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OM-487 187 558M
January 2001
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
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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
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause p
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. 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 n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil On Battery (Engine) Clearance Read Operator’s Engine Amperes Volts A Manual V MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire Alternating Current Positive Negative Output (AC) Protective Earth Time Hours Seconds (Ground) s h Do not switch while Remote 14 Work Connection Glow Plug 14 welding Receptacle Electro
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3-2. Dimensions, Weights, And Operating Angles Dimensions A B Height 33-1/2 in (851 mm) C C Width 18-3/4 in (476 mm) Do not exceed tilt angles or engine could Depth 48 in (1219 mm) be damaged or unit could tip. D Do not move or operate unit where it could A 18 in (457 mm) G tip. tip. 4 Holes B 16-1/2 in (419 mm) C 3/4 in (19 mm) E F D 3-1/8 in (79 mm) 20 20° E 32-3/4 in (832 mm) 20° ° 20° F 48 in (1219 mm) 20° ° G 13/32 in (10 mm) Dia. Weight 740 lb (336 kg) Engine End ST-800 426 3-3. Fuel
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3-4. Auxiliary Power Curve The ac auxiliary power curve shows the auxiliary power available 280 140 in amperes at the receptacles. 240 120 200 100 160 80 120 60 80 40 40 20 0 0 0 20 40 60 80 100 120 140 160 AC POWER AMPERES AT 120V 0 10 20 30 40 50 60 70 80 AC POWER AMPERES AT 240V ST-189 268 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated 100% Duty Cycle at 290 Amperes DC load without overheating. Exceeding duty cycle can damage unit and void warranty. C
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3-6. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/AC Mode the welding generator. Curves of 80 other settings fall between the curves shown. 70 60 50 MAX 40 30 MIN 20 10 0 0 50 100 150 200 250 300 350 400 AC AMPERES B. CC/DC Mode 80 70 60 50 MAX 40 30 MIN 20 10 0 0 50 100 150 200 250 300 350 400 DC AMPERES C. CV/DC Mode DC AMPERES ST-189 278 / ST-189 280 / ST-189 282-A OM-487 Page 12 DC VOLTS DC VOLTS AC VOLTS
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- Movement Airflow Clearance vided in base. 18 in Do not lift unit from end. Always securely fasten (460 mm) welding generator onto 18 in transport vehicle or trailer (460 mm) and comply with all DOT and 18 in other applicable codes. (460 mm) OR Always ground generator frame to vehicle frame to pre- vent electric shock and
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4-3. Engine Prestart Checks 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 tem- perature is high. Check radiator coolant This unit has a low oil pressure shut- level when fluid is low in down switch. However, some condi- recovery tank. tions may cause engine damage be- fore the engine shuts down. Check 1/2 in oil level often and do not use the oil Full (13 mm) Full pressure shutdown system
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4-4. Adding Coolant To Radiator Stop engine and let cool. Check coolant level according to Section 4-3 before starting Full this procedure. If coolant level is below bottom of radiator filler neck, add coolant as follows: Capacity: w/Overflow Tank 6.9 qt (6.5 L) 1 Thermostat Housing Plug Remove thermostat housing plug. Add coolant to radiator until coolant is at bottom of filler neck and cool- ant trickles out of thermostat hous- ing plug hole. This ensures all air is purged from the system.
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4-7. Selecting Weld Cable Sizes Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Weld Output Terminals Stop engine before 10 – 60% 60 – 100% Welding connecting to weld out- Duty Duty 10 – 100% Duty Cycle put terminals. Amperes Cycle Cycle Do not use worn, dam- aged, undersized, or poorly spliced cables. 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0
