Hobart Welding Products 3025 manual Table of Contents

Page 3

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 con- stituents 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 = GTAW

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 UTILISATION

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. Duty Cycle And Overheating

10

3-4.

Volt-Ampere Curves

11

3-5.

Fuel Consumption

12

SECTION 4 – INSTALLATION

12

4-1.

Installing Welding Generator

12

4-2.

Engine Prestart Checks

13

4-3.

Adding Coolant To Radiator

14

4-4.

Connecting The Battery

14

4-5.

Installing Exhaust Pipe

15

4-6.

Connecting To Weld Output Terminals

15

4-7.

Selecting Weld Cable Sizes

16

4-8.

Remote 14 Receptacle RC5 Information

16

SECTION 5 – OPERATING WELDING GENERATOR

18

5-1. Controls (See Section 5-2)

18

5-2. Description Of Controls (See Section 5-1)

19

5-3.

Meter Functions

20

5-4.

Mode Switch Settings

20

5-5.

Lift-Arc TIG Procedure

21

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

22

6-1. Auxiliary Power Receptacles And Circuit Breakers

22

6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

23

6-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P)

23

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING

24

7-1.

Routine Maintenance

24

7-2.

Maintenance Label

26

7-3.

Servicing Air Cleaner

27

7-4. Servicing Optional Spark Arrestor

27

7-5. Servicing Engine Lubrication And Fuel Systems

28

7-6. Servicing Engine Cooling System

29

7-7.

Adjusting Engine Speed

30

7-8.

Overload Protection

31

7-9.

Voltmeter/Ammeter Help Displays

32

7-10. Troubleshooting

33

SECTION 8 – ELECTRICAL DIAGRAMS

38

SECTION 9 – RUN-IN PROCEDURE

40

9-1.

Wetstacking

40

9-2. Run-In Procedure Using Load Bank

41

9-3. Run-In Procedure Using Resistance Grid

42

SECTION 10 – AUXILIARY POWER GUIDELINES

43

SECTION 11 – PARTS LIST

50

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents OM-492 ProcessesDescription From Hobart to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsOverheating Dimensions, Weights, and Operating AnglesDimensions Duty Cycle And OverheatingCC Mode CV ModeVolt-Ampere Curves Movement Airflow Clearance Do not lift unit from end InstallationInstalling Welding Generator Fuel ConsumptionFuel Do not use gasoline. Gasoline will damage engine Keep radiator and air intake clean and free of dirtEngine Prestart Checks Full 13 mm DieselAdding Coolant To Radiator Connecting The BatteryConnecting To Weld Output Terminals Installing Exhaust Pipe10 100% Duty Cycle Selecting Weld Cable SizesRemote 14 Receptacle RC5 Information 100 ft 30 m Or LessOM-492 Controls See Section Operating Welding GeneratorDescription Of Controls See Section Meter Functions Mode Switch SettingsMode Meter Reading At Idle Meter Reading While Welding Mode Switch Setting Process Output On/Off ControlTouch Seconds Do not Strike Like a Match Lift-Arc TIG ProcedureWeld Total 120 Auxiliary Power Receptacles And Circuit BreakersThree-Phase 240 Operating Auxiliary Equipment120V Plug Wired for 240 V, 2-Wire Load Load. See circuit diagramPlug Wired for 120/240 Wire LoadMaintenance and Troubleshooting 2000 h 500 h800 h 1000 hMaintenance Label Servicing Optional Spark Arrestor Servicing Air CleanerTo Clean air filter Do not clean housing with air hoseServicing Engine Lubrication And Fuel Systems Servicing Engine Cooling System Weld Speed Jam Nut Adjustment Screw Adjusting Engine SpeedAdjusting Idle Speed Adjusting Weld/Power SpeedOverload Protection Voltmeter/Ammeter Help Displays Troubleshooting WeldingTrouble Remedy Auxiliary Power No power output Reset circuit breakers see SectionNecessary parts Engine CT1 Reset circuit breaker CB9 see SectionOM-492 Circuit Diagram For Welding Generator Electrical Diagrams200 Wetstacking RUN-IN ProcedureRun-In Procedure Using Load Bank Load BankWelding Generator Weld Cables From flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/gridAuxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible109 108 107 106 Parts List112 104 103 102 101 100 1054746 8988 Item Dia Part Mkgs Description Quantity PLG11 Front Panel Front Panel -5, Item Inverter Assembly Inverter Assembly -5, Item Generator Support ServiceContact your Distributor for Hobart Welding ProductsCall
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