaker. 3 Fuse F5 (See Parts List)

F5 protects the throttle solenoid from overload. If F5 opens, the engine will not start at idle speed or return to idle speed.

4 Fuse F6 (See Parts List) F6 protects the engine wiring sys-

tem from overload. If F6 opens, the engine will not crank.

5 Fuse F1 (See Parts List) 6 Fuse F2 (See Parts List) Remove side panel. F1 protects the exciter excitation

winding from overload. If F1 opens, weld and auxiliary power output stops.

F2 protects the stator winding from overload. If F2 opens, weld output stops. Auxiliary power is still available.

Replace any open fuses. Reinstall cover before operating unit.

7-8. Servicing Optional Spark Arrestor

Tools Needed:

1/4 in

ST-801 962-C / Ref. ST-187 602-A

 Stop engine and let cool.

1 Spark Arrestor Screen Clean and inspect screen. Replace

spark arrestor if screen wires are broken or missing.

ST-801 939-C / Ref. ST-801 695-A / Ref. ST-187 602-A

OM-487 Page 31

7-9. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check control settings.

Check weld connections. Disconnect equipment from auxiliary power receptacles during start-up. Place Output (Contactor) switch in On position, or move switch to Remote 14 position and connect

remote contactor to Remote 14 receptacle RC1 (see Section 4-8). Check fuses F1 and F2, and replace if necessary (see Section 7-7). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Low weld output. Check control settings.

Place Remote Amperage/Voltage switch in Panel position, or move switch to Remote 14 position and connect remote amperage/voltage control to Remote 14 receptacle RC1 (see Section 4-8).

Check and clean air cleaner as necessary (see Section 7-3). Check engine speed, and adjust if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. See engine manual.

High weld output. Check control settings.

Check engine speed, and adjust if necessary (see Section 7-6). Check for obstructed movement of solenoid linkage (see Section 7-6). Have Factory Authorized Service Agent check field current control board PC2.

Weld output cannot be adjusted. Check position of Remote Amperage/Voltage switch (see Section 5-1).

Have Factory Authorized Service Agent check field current control board PC2.

Erratic weld output. Check control settings.

Clean and tighten connections both inside and outside unit. Check and secure lead connections to A/V control. Be sure connection to work piece is clean and tight. Remove excessive coils from weld cables. Use dry, properly stored electrodes. Check engine speed, and adjust if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Remote contactor control does not activate contactor.

Place Output (Contactor) switch in Remote 14 position (see Section 5-1).

Check and tighten connections to Remote 14 receptacle RC1 (see Section 4-8).

No power output at Remote 14 receptacle RC1.

Lack of high frequency; difficulty in establishing Gas Tungsten Arc Welding arc.

OM-487 Page 32

Reset circuit breaker CB1 and/or CB2 (see Section 7-7).

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts.

Trouble Remedy

Wandering arc – poor control of arc direction.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

Shield weld zone from drafts.

Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten.

B. Auxiliary Power

Trouble Remedy

No power output. Reset circuit breakers CB1, CB2, CB3 and/or CB4 (see Section 6-1).

Check fuse F1, and replace if necessary (see Section 7-7). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Low power output. Check air cleaner, and clean or replace element if necessary.

Check engine speed, and adjust if necessary (see Section 7-6).

See engine manual. High power output. Check engine speed, and adjust if necessary (see Section 7-6). Erratic power output. Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Check receptacle wiring and connections.

Check governor according to engine manual.

C. Engine

Trouble Remedy

Engine will not crank. Check fuse F6, and replace if open (see Section 7-7).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2. Engine does not start. Check fuel level (see Section 4-3).

Open fuel valve (see Section 4-3).

Service primary and secondary fuel filters (see Section 7-5).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Bleed air from fuel system according to engine manual.

See engine manual. Engine starts but stops when Engine

Control switch returns to Run position.

Check oil level (see Section 4-3). Engine will not start if oil pressure is too low.

Check coolant level and fan belt (see Section 4-3 and engine manual). Engine will not start if engine

temperature is too high.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Sec-

tion 7-1).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem-

perature switch S7. Engine does not stop. Stop engine by closing fuel valve (see Section 4-3). Adjust shutdown solenoid (see Section 7-6).

OM-487 Page 33

Trouble Remedy

Engine stopped during normal operation.

Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.

Engine does not return to idle speed. Be sure Engine Control switch S2 is in Run/Idle position.

Engine does not remain at weld/power speed when power or weld load is applied with Engine Control switch in Run/Idle position.

Engine uses oil during run-in period; wetstacking occurs.

Check fuel level (see Section 4-3).

Open fuel valve (see Section 4-3).

Check oil level (see Section 4-3). Engine stops if oil pressure is too low.

Check coolant level and fan belt (see Section 4-3 and engine manual). Engine stops if engine temper-

ature is too high.

Bleed air from fuel system according to engine manual.

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem-

perature switch S7.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

Remove all weld and auxiliary power loads.

Turn off remote device connected to Remote 14 receptacle RC1 (see Section 4-8).

Check for obstructed movement of solenoid linkage (see Section 7-6).

Check fuse F5, and replace if open (see Section 7-7)

Have Factory Authorized Service Agent check idle module PC1 and current transformer CT1.

Place Engine Control switch in the Run position for small loads.

Dry engine (see Section 9 and engine manual).

OM-487 Page 34

Notes

OM-487 Page 35

SECTION 8 – ELECTRICAL DIAGRAM

OM-487 Page 36

Figure 8-1. Circuit Diagram For Welding Generator

OM-487 Page 37

SD-184 799-A

ST-198 117-A

9-1. Wetstacking

SECTION 9 – RUN-IN PROCEDURE

1 Welding Generator Run diesel engines near rated out-

put during run-in period to properly seat piston rings and prevent wetstacking. See nameplate or rating label t o 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 additional engine run-in information.

run_in1 6/96

OM-487 Page 38

9-2. Run-In Procedure Using Load Bank

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 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 generator auxiliary power receptacle.

2 Welding Generator Place A/V range switch in maxi-

mum position, A/V control in minimum 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.

 Stop engine and let cool.

4 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

S-0683

OM-487 Page 39

9-3. Run-In Procedure Using Resistance Grid

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 Keep exhaust and pipe away

from flammables.

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 minimum 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 connectors (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.

 Stop engine and let cool.

6 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

OM-487 Page 40

S-0684

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 Plug From Double

Insulated Equipment

Be sure equipment has this symbol and/or wording.

10-2. Grounding Generator To Truck Or Trailer Frame

3 4

GND/PE

aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by metal-to-metal contact.

S-0854

OM-487 Page 41

10-3. Grounding When Supplying Building Systems

1 2

GND/PE

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 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.

10-4. How Much Power Does Equipment Require?

AMPERES x VOLTS = WATTS

EXAMPLE 1 : If a drill uses 4.5 amperes at 115 volts, calculate its running power

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

1 Resistive Load A light bulb is a resistive load and

requires a constant amount of power.

2 Non-Resistive Load Equipment with a motor is a non-re-

sistive load and requires approximately six times more power while starting the motor than when running (see Section 10-8).

3 Rating Data Rating shows volts and amperes,

or watts required to run equipment.

OM-487 Page 42

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

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 W atts

Stock Tank De-Icer 1000 1000 Grain Cleaner 1/4 HP 1650 650 Portable Conveyor 1/2 HP 3400 1000 Grain Elevator 3/4 HP 4400 1400 Milk Cooler 2900 1100 Milker (Vacuum Pump) 2 HP 10500 2800 FARM DUTY MOTORS 1/3 HP 1720 720 Std. (e.g. Conveyors, 1/2 HP 2575 975 Feed Augers, Air 3/4 HP 4500 1400 Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 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-487 Page 43

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 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 & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-487 Page 44

10-8. Power Required To Start Motor

4 1

VOLTS AMPS

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJKLMNP

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

11.2 x 1/4 x 1000 230

= 12.2 A

CODE 60

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

1/4

= STARTING AMPERAGE

Hz PHASE

1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage 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 motor’s running amperage.

S-0624

10-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, 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-487 Page 45

10-10. Typical Connections To Supply Standby Power

 Customer-supplied equipment is required if

generator is to supply standby power during emergencies or power outages.

120/240 Volt

60 Hz

Three-Wire

Service

Load

240 V

120 V

Neutral

240 V

120 V

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-

quate amperage capacity to cord. Follow all applicable codes and safety practices.

Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting o r s t o p p i n g , t h e e ngine has low speed which causes low voltage and frequency.

7 Load Connections

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection

240 V

120 V

Ground

Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit.

OM-487 Page 46

S-0405-A

10-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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) 37 (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  If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

Load (Watts) 4 6 8 10 12 14

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

OM-487 Page 47

OM-487 Page 48

Figure 11-1. Main Assembly

SECTION 11 – PARTS LIST

56–Fig.10–3

ST-802 106-B

80–Fig.10–2

45 46

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

1 182 367 PANEL, right side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1+♦185 352 PANEL, right side stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 182 366 PANEL, left side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2+♦185 353 PANEL, left side stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +187 466 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3+♦189 678 COVER, top stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 182 761 LABEL, general precautionary engine drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 192 041 LABEL, warning engine fuel/diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 181 881 GROMMET, neck filler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 147 601 CAP, tank screw-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 108 487 LABEL, warning falling equipment etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 183 314 CLAMP, muffler 1.625 dia. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 183 433 PIPE, exhaust elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 187 890 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 +188 932 GUARD, fan belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 188 928 LABEL, warning antifreeze 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 187 465 PANEL, rear upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 +♦189 679 PANEL, rear upper stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 187 566 BRACKET, mtg air cleaner inlet hose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 186 670 UPRIGHT, base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 181 789 SEAL, barrel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 187 480 PANEL, rear lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 198 105 ENGINE, kubota diesel (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 571 SWITCH, coolant temp (230

F) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 187 639 ADAPTER, oil switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 187 542 SWITCH, oil pressure 11psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 189 766 GASKET, muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 187 428 MUFFLER, exhaust engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 064 MANIFOLD, exhaust Kubota 722 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 065 GASKET, exhaust manifold to head Kubota 722 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 187 436 HOSE, radiator upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 +187 590 GUARD, belt fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 FS1 198 107 SOLENOID, fuel w/bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 187 429 FAN, spacer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 198 018 LINK, throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 TS1 198 106 SOLENOID, throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 108 BRACKET, mounting solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 187 435 HOSE, radiator lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 187 457 BRACKET, engine mtg LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 458 BRACKET, engine mtg RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 187 432 BRACKET, air cleaner mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 187 434 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 187 431 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 441 ELEMENT, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 187 640 CLAMP, air cleaner w/latch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 187 442 ELEMENT, fuel filter (engine mounted) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 444 BRACKET, mtg fuel filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 443 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 459 BELT, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 819 INJECTOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 820 GLOW PLUG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 821 REGULATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 529 FITTING, hose brs barbed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 854 HOSE, sae .500 ID x .780 OD (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

006 372 SCREW, M8-1.2 x 25 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174 828 SCREW, M8-1.2 x 45 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

090 106 SCREW, M6-1.0 x 16 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 024 SCREW, M8-1.2 x 16 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 656 SCREW, M10-1.25 x 20 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 579 SCREW, M8-1.2 x 20 hex hd As Req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 834 HOSE, sae .187 ID x .410 OD (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 835 HOSE, sae .312 ID x .560 OD (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-487 Page 49

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly (Continued)

PLG5 135 275 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC5 147 663 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 187 589 HOSE, air cleaner intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 +182 897 DOOR, access bat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 182 935 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 187 616 CABLE, bat pos 32.000 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 Batt 168 037 BATTERY, stor 12V 450crk 75rsv GP58 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 167 730 CABLE, battery neg 29.00 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165 600 CABLE, battery neg 18.50 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 187 728 HOLDER, fuse (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F6 *073 429 FUSE, gl slo-blo 15A 32V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 198 114 HOLDER, fuse (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F5 *125 847 FUSE, gl slo-blo 12A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 187 569 BRACKET, mtg components 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 M1 198 113 MODULE, solenoid control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 CR2, CR3 113 247 RELAY, encl 12VDC DPDT 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 D4 135 184 DIODE BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 CR4 173 069 RELAY, encl 12VDC SPDT 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 SR4 035 704 RECTIFIER, integrated 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 CR1, CR5 155 309 CONTACTOR, solenoid 12VDC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 187 821 REGULATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 187 691 CONNECTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 Fig 11-3 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 187 454 BRACKET, mtg engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 187 550 MOUNT, engine 60 duro flan 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 187 462 BOTTLE, overflow w/ cap (included w/engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 187 588 LABEL, engine maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 187 551 MOUNT, generator 70 duro flan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 187 455 BRACKET, mtg generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 +187 464 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 181 057 COVER, base 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 DC-Z 187 018 STABILIZER ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 020 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 625 BRACKET, mtg rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

164 920 BRACKET, mtg stab/reactor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 SR1 183 051 RECTIFIER, si 3ph 300A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 R4,5 139 812 RESIST OR, WW fxd 30W 5K 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 1T 172 661 BLOCK, stud connection 6posn (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 734 JUMPER LINK 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 172 731 HOLDER, fuse mintr (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1,F2 *169 296 FUSE, mintr gls 25A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 SR2, SR3 035 704 RECTIFIER, integrated 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 D2 135 184 DIODE, board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 C1 176 719 CAPACITOR, electl 1000uf 75VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 177 136 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 CT1 187 144 TRANSFORMER, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 PC2 198 359 CIRCUIT CARD ASSEMBLY. field current controller 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 174 823 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 174 824 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 135 275 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 168 071 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 174 823 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 174 824 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 174 823 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC10 174 824 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11, PLG12 130 204 CONNECTOR & PINS & SOCKETS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 167 SEAL, wire universal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 181 587 TRAY, pc board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 C52 176 007 CAPACITOR, slectl 1200uf 300VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 176 199 CLAMP, capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 180 628 PANEL, lower front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-487 Page 50

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-1. Main Assembly (Continued)

80 Fig 11-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 187 479 TANK, fuel 10 gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 253 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182 922 BUSHING, fuel tank 1.210 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182 925 GAUGE, fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 586 FITTING, stand pipe .312 x 7.375 lg 90 degree 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 501 FITTING, stand pipe .187 x 7.375 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 172 707 SEAL, fuel hose fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 066 113 FILTER, fuel inline 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 187 510 GUARD, fan engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 187 412 FAN, engine cooling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 187 446 SHROUD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 197 801 RADIATOR, with 14 lb cap (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 120 CAP, radiator 14 lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

006 015 FITTING, pipe brs drain cock (radiator) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 591 SPACER, al .250 ID x .500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 197 930 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

♦Optional *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-487 Page 51

 Hardware is common and

not available unless listed.

Figure 11-2. Panel, Front w/Components

ST-802 107-B

OM-487 Page 52

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 80)

1 187 593 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 R3,VR1 046 819 SUPPRESSOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S1 187 190 SWITCH, changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 187 189 BRACKET, shunt mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 030 080 SHUNT, meter 50MV 400A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 R1 072 623 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S6 088 409 SWITCH, toggle DPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC1 202 124 MODULE, pull to idle 4 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC4 147 554 CIRCUIT CARD ASSEMBLY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 165 668 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S4 011 609 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S3 011 611 SWITCH, tgl DPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 CB5,6 083 432 CIRCUIT BREAKER, man reset 1P 10A 250VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 S2 176 606 SWITCH, ign 4posn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 177 859 CONNECTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 S9 011 609 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 RC2,3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI2,3 ♦147 939 RECEPTACLE, str dx grd 2P3W 15A 125VAC GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . .

16 S8 021 467 SWITCH, tgl SPST 3A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PC3 148 021 CIRCUIT CARD, filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CB1,2 117 501 CIRCUIT BREAKER, man reset 1P 40A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 CB3,4 093 996 CIRCUIT BREAKER, man reset 1P 20A 250V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 PC5 148 030 CIRCUIT CARD, filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 073 756 STAND OFF, 6-32 x .625 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 082 788 HOLDER, light 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 048 155 BULB, incand min bayonet 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 176 246 LENS, light amber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 082 789 LENS, light red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 021 385 BOOT, toggle switch lever 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 099 255 TERMINAL, pwr output 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 083 030 STUD, brs .250-20 x 1.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 010 915 WASHER, flat brs .250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 601 836 NUT, brs hex jam .250-20 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 188 039 COVER, receptacle with gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 159 921 BEZEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 RC1 182 954 RECEPTACLE, grd 3P4W 50A 125/250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 172 PLUG, st 50A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 170 391 CAP, dust connector 9760-20 protector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 HM 145 247 METER, hour 10-32VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 072 590 LOCK, shaft .375-32 x .250dia shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 115 493 HANDLE, range switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-487 Page 53

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-3. Generator (Fig 11-1 Item 56)

1 +187 500 STATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 013 367 LABEL, warning moving parts can cause serious injury 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 187 494 ROTOR ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 181 143 BEARING, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 187 493 F AN, rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 186 365 ADAPTER, engine (part of engine assembly) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 187 151 STUD, stl .375 -16 x 23.750 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 047 878 BAR, retaining brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 161 306 CAP, brushholder 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 *126 984 BRUSH, w/spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 005 614 HOLDER, brush 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 187 183 BRACKET, mtg brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 187 536 ENDBELL, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 183 419 O-RING, 1.984 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

 Hardware is common and

not available unless listed.

ST-802 108

Figure 11-3. Generator

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

OM-487 Page 54

Warranty Questions?

Call 1-877-HOBART1 for your local Hobart distributor.

Service

Y ou 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.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original ret a i l p urchaser 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 EXPRESSL Y 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 e i ghteen 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 rectifiers 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 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Hobart Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & 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

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & 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.

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 bas e d u p o n 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 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 standard 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

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 manufacturer’s Transportation Department.

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.

Hobart Welding Products

An Ill inoi s 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

PRINTED IN USA  2000 Hobart Welding Products. 1/00

Hobart Arcstar 300D NT User guide

Specifications and Main Features

Frequently Asked Questions

User Manual