Hobart Welding Products OM-487 manual

Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding MIG (GMA W) W elding Flux Cored (FCAW) Engine Driven Welding Generator OM-487 187 558M January 2001 Arcstar 300D NT Visit our website at www.HobartWelders.com[...]

Hobart W elders 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. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

The following terms are used interchangeably throughout this manual: MIG = GMAW , Wire W elding TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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OM-487 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means W arning! W atch 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. This group of symbols means W arning! W[...]

OM-487 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks c a n 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 b e sure the a[...]

OM-487 Page 3 MOVING P ARTS 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 .  T o prevent acci[...]

OM-487 Page 4 H. F . RADIA TION 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.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

OM-487 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 1 1/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.  Identifie un message de s é curit é parti[...]

OM-487 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

OM-487 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement.  Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

OM-487 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences.  Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.  Demander seulement à des personnes qualifi ?[...]

OM-487 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil On Check V alve Clearance Battery (Engine) Engine Read Operator ’ s Manual A Amperes V V olts MIG (GMAW), Wire Stick (SMAW) TIG (GT AW) Circuit Breaker Positive [...]

OM-487 Page 10 3-2. Dimensions, W eights, And Operating Angles Dimensions A Height 33-1/2 in (851 mm) B C Width 18-3/4 in (476 mm) C  Depth 48 in (1219 mm) D  Do not exceed tilt angles or engine could be damaged or unit could tip. A 18 in (457 mm) G  Do not move or operate unit where it could tip. B 16-1/2 in (419 mm) 4 Holes tip. C 3/4 in[...]

OM-487 Page 1 1 ST-189 268 The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. 3-4. Auxiliary Power Curve 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 0 120 80 40 200 160 280 240 AC POWER AMPERES A T 120V AC POWER AMPERES A T 240V 0 10 20 30 40 60 50 70 80 AC POWER VOL TS Duty cycle is the perc[...]

OM-487 Page 12 ST-189 278 / ST -189 280 / ST-189 282-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. A. CC/AC Mode B. CC/DC Mode C. CV/DC Mode 3-6. V olt-Ampere Curves 0 0 AC AMPERES AC VOL TS 50 100 150 200 250 300 350 [...]

OM-487 Page 13 SECTION 4 – INST ALLA TION install1 10/00 – Ref. ST -800 652 / Ref. ST-800 477-A / ST -158 936-A / S-0854  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- vided in base.  Always securely fasten welding generator onto transport vehicle or trailer an d comply with[...]

OM-487 Page 14 4-3. Engine Prestart Checks ST-801 939-C / ST -801 940 / ST-801 961 1/2 i n (13 mm) Full Diesel Full Open V alve Full Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops i f oil pressure is low or engine tem- perature is high.  This unit has a low oil pressure sh[...]

OM-487 Page 15 4-4. Adding Coolant T o Radiator ST-801 939-C / Ref. ST -187 602-A  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. Ad d coolant to r[...]

OM-487 Page 16 4-7. Selecting W eld Cable Sizes W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  Stop engine before connecting to weld out- put terminals.  Do not use worn, d[...]

OM-487 Page 17 4-9. Adjusting MIG Weld Puddle Consistency Ref. ST-801 944-B / Ref. ST -187 602 – A  Stop engine. Stabilizer DC-Z is factory connected to suit most MIG (Wire W elding) applications. T o change MIG weld puddle consis- tency , proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three lead[...]

OM-487 Page 18 SECTION 5 – OPERA TING WELDING GENERA TOR 5-1. Front Panel Controls Ref. ST-187 602-A 1 DC Polarity/AC Switch  Do not switch under load. Us e 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[...]

OM-487 Page 19 5-2. Remote Amperage/V oltage 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 con- nected to the remote 14 recep- tacle is running. ST-801 941-A / ST -187602 – A / S-07[...]

OM-487 Page 20 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Ref. ST-187 602-A 1 4 2 5 3  If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord.  Auxiliary power decreases as weld current increases. 1 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power[...]

OM-487 Page 21 6-2. Optional Auxiliary Power Receptacles  If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord.  Auxiliary power decreases as weld current increases. Combined output of all receptacles limited to 8 kV A/kW rating of the generator . GFCI Receptacle Option 1 120 V 15 A AC GFCI Recep- tacles GFCI2 and GFCI[...]

OM-487 Page 22 6-3. Wiring Optional 240 V olt Plug ST-120 813-D 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 [...]

OM-487 Page 23 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Maintenance Label[...]

OM-487 Page 24 7-2. Routine Maintenance Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE  Stop engine before maintaining.  See also Engine Manual and maintenance label. Service engine more often if used in severe conditions. * T o be done by Factory Authorized Service Agen[...]

OM-487 Page 25 200 h Replace primary fuel filter . See Section 7-6. Check radiator hoses and clamps. Replace unreadable labels. 400 h Replace secondary fuel filter (see Section 7-6). 500 h Replace fan belt. Flush radiator . Service welding generator brushes and slip rings. Service more often in dirty conditions.* Repair or replace cracked cables. 8[...]

OM-487 Page 26 7-3. Servicing Air Cleaner aircleaner1 9/00 – ST-153 929-B / ST -153 585 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. E n - gine damage caused by using a damaged element is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding capac[...]

OM-487 Page 27 7-4. Servicing Engine Cooling System 801 939 / 802 727  Stop engine and let cool. 1 Radiator Cap 2 Radiator Drain Cock Drain engine coolant according to procedure in engine manual. Add engine coolant according to procedure in Section 4-4. 1 2  Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace s[...]

OM-487 Page 28 7-6. Servicing Engine Fuel And Lubrication Systems Ref. ST-801 961 / ST -801 940 / Ref. ST-187 602-A / S-0842  Stop engine and let cool. 1 Oil Drain V alve 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 run- ning engine. Fill crankca[...]

OM-487 Page 29 7-7. Adjusting Engine Speed 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 fo[...]

OM-487 Page 30 B. Checking Throttle Solenoid Ref. ST-801 961 / ST -802 649  Stop engine. If the engine does not stay at idle speed, verify the the throttle sole- noid and linkage is installed proper- ly . Adjusting Throttle Solenoid 1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bolt 5 Throttle Lever 6 Solenoid Rod 7 Throttle Solenoid [...]

OM-487 Page 31 C. Making Engine Speed Adjustments Ref. ST-801 961 / ST -801 963  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. Turn A/V control to max. Adju[...]

OM-487 Page 32  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, 1 15 volt ac output to RC1 stops. 2 Circuit Breaker CB5 CB5 protects the 24 volt[...]

OM-487 Page 33 T rouble Remedy Low weld output. Check control settings. Place Remote Amperage/V oltage 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[...]

OM-487 Page 34 B. Auxiliary Power T rouble 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 7-8). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. Low power output. Check air cleaner , and clean or repl[...]

OM-487 Page 35 T rouble Remedy Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water . Periodically recharge battery (approximately every 3 months). Replace battery . Check voltage regulator according to engine manual. Engine does not return to idle speed. Be sure Engine Control switch S2 [...]

OM-487 Page 36 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator[...]

OM-487 Page 37 201 926[...]

OM-487 Page 38 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. W etstacking 1 W elding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output.  Do not idle engine longer than necessary . Piston rings seat faster if engine r[...]

OM-487 Page 39 9-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 Wel[...]

OM-487 Page 40 9-3. Run-In Procedure Using Resistance Grid S-0684  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 Of f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V cont[...]

OM-487 Page 41 SECTION 10 – AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 10-2. Grou[...]

OM-487 Page 42 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG 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. GND/PE 1 2 Us e ground device as stated in electric[...]

OM-487 Page 43 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running W atts 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[...]

OM-487 Page 44 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts 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 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 39[...]

OM-487 Page 45 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

OM-487 Page 46 10-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer 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 Sw[...]

OM-487 Page 47 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

OM-487 Page 48 SECTION 1 1 – P ARTS LIST ST-802 106-B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 30 31 19 32 33 37 34 35 36 38 39 40 41 42 43 44 46 48 50 51 52 53 54 55 56 – Fig.10 – 3 48 58 57 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 70 69 74 75 76 77 78 79 80 – Fig.10 – 2 81 82 83 84 85 86 87 88 29 45 49[...]

OM-487 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 182 367 P ANEL, right side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1+ ♦ 185 352 P ANEL, right side stainless 1 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-487 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 134 835 HOSE, sae .312 ID x .560 OD (order by ft) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG5 135 275 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-487 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 79 180 628 P ANEL, lower front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fig 1 1-2 P ANEL, front w/components 1 . . . . . . . . . . . . . . . . . . . . . [...]

OM-487 Page 52 ST-802 107-B  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 11 Figure 1 1-2. Panel, Front w/Components[...]

OM-487 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Fig 1 1-1 Item 80) Quantity 1 187 593 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R3,VR1 046 819 SUPPRESSOR 1 . . . . . . . . . . . . . . . .[...]

OM-487 Page 54 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Generator (Fig 1 1-1 Item 56) Quantity 1 +187 500 ST A TOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 013 367 LABEL, warning moving parts can cause serious injury 1 . . . . . [...]

Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u 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 distrib[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]