Hobart Welding Products 3225D manual

Processes OMĆ 480 128 576W August 2000 Contractor 3225D Stick (SMA W) W elding Flux Cored (FCAW) With V olt - age-Sensing Wire Feeder With Optional Equipment: Air Carbon Arc (CAC-A) Cut- ting And Gouging Engine Driven Welding Generator Descrip tio n 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: Stick = SMAW CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other reproductive harm. T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . .[...]

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OM-480 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. 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! W[...]

OM-480 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-480 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-480 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-480 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-480 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-480 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-480 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-480 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Amperes V V olts [...]

OM-480 Page 10 SECTION 3 – SPECIFICA TIONS 3-1. W eld, Power , And Engine Specifications Rated Welding Output Amperage Range Maximum Open-Circuit V oltage DC (Nominal) Auxiliary Power Rating Engine Fuel Capacity 250 A, 40 V olts DC, 100% Duty Cycle 40 – 400 95 (90) Single-Phase, 3 kV A/kW , 26 A, 120 V AC, 60 Hz Deutz F3L-101 1 Air/Oil-Cooled, [...]

OM-480 Page 1 1 3-3. Fuel Consumption SB-137 487-A The curve shows typical fuel use under weld or power loads. 3-4. Duty Cycle And Overheating rduty1 5/95 – SB-070 999-B Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . Continuous Welding 10[...]

OM-480 Page 12 3-5. AC Auxiliary Power Th e 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. V olt-Ampere Curves ST-183 882 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of a l l ot[...]

OM-480 Page 13 3-7. Optional AC Power Plant Curves rsb13.1 12/94 - ST-134 636-A / ST -134 637-A Th e 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 KV A/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 10 KV A/KW Three-Phase Auxiliary Power Plant (No [...]

OM-480 Page 14 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 12/99 – Ref. ST-800 652 / Ref. ST -800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 3 4  Always ground generator frame t o vehicle frame to pre- vent electric shock and static electric[...]

OM-480 Page 15 4-3. Installing Muffler Pipe exh_pipe2 12/96 – ST-154 089-A / ST -154 61 1 / Ref. ST-188 448  Stop engine and let cool.  Do not blow exhaust toward air cleaner or air intake. T op V iew 1/2 in T ools Needed: 4-4. Engine Prestart Checks Ref. ST-800 159-D Full 1/2 i n (13 mm) Full Diesel V alve Open Check all fluids daily . Eng[...]

OM-480 Page 16 ether1 12/96 – ST-153 382-A / Ref. ST -188 448  Stop engine.  Improper handling or expo- sure to ether can harm your health. Follow manufactur- er ’ s safety instructions on cylinder .  Do not use Ether Starting Aid while engine is running. Open side door(s). 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozz[...]

OM-480 Page 17 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) Amperes 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[...]

OM-480 Page 18 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Controls (See Section 5-2) Ref. ST-188 448 / ST -800 162-A / ST-800 159-D 1 2 12 13 5 3 4 6 7 10 11 8 9 14 15[...]

OM-480 Page 19 5-2. Description Of Front Panel Controls (See Section 5-1)  This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output control returns to the front panel or remote con- trol setting. The Amperage/voltage Con- trol adjusts amperage only when [...]

OM-480 Page 20 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 12 6-1. 120 V olt Duplex And Optional GFCI Receptacles Ref. ST-188 448 4 3  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 120 V 15 A AC Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 15 A AC GFCI Receptacles GFCI1 And GFCI2 (Optional) Receptacl[...]

OM-480 Page 21 6-2. 240 V olt Duplex Receptacle (Optional) Ref. ST-188 448 / ST -174 408  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 240 V 15 A AC Receptacle RC1 Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kV A/kW . 2 Circuit Breakers CB1 And CB2 CB1 and CB2 protect[...]

OM-480 Page 22 6-3. Connecting Optional Auxiliary Power Plant Ref. S-179 637-B  Stop engine.  Power and weld outputs are live at the same time. Disconnect or insulate unused cables.  Have qualified person install according to circuit diagram and Auxiliary Power Guidelines (Section 10). Remove junction box cover . 1 Lead 93 2 Lead 92 3 Lead[...]

OM-480 Page 23 6-4. 120/240 V olt T wistlock Receptacle (Optional) ST-801 057-A 1 120/240 V 50 A T wistlock Re- ceptacle RC9 RC9 is connected to the optional auxiliary power plant and supplies 60 Hz single-phase power at weld/ power speed. Maximum output from receptacle is 7.5 kV A/kW . Power available at RC9 is reduced when welding. Fuses F1 and F[...]

OM-480 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e also Engine Manual and Maintenance Label. Service engine more often if used in severe condi- tions. * T o be done by Factory Authorized Service Agent. 8 h Wipe Up Spills. Check Fluid Levels. See S[...]

OM-480 Page 25 Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-2. Maintenance Label[...]

OM-480 Page 26 7-3. Servicing Air Cleaner aircleaner4 9/99 – 802 495 / Ref. S-0698-B  Stop engine. 1 Air Cleaner 2 Service Indicator (Optional) 3 Window 4 Reset Button Service air cleaner element if red band appears in window . A green band means air cleaner is okay . Press button to reset indicator .  Do not run engine without a ir cleaner[...]

OM-480 Page 27 7-4. Servicing Fuel And Lubrication Systems Ref. ST-800 159-E / Ref. ST -188 448  Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/ W ater Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff V alve 8 Fuel Line 9 Sludge Drain Plug T o change oil and filter: See engine manual[...]

OM-480 Page 28 7-5. Adjusting Engine Speed Ref. ST-801 179 / Ref. ST -800 159-D / Ref. ST-800 161 After tuning engine, check engine no load speed with a tachometer (see table for no load speeds). If necessary , adjust speed as follows: Start engine and run until warm. T urn Amperage/V oltage Control to 100. Standard Models: 1 Engine Speed Adjustmen[...]

OM-480 Page 29 7-6. Overload Protection Ref. ST-156 199-B / ST -801 320-B  Stop engine.  When a fuse opens, it usually indicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. 1 Magnetic Shutdown Switch MS1 (Optional) 2 Fuse F (See Parts List) Fuse F protects magnetic shut- down switch MS1. If fuse F opens, the e[...]

OM-480 Page 30 7-8. Inspecting And Cleaning Optional Spark Arrestor ST-800 523 / Ref. ST -188 448  Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhau[...]

OM-480 Page 31 B. Auxiliary Power T rouble Remedy No output at auxiliary power receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 6-1 or 6-2). Disconnect equipment from auxiliary power receptacles during start-up. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Low or high output at auxi[...]

OM-480 Page 32 SECTION 8 – ELECTRICAL DIAGRAM SC-190 650-B Figure 8-1. Circuit Diagram For Welding Generator[...]

OM-480 Page 33 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 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-480 Page 34 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-480 Page 35 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 Place A/V range switch in maxi- mum position, A/V cont[...]

OM-480 Page 36 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-480 Page 37 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-480 Page 38 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-480 Page 39 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-480 Page 40 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-480 Page 41 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-480 Page 42 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-480 Page 43 Notes[...]

OM-480 Page 44 SECTION 1 1 – P ARTS LIST Figure 1 1-1. Main Assembly  Hardware is common and not available unless listed. 1 3 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 73 74 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 11 0 1 1 1(Fig 1 1-4) 11 2 11 4 11 5 11 6 11 7 11 8 11 9 120 121 122 123 124 125[...]

OM-480 Page 45 ST-129 956-T 19 20 21 22 23 24 25 26 27 28 29 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65(Fig 1 1 – 3) 66 67 68 69 70 30 31 33 34 35 36 37 38 32 40 41 42 43 44 126[...]

OM-480 Page 46 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 134 771 PLUG, protective .640sq 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 676 T ANK, fuel (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-480 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 128 287 STUD, adjusting throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ♦ 127 648 CLEVIS, throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-480 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 101 173 982 P ANEL, mtg components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 RC9 168 071 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-480 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Fig 1 1-1 Item 1 1 1) (Cont ’ d) Quantity 13 021 385 BOOT , toggle switch lever 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ♦ 129 860 GAUGE, oil pressure 1 . . . . . . . [...]

OM-480 Page 50 ST-1 10 922-F  Hardware is common and not available unless listed. 14 15 16 17 18 12 21 22 19 23 24 25 26 27 1 2 4 5 6 4 3 12 28 20 13 8 7 9 10 11 Figure 1 1-3. Generator[...]

OM-480 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Generator (Fig 1 1-1 Item 65) Quantity 1 106 426 INSULA T OR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-480 Page 52 Description Quantity Part No. Item No. 1 14 193 Figure 1 1-4. Switch, Range (Fig 1 1-2 Item 1) 1 1 14 235 BRACKET , mtg switch (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 671 SPRING, ext x .312 OD x .042 wire x 1.875pld 1 . . . . . . . . . . . . . . . . . .[...]

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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 Com pany 600 W est Mai n Street Troy , OH 45373 USA For T ech nical Assi stance: Call1-800-332-3281 For Lit erature Or Nearest D ealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o[...]