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OM-130 098V
August 2000
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A) Cut-
ting And Gouging
With Optional Equipment:
Flux Cored (FCAW) With
Voltage-Sensing Wire Feeder
Contractor 3225DX
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. Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Fast/Slow Battery (Engine) Circuit Breaker Engine Oil (Run/Idle) Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes Volts Panel/Local Remote A V Read Operator’s G Engine Temperature Output 1 Manual Alternating Time Hours Seconds Current h s Do Not Switch Single Phase Three Phase Ether Starting Ai
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SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Maximum Open-Circuit Rated Welding Amperage Voltage DC Auxiliary Power Engine Fuel Capacity Output Range (Nominal) Rating Deutz F3L-1011 400 A, Single-Phase, Air/Oil-Cooled, 40 Volts DC, 40 – 400 95 (90) 3 kVA/kW, 26 A, 11.3 gal (42.8 L) Three-Cylinder, 40% Duty Cycle 120 V AC, 60 Hz 29 HP Diesel Engine 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 40-1/2 in (1029 mm) Width 24-5/8 in (625 mm) N Depth 56 i
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3-3. Fuel Consumption The curve shows typical fuel use under weld or power loads. SB-137 487-A 3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 40% Duty Cycle At 400 Amperes utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 4 Minutes Welding 6 Minutes Resting rduty1 5/95 – SB-070 999-B OM-130 098 Page 11
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3-5. AC Auxiliary Power The ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. rsb3.1 2/92 – ST-109 365-C 3-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. ST-183 882 OM-130 098 Page 12
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3-7. Optional AC Power Plant Curves The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) rsb13.1 12/94 - ST-134 636-A / ST-134 637-A OM-130 098 Page 13
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) 3 1 Grounding 1 Generator Base 4 GND/PE 2 Metal Vehicle Frame 3 Equipment Grounding Terminal OR 4 Grounding Cable Use #10 AWG or larger insulated copper wire. If unit does not have GFCI re- Electrically bond generator frame to ceptacles, use GFCI- vehicle frame by metal-to-metal protected exte
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4-3. Activating The Dry Charge Battery Remove battery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 4 5 Well 1 3 Fill each cell with electrolyte to bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electro- lyte level. If necessary, add electro- lyte to raise to proper level. Reins- tall vent caps. 6 Battery Charger 2 Read and follow all instruc- tions supplied w
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4-4. Connecting The Battery Connect Negative (–) Cable Last. – + Tools Needed: 1/2 in ST-156 011-A / Ref. ST-188 449 / S-0756 4-5. Engine Prestart Checks 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. 1 Fuel Do not use gasoline. Gaso- line will damage engine. 1/2 in Add fresh diesel fuel before starting (13 mm) Full engine the first time (see mainte-
