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OM-492 190 603J
August 2000
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
Contractor 3025
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 12 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 12-1. 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. 12-2. Arc We
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. 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 par
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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 Touch Start Foot Control Manual Control Pulsed (GTAW) Alternating Current Positive Negative Output (AC) Protective Earth Time Hours Seconds (Ground) s h Do not switch while Remote 14 W
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3-2. Dimensions, Weights, and Operating Angles Dimensions A B Height 36 in (914 mm) C C Width 24 in (610 mm) Do not exceed tilt angles or engine could Depth 59 in (1499 mm) be damaged or unit could tip. D Do not move or operate unit where it could A 19-7/8 in (505 mm) G tip. tip. 4 Holes B 18 in (457 mm) C 1 in (25 mm) E F D 15-5/8 in (397 mm) 20 20° E 26-3/8 in (679 mm) 20° ° 20° F 58-3/4 in (1492 mm) 20° ° G 13/32 in (10 mm) Dia. Weight 925 lb (420 kg) Front Panel End 800 426 3-3. Duty
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3-4. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode ARC CONTROL B. CV Mode 178 652 / 178 653 OM-492 Page 11
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3-5. Fuel Consumption 7.57 1.70 2.00 6.62 1.46 1.75 5.67 1.25 1.50 4.73 1.04 1.25 3600 RPM 3.78 0.83 1.00 2.84 0.62 0.75 1.98 0.40 0.50 IDLE 0.95 0.21 0.25 0 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 193 458 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- vided in base. Movement Airflow Clearance Always ground generator 18 in Do not l
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4-2. Engine Prestart Checks Check radiator coolant lev- el when fluid is low in re- covery tank. Full Capacity w/Overflow Tank 6.4 qt (6 L) Full 1/2 in (13 mm) Full Diesel Full 802 330-B Check all fluids daily. Engine must be cold Oil Keep radiator and air intake clean and free and on a level surface. Unit is shipped with of dirt. After fueling, check oil with unit on level sur- 10W30 engine oil. face. If oil is not up to full mark on dipstick, Incorrect engine temperature can add oil (see mai
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4-3. Adding Coolant To Radiator Stop engine and let cool. Check coolant level according Full to Section 4-2 before starting this procedure. 1 If coolant level is below bottom of radiator filler neck, add coolant as Capacity follows: w/Overflow Tank 1 Radiator Air Bleed Screw 6.4 qt (6 L) Remove radiator air bleed screw. Add coolant to radiator until coolant is at bottom of filler neck. This en- sures all air is purged from the sys- tem. Reinstall screw and radiator cap. Check coolant level i
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4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. Tools Needed: 1/2 in 802 173-B / Ref. 189 438-A 4-6. Connecting To Weld Output Terminals 1 Positive (+) Weld Output Terminal 2 Negative (–) Weld Output Terminal For MIG welding, connect work cable to Negative (–) terminal and wire feeder cable to Positive (+) ter- minal. For Stick/TIG welding, connect work cable to Negative (–) terminal and electr
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4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft Welding 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Amperes 10 – 60% 60 – 100% Duty 10 – 100% Duty Cycle Duty Cycle Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 *Weld cable size (AWG)
