Hobart 3225D - Manuals - manualsarea.com

Page 2 - From Hobart to You

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Hobart distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-877-Ho...

Page 3 - CALIFORNIA; TABLE OF CONTENTS; WARNING

The following terms areused interchangeablythroughout this manual: Stick = SMAW CALIFORNIA Proposition 65Warning Diesel engine exhaust andsome of its constituentsare known to the State ofCalifornia to causecancer, birth defects, andother reproductive harm. TABLE OF CONTENTS SECTION 1 – SAFETY PRECAU...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.

OM-480 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This gro...

Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.

OM-480 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ove...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance

OM-480 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed 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 ne...

Page 8 - Principal Safety Standards

OM-480 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qualif...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-480 Page 5 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 procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message ...

Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur

OM-480 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendies...

Page 11 - LIRE LES INSTRUCTIONS.

OM-480 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branch...

Page 13 - SECTION 2 – DEFINITIONS; Symbols And Definitions

OM-480 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trai...

Page 14 - SECTION 3 – SPECIFICATIONS; Dimensions, Weights, And Operating Angles

OM-480 Page 10 SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC (Nominal) Auxiliary Power Rating Engine Fuel Capacity 250 A, 40 Volts DC, 100% Duty Cycle 40 – 400 95 (90) Single-Phase, 3 kVA/kW, 26 A,120 V AC, ...

Page 16 - AC Auxiliary Power

OM-480 Page 12 3-5. AC Auxiliary Power The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacles. rsb3.1 2/92 – ST-109 365-C 3-6. Volt-Ampere Curves ST-183 882 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe...

Page 17 - Optional AC Power Plant Curves

OM-480 Page 13 3-7. Optional AC Power Plant Curves rsb13.1 12/94 - ST-134 636-A / ST-134 637-A The ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt orthree-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 10 KV...

Page 18 - SECTION 4 – INSTALLATION; Installing Welding Generator; Connecting The Battery

OM-480 Page 14 SECTION 4 – INSTALLATION 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 tovehicle frame by metal-to-metalcontact. GND/PE 3 4 Always ground generatorframe to vehicle frame to pre-vent ...

Page 19 - Installing Muffler Pipe; Engine Prestart Checks

OM-480 Page 15 4-3. Installing Muffler Pipe exh_pipe2 12/96 – ST-154 089-A / ST-154 611 / Ref. ST-188 448 Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake. Top View 1/2 in Tools Needed: 4-4. Engine Prestart Checks Ref. ST-800 159-D Full 1/2 in (13 mm) Full Diesel Valve O...

Page 21 - Selecting Weld Cable Sizes

OM-480 Page 17 4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding 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 1...

Page 22 - SECTION 5 – OPERATING THE WELDING GENERATOR

OM-480 Page 18 SECTION 5 – OPERATING THE WELDING GENERATOR 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

Page 24 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; 20 Volt Duplex And Optional GFCI Receptacles

OM-480 Page 20 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 1 2 6-1. 120 Volt 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 ReceptacleRC1 2 120 V 15 A AC ReceptacleRC2 3 120 V 15 A AC GFCIReceptacles...

Page 26 - Connecting Optional Auxiliary Power Plant

OM-480 Page 22 6-3. Connecting Optional Auxiliary Power Plant Ref. S-179 637-B Stop engine. Power and weld outputs arelive at the same time.Disconnect or insulateunused cables. Have qualified person installaccording to circuit diagramand Auxiliary Power Guidelines(Section 10). Remove junction box co...

Page 28 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance

OM-480 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label.Service engine more often if used in severe condi-tions. * To be done by Factory Authorized Service Agent. 8 h Wipe ...

Page 29 - NOTE; Maintenance Label

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

Page 30 - Servicing Air Cleaner

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 redband appears in window. A greenband means air cleaner is okay.Press button to reset indicator. Do no...

Page 31 - Servicing Fuel And Lubrication Systems

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/Water Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff Valve 8 Fuel Line 9 Sludge Drain Plug To...

Page 32 - Adjusting Engine Speed

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 engineno load speed with a tachometer(see table for no load speeds). Ifnecessary, adjust speed as follows: Start engine and run until warm.Turn Amperage/Voltage Control to100. ...

Page 34 - Inspecting And Cleaning Optional Spark Arrestor; Troubleshooting

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 dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed toblow out cleanout hole. If nothingblo...

Page 36 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator

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

Page 37 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking

OM-480 Page 33 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking 1 Welding Generator Run diesel engines near rated out-put during run-in period to properlyseat piston rings and prevent wets-tacking. See nameplate or ratinglabel to find rated output. Do not idle engine longer thannecessary. ...

Page 38 - Run-In Procedure Using Load Bank

OM-480 Page 34 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Load Bank Turn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall receptacle or genera-tor auxi...

Page 39 - Run-In Procedure Using Resistance Grid

OM-480 Page 35 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Resistance Grid Use grid sized for generator ratedoutput. Turn Off grid. 2 Welding Generator Place A/V range switc...

Page 40 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame

OM-480 Page 36 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this ...

Page 41 - 0-3. Grounding When Supplying Building Systems

OM-480 Page 37 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 U...

Page 42 - 0-5. Approximate Power Requirements For Industrial Motors

OM-480 Page 38 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts 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 ...

Page 43 - 0-7. Approximate Power Requirements For Contractor Equipment

OM-480 Page 39 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts 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 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 i...

Page 45 - 0-10. Typical Connections To Supply Standby Power

OM-480 Page 41 10-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection. ...

Page 47 - Notes

Page 48 - SECTION 11 – PARTS LIST

OM-480 Page 44 SECTION 11 – PARTS LIST Figure 11-1. Main Assembly Hardware is common andnot 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 99 100 101 102 103 104 105 106 107 108 109 110 111(Fig 11-4) 112 114 115 116 117 11...

Page 59 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-877-HOBART1for your localHobart distributor. hobart standard 7/00 ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contact your distributor orcall 1-800-33...

Page 60 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equ...