Instruction/ maintenance manual of the product OM-487 Hobart Welding Products
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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.
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.
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.
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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.
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.
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 .
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.
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.
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.
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.
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.
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 al.
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.
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 12.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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).
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 .
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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.
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.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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-.
An important point after buying a device Hobart Welding Products OM-487 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products OM-487 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-487 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-487 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-487 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-487, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-487.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-487. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-487 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
