Instruction/ maintenance manual of the product OM-494 Hobart Welding Products
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Hobart 300/300 Processes Description Dual-Operator Engine Driven W elding Generator OM-494 191 862F February 2001 Air Carbon Arc (CAC-A) Cutting and Gouging TIG (GT A W ) W elding Stick (SMA W) W elding MIG (GMA W) W elding Flux Cored (FCA W) W elding 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: Stick = SMAW MIG = GMAW TIG = GT AW CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other reproductive harm.
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OM-494 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-494 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-494 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-494 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-494 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-494 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-494 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-494 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-494 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While W elding Or Under Load Battery (Engine) Circuit Breaker Engi.
OM-494 Page 10 SECTION 3 – SPECIFICA TIONS 3-1. Description This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 5-2).
OM-494 Page 1 1 3-4. Fuel Consumption The curve shows typical fuel use u n- der the combined weld loads of both sides (Welder A and W elder B). 195 71 1 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES A T 40% DUTY CYCLE CV CC 0 0.25 0.
OM-494 Page 12 3-6. Duty Cycle And Overheating Ref. rduty1 5/95 – 194 313-A Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating.
OM-494 Page 13 3-7. V olt-Ampere Curves 194 397 / 194 398 / 194 399 The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capa- bilities of the welding generator . Curves of all other settings fall be- tween the curves shown.
OM-494 Page 14 SECTION 4 – NST ALLA TION When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left. NOTE 4-1. Installing Welding Generator install1 10/00* – Ref.
OM-494 Page 15 4-2. Activating The Dry Charge Battery Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-494 Page 16 4-3. Connecting The Battery – + Connect ( – ) Cable Last. 190 377 4-4. Installing Exhaust Pipe Stop engine and let cool. 1/2 in T ools Needed: exh_pipe2 4/96 – 154 089-A / 154 61 1 / 190 377 Do not blow exhaust toward air cleaner or air intake.
OM-494 Page 17 4-5. Engine Prestart Checks Full 1/2 i n (13 mm) Full Ref. 158 633-C / S-176 697 Diesel Check all fluids daily . Engine must be cold and on a level surface. Follow run-in procedure in engine manual. If unburned fuel and oil col- lect in exhaust pipe during run-in, see Section 9.
OM-494 Page 18 4-6. Safety Information For Connecting T o W eld Output T erminals UNEXPECTED WELD OUTPUT can cause injury or fire. Both weld outputs can be live (ON) when Welder Selector switch is in W elder A/Welder B position and engine is running.
OM-494 Page 19 4-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 5-1). See Section 4-15 for proper cable size.
OM-494 Page 20 4-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 4-15 for proper cable size).
OM-494 Page 21 4-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 5-1). See Section 4-15 for proper cable size.
OM-494 Page 22 4-1 1. Making Dual Operator CV Weld Connections w/ Common W ork Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 4-15 for proper cable size).
OM-494 Page 23 4-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 5-1). See Section 4-15 for proper cable size.
OM-494 Page 24 4-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 4-15 for proper cable size).
OM-494 Page 25 4-14. Making Single Operator CC Weld Connections 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. W elder A (left) weld output terminals are disabled in Single Operator mode. Connect only to W elder B (right) termi- nals for Single Operator mode opera- tion.
OM-494 Page 26 4-15. Selecting W eld Cable Sizes T otal Cable (Copper) Length In Weld Circuit Not Exceeding W elding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 f.
OM-494 Page 27 4-17. Remote 14 Receptacle Information Place W elder Selector switch in Welder A/W elder B position (dual operator mode) for both remote receptacles to work. Welder A (left) remote receptacle output contactor and control is disabled when switch is in Welder B position.
OM-494 Page 28 4-18. Remote 14 Receptacle Connections Single Operator Operation Dual Operator Operation OR OR OR AJ B K I C L NH D M G E F 60 0 AM PS AJ B K I C L NH D M G E F AJ B K I C L NH D M G E F Ref.
OM-494 Page 29 SECTION 5 – OPERA TING THE WELDING GENERA TOR When facing the front panel, the Wel der B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left. NOTE 5-1. Engine Controls See Section 5-3 for weld control descriptions.
OM-494 Page 30 5-2. W eld Controls (See Section 5-3) Ref. 191 848 8 97 5 6 34 2 60 0 AM PS 300 AMPS 300 AMPS 600 AMPS WELDER A Welder B Welder B 1 10.
OM-494 Page 31 5-3. W eld Control Descriptions (See Section 5-2) 1 W elder Selector Switch Use switch to select Dual Operator or Single Operator welding mode. Place switch in W elder A/W elder B (dual oper- ator) position for CC and CV output from W e l d- er A (left) and W elder B (right) weld output ter- minals.
OM-494 Page 32 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt And 240 V olt Duplex Receptacles 190 376 Be sure equipment connected to the 240 V receptacles is GFCI-pro- tected. Auxiliary power is not affected by posi- tion of Welder Selector switch.
OM-494 Page 33 100 h Clean And T ighten Battery Connections. Change Oil. See Section 7-4. Change Oil Filter . Se e Section 7-4. Check air cleaner hoses for cracks and loose clamps. 200 h Replace Unreadable Labels. 250 h Check An d Clean Spark Arrestor .
OM-494 Page 34 7-2. Maintenance Label.
OM-494 Page 35 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-494 Page 36 7-4. Servicing Fuel And Lubrication Systems Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil .
OM-494 Page 37 7-5. Adjusting Engine Speed Ref. 045 768-B Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer . See table for proper no load speed. If neces- sary , adjust speed as follows: 1 High Speed Stop Screw 2 Lock Nut Loosen nut.
OM-494 Page 38 7-7. Checking And Replacing Alternator Belt 158 632 / Ref. 190 377 Stop engine. T o check belt tension: Remove rear panel. 1 Alternator V -Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul- leys. Pull down belt as far as it will go, then measure distance from belt to straight edge.
OM-494 Page 39 7-8. Resetting Fan Belt Safety Shutdown 158 715 / Ref. 158 632 / Ref. 190 377 Stop engine. 1 Cooling Fan V -Belt See engine manual to replace or tighten belt.
OM-494 Page 40 7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 800 633-B / Ref. 190 377 Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run several min- utes to blow out cleanout hole.
OM-494 Page 41 7-10. Circuit Protection Ref. 802 300 / Ref. 802 292-A Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent. 1 Fuse F1 2 Fuse F2 3 Fuse F3 4 Fuse F4 Open front panel.
OM-494 Page 42 7-1 1. T roubleshooting A. Welding T rouble Remedy No weld output on either side; auxiliary power output okay . Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect remote contactors to remote receptacles RC8 and RC9 (see Section 5-3).
OM-494 Page 43 T rouble Remedy High weld output on both sides. Have Factory Authorized Service Agent check field current regulator board PC4. Erratic weld output on either side. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and tight.
OM-494 Page 44 C. Engine T rouble Remedy Engine will not crank. Check battery voltage, and replace battery if necessary . Check battery connections and tighten if necessary . Have Factory Authorized Service Agent check Engine Start Button PB1. Engine cranks but does not start.
OM-494 Page 45 Notes.
OM-494 Page 46 SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Welding Generator.
OM-494 Page 47 ST-192 298-F.
OM-494 Page 48 SECTION 9 – RUN-IN PROCEDURE run_in3 6/99 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-494 Page 49 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-494 Page 50 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-494 Page 51 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-494 Page 52 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-494 Page 53 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-494 Page 54 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2.
OM-494 Page 55 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-494 Page 56 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-494 Page 57 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-494 Page 58 SECTION 1 1 – P ARTS LIST Hardware is common and not available unless listed. 802 317-B 1 2 3 4 5 6 7 8 9 10 11 12 13 9 10 14 15 16 17 18 19 20 21 22 23 24 25 – SEE FIG 1 1 – 4 26 9 10 27 28 29 30 31 32 33 34 35 36 37 38 83 84 85 86 87 88 89 90 91 92 – SEE FIG 1 1 – 2 93 94 95 96 97 98 99 Figure 1 1-1.
OM-494 Page 59 802 317-B 39 40 41 42 43 44 45 46 47 48 49 51 52 53 54 46 55 56 57 – SEE FIG 1 1 – 3 58 59 60 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 37 36 78 – SEE FIG 1 1 – 5 35 34 79 80.
OM-494 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 605 288 FITTING, pipe galv plug sqhd .250NPT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 070 010 BOL T , J stl .
OM-494 Page 61 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 61 189 764 AIR CLEANER, intake 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 62 Hardware is common and not available unless listed. 802 318 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 13 17 2 18 19 20 21 22 23 21 12 18 22 24 25 26 27 28 29 30 31 32 33 34 30 36 37 38 35 39 40 41 42 Figure 1 1-2.
OM-494 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Front Panel (Figure 1 1-1 Item 92) Quantity 1 193 258 COVER, receptacle GFCI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 64 Hardware is common and not available unless listed. 802 320-A 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 12 22 23 24 25 26 27 28 29 30 31 32 33 34 Figure 1 1-3.
OM-494 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Side Control Panels (Figure 1 1-1 Item 57) Quantity 1 +192 330 P ANEL, side output RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Side Control Panels (Continued) Quantity 601 880 NUT , 500-13 x .75 hex .31H 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 67 Hardware is common and not available unless listed. 802 319 1 2 3 4 5 6 7 8 9 10 Figure 1 1-4. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 1 1-4. Rectifier (Figure 1 1-1 Item 25) Quantity 192 310 RECTIFIER ASSEMBL Y (consisting of) 1 .
OM-494 Page 68 Ref. 048 456-E 1 3 4 5 7 6 9 10 11 8 12 13 15 14 Hardware is common and not available unless listed. 2 Figure 1 1-5. Generator.
OM-494 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Generator (Figure 1 1-1 Item 78) Quantity 1 *151 299 BRUSH, contact elect clrg .375 x .750 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes.
Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 4/00 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.
PRINTED IN USA 2001 Hobart Welding Products. 1/01 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-494 (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-494 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-494 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-494 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-494 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-494, 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-494.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-494. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-494 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
