Hobart Welding Products 3025 manual

Processes Descrip tio n TIG (GT A W ) W elding Stick (SMA W) W elding MIG (GMAW) and Pulsed MIG (GMA W -P) Welding Engine Driven Welding Generator OM -492 190 603J August 2000 Contractor 3025 Air Carbon Arc (CAC-A) Cutting and Gouging Flux Cored (FCA W) W elding Visit our website at www.HobartWelders.com[...]

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. Thank you and congratulations on ch[...]

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. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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OM-492 Page 1 SECTION 12 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 12-1. 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.  Means “Note”; not safety related. This group of symbols means W arning![...]

OM-492 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. Check and b e sure the a[...]

OM-492 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 .  T o prevent acci[...]

OM-492 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.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

OM-492 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.  Identifie un message de s é curit é parti[...]

OM-492 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. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

OM-492 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.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

OM-492 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.  Demander seulement à des personnes qualifi ?[...]

OM-492 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 alve Clearance Battery (Engine) Engine Read Operator ’ s Manual A Amperes V V olts MIG (GMAW), Wire Stick (SMAW) TIG (GT AW) Circuit Breaker Foot Cont[...]

OM-492 Page 10 3-2. Dimensions, W eights, and Operating Angles Dimensions A Height 36 in (914 mm) B C Width 24 in (610 mm) C  Depth 59 in (1499 mm) D  Do not exceed tilt angles or engine could be damaged or unit could tip. A 19-7/8 in (505 mm) G  Do not move or operate unit where it could tip. B 18 in (457 mm) 4 Holes tip. C 1 in (25 mm) E[...]

OM-492 Page 1 1 3-4. V olt-Ampere Curves 178 652 / 178 653 V olt-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 B. CV Mode ARC CONTROL[...]

OM-492 Page 12 193 458 3-5. Fuel Consumption 0 5 0 100 150 200 250 300 350 400 450 500 DC W ELD AMPERES A T 100% DUTY CYCLE 3600 RPM 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0.40 0.21 0.62 0.83 1.25 1.04 1.46 1.70 1.98 0.95 2.84 3.78 5.67 4.73 6.62 7.57 U.S. GAL./HR. IMP . GAL./HR. LITERS/HR. IDLE SECTION 4 – INST ALLA TION install1 12/99 – Re[...]

OM-492 Page 13 4-2. Engine Prestart Checks 802 330-B 1/2 i n (13 mm) Full Diesel 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 too low or en- gine temperature is too high.  This unit has a low oil pressure shut- down switch. However , some condi- tions [...]

OM-492 Page 14 4-3. Adding Coolant T o Radiator Ref. 802 330-B  Stop engine and let cool.  Check coolant level according to Section 4-2 before starting this procedure. If coolant level is below bottom of radiator filler neck, add coolant as follows: 1 Radiator Air Bleed Screw Remove radiator air bleed screw . Ad d coolant to radiator until co[...]

OM-492 Page 15 4-5. Installing Exhaust Pipe 802 173-B / Ref. 189 438-A  Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel. T ools Needed: 1/2 in 4-6. Connecting T o W eld Output T erminals 1 Positive (+) W eld Output T erminal 2 Negative ( – ) W eld Output T erminal For MIG w[...]

OM-492 Page 16 4-7. Selecting W eld Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding W elding Amperes 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) 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3[...]

OM-492 Page 17 Notes[...]

OM-492 Page 18 SECTION 5 – OPERA TING WELDING GENERA TOR 5-1. Controls (See Section 5-2) Ref. 200 379 / 802 330-B 56 8 9 11 12 13 14 7 10 3 2 1 4 15[...]

OM-492 Page 19 5-2. Description Of Controls (See Section 5-1)  The fan motor is thermostatically controlled and only runs when cooling is needed. Engine Lights 1 Battery Charging Light Light goes on if engine alternator is not charg- ing battery . Engine continues to run.  Stop engine and fix trouble if Battery Charging light goes on. 2 Engin[...]

OM-492 Page 20 5-3. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. NOTE Mode Meter Reading At Idle Meter Reading While W elding Scratch Start TIG VA Actual V olts (OCV) Preset Amps 80.0 85 Actual V olts Actual Amps VA 10.3 85 Lift-Arc TIG Actual V olts Preset Amps VA 7.0 85 [...]

OM-492 Page 21 5-5. Lift-Arc TIG Procedure With Mode Switch in the Lift-Arc TI G position, start an arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , an d slow ly lift electrode. An arc will form when electrode is lifted. Normal open-circuit volta[...]

OM-492 Page 22 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers  If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Auxiliary power decreases as weld current increases. 1 240 V 50 A AC Receptacle RC3 RC 3 supplies 60 Hz single-phase power at weld/power speed. Maxi[...]

OM-492 Page 23 6-2. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) Plug1 7/99 – 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[...]

OM-492 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. Note Recycle engine fluids.  Stop engine before maintaining.  See also Engine Manual and Maintenance Label. Service engine more often if used i[...]

OM-492 Page 25 500 h Replace fan belt. Flush radiator . Repair or replace cracked cables. Drain sludge from fuel tank. FUEL SLUDGE 800 h Check valve clearance.* 1000 h Blow out or vacuum inside. During heavy service, clean monthly . OR Service welding generator brushes and slip rings. Service more often in dirty conditions.* 2000 h Replace radiator[...]

OM-492 Page 26 7-2. Maintenance Label[...]

OM-492 Page 27 7-3. Servicing Air Cleaner Ref. 189 438-A / 801 964  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 Evacuator V alve 2 Dust Cap 3 Element 4 Housing Open e v a cuator valve weekly to re- move dust. Clean or replace ele- ment if dirty or damaged. Replace element yearly or after six cleanings. T o Cl[...]

OM-492 Page 28 7-5. Servicing Engine Lubrication And Fuel Systems Ref. 189 438-A / 802 330-B / S-0842 T ools Nee d e d : 5 4 4 2 3  Stop engine and let cool. 1 Oil Filter 2 Oil Drain V alve 3 1/2 ID x 12 in Hose 4 Fuel Line 5 Primary Fuel Filter 6 Secondary Fuel Filter 7 Petcock 8 Fuel T ank Sludge Drain T o change oil and filter: Pull oil drain[...]

OM-492 Page 29 7-6. Servicing Engine Cooling System 802 330-B / 802 581  Stop engine and let cool. 1 Radiator Draincock 2 Radiator Cap 3 Radiator Air Bleed Screw Change coolant according to engine manual. Add coolant according to Sec- tion 4-3). Run engine until engine reaches normal operating temperature. Loosen air bleed screw to remove air fr[...]

OM-492 Page 30 7-7. Adjusting Engine Speed 802 330-B After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. T urn V/A control to max. Adjusting Idle Speed Turn Engine Control switch to Run/ Idle position. 1 Throttle Solenoid 2 Idle Speed Jam Nut 3 Idle Speed [...]

OM-492 Page 31  Stop engine.  When a circuit breaker opens, it usually indicates a more seri- ous problem exists. Contact Factory Authorized Service Agent. 1 Circuit Breaker CB12 CB12 protects the 1 15 volt ac out- put to Remote 14 receptacle RC5. If CB12 opens, 1 15 volt ac output to RC5 stops. 2 Circuit Breaker CB1 1 CB1 1 protects the 24 v[...]

OM-492 Page 32 7-9. V oltmeter/Ammeter Help Displays Use the voltmeter/ammeter help displays to help determine the cause of no weld output. When a help display is shown, the inverter module weld output has stopped but the en- gine continues to run. Correct the problem before r esuming operation. The display screen resets when the fault is corrected[...]

OM-492 Page 33 7-10. T roubleshooting A. Welding T rouble Remedy No weld output. Check control settings. Check weld connections. Disconnect equipment from auxiliary power receptacles during start-up. Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon- necting board PC2, and control board PC1. If u[...]

OM-492 Page 34 T rouble Remedy Remote contactor control does not activate contactor . Check and tighten connections to Remote 14 receptacle RC5 (see Section 4-8). Lack of high frequency; difficulty in establishing Gas Tungsten Arc W eld- ing arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cabl[...]

OM-492 Page 35 C. Engine T rouble Remedy Engine will not crank. Reset circuit breaker CB8 (see Section 7-8). Check battery voltage. Check battery connections and tighten if necessary . Have Factory Authorized Service Agent check Engine Control switch S1. Engine cranks, but does not start. Check fuel level (see Section 4-2). Open fuel valve (see Sec[...]

OM-492 Page 36 T rouble Remedy Engine does not go to low (idle) speed with Engine Control switch in Run/Idle position. Be sure Engine Control switch S1 is in Run/Idle position. Remove all weld and auxiliary power loads. T urn of f remote device connected to Remote 14 receptacle RC5 (see Section 4-8). Check for obstructed movement of throttle soleno[...]

OM-492 Page 37 Notes[...]

OM-492 Page 38 SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-2. Circuit Diagram For Welding Generator[...]

OM-492 Page 39 200 955[...]

OM-492 Page 40 SECTION 9 – RUN-IN PROCEDURE run_in4 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.  Do not idle engine longer than necessary . Piston rings seat faster if engine r[...]

OM-492 Page 41 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. 2 Wel[...]

OM-492 Page 42 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. Turn Of f grid. 2 Welding Generator 3 W eld Cables Connect grid to generator weld output t[...]

OM-492 Page 43 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. 3 1 10-2. Grou[...]

OM-492 Page 44 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. GND/PE 1 2 Us e ground device as stated in electric[...]

OM-492 Page 45 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 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850 3[...]

OM-492 Page 46 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 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 3[...]

OM-492 Page 47 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. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

OM-492 Page 48 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. 4 Circuit Breakers or Fused Disconnect Sw[...]

OM-492 Page 49 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. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

OM-492 Page 50 SECTION 1 1 – P ARTS LIST  Hardware is common and not available unless listed. 20 21 103 96 – Fig 1 1-2 100 99 98 101 90 111 – Fig. 1 1- 3 102 11 2 1 3 2 4 5 6 8 26 25 24 23 95 94 97 107 108 106 104 105 22 109 11 0 27 28 18 10 11 10 7 9 13 12 15 17 16 14 93 19 91 Figure 1 1-5. Main Assembly[...]

OM-492 Page 51 802 324-D 29 – Fig. 1 1-4 31 30 34 35 14 36 37 38 39 40 44 45 46 47 48 49 50 51 52 53 54 55 56 69 33 57 58 59 60 61 64 63 62 65 66 67 68 70 71 72 87 76 73 77 88 81 89 79 80 84 83 82 86 78 75 74 41 42 14 85 90 43 32 92 91[...]

OM-492 Page 52 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Main Assembly Quantity 1 +198 157 P ANEL, generator left 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +198 155 COVER, generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-492 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Main Assembly (Continued) Quantity 55 192 475 SUPPORT , engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 192 476 MOUNT , engine vibration 2 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-492 Page 54 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Main Assembly (Continued) Quantity 197 535 HARNESS, wiring engine compartment (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC15 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-492 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 1 1-6. Front Panel (Figure 1 1-5, Item 96) Quantity 1 198 049 UPRIGHT , base front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +191 737 P ANEL, front louver 1 . . . . . . . . . . . . . . . . . . . . . [...]

OM-492 Page 56  Hardware is common and not available unless listed. 802 326-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 5 27 18 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Figure 1 1-7. Inverter Assembly[...]

OM-492 Page 57 Description Part No. Dia. Mkgs. Item No. Figure 11-7. Inverter Assembly (Figure 1 1-5, Item 1 1 1) Quantity 1 PC2 196 148 CIRCUIT CARD ASSEMBL Y , interconnecting 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 C3,C4,C5 174 980 CAP ACITOR, elctlt 2700uf 420 3 . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-492 Page 58  Hardware is common and not available unless listed. 802 338-A 1 3 4 2 5 6 7 8 9 10 11 12 13 14 15 16 17 Figure 1 1-8. Generator Description Part No. Dia. Mkgs. Item No. Figure 1 1-8. Generator Assembly (Figure 1 1-5, Item 29) Quantity 1 160 943 ENDBELL 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. The expertise of the distrib[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Company 600 West M ain S treet Troy , O H 4 5373 U SA For Technical Assi stance: Call1-800-332-3281 For Lit erature O r Nearest D ealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]