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Hobart 3225DX manual

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Table of contents for the manual

  • Page 1

    Processes OM -130 098V August 2000 Contractor 3225DX Stick (SMA W) W elding Flux Cored (FCAW) With V oltage-Sensing Wire Feeder With Optional Equipment: Air Carbon Arc (CAC-A) Cut- ting And Gouging Descripti on TIG (GT A W) W elding Visit our website at www.HobartWelders.com[...]

  • Page 2

    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[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-130 098 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 arnin[...]

  • Page 6

    OM-130 098 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks c a n fly of f 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 [...]

  • Page 7

    OM-130 098 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 [...]

  • Page 8

    OM-130 098 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[...]

  • Page 9

    OM-130 098 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 p[...]

  • Page 10

    OM-130 098 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 [...]

  • Page 11

    OM-130 098 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[...]

  • Page 12

    OM-130 098 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 quali[...]

  • Page 13

    OM-130 098 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 o[...]

  • Page 14

    OM-130 098 Page 10 SECTION 3 – SPECIFICA TIONS 3-1. W eld, Power , And Engine Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC (Nominal) Auxiliary Power Rating Engine Fuel Capacity 400 A, 40 V olts DC, 40% 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-Coo[...]

  • Page 15

    OM-130 098 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 m in - utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 40% Duty Cycle A[...]

  • Page 16

    OM-130 098 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 [...]

  • Page 17

    OM-130 098 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 [...]

  • Page 18

    OM-130 098 Page 14 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 3/96 – 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 1 Generator Base 2 Metal V ehicle Frame 3 Equipment Grounding T erminal 4 Grounding Cable Use #1[...]

  • Page 19

    OM-130 098 Page 15 4-3. Activating The Dry Charge Battery drybatt1 2/96 – S-0886 Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai[...]

  • Page 20

    OM-130 098 Page 16 4-4. Connecting The Battery ST-156 01 1-A / Ref. ST -188 449 / S-0756 1/2 i n + –  Connect Negative ( – ) Cable Last. T ools Needed: 4-5. Engine Prestart Checks Ref. ST-801 739 Full 1/2 i n (13 mm) Full Diesel V alve Open Check all fluids daily . Engine must be cold and on a level surface. Follow run-in procedure in engine[...]

  • Page 21

    OM-130 098 Page 17 ether1 12/96 – ST-153 382-A / Ref. ST -188 449  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 [...]

  • Page 22

    OM-130 098 Page 18 4-8. 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[...]

  • Page 23

    OM-130 098 Page 19 Notes[...]

  • Page 24

    OM-130 098 Page 20 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Controls (See Section 5-2) Ref. ST-188 449 / ST -800 162-A / ST-800 159-D 14 15 1 2 12 13 5 3 4 6 7 10 11 8 9[...]

  • Page 25

    OM-130 098 Page 21 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 w[...]

  • Page 26

    OM-130 098 Page 22 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt And 240 V olt Duplex Receptacles Ref. ST-188 449 12  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord.  Auxiliary power is not affected by weld output. If a circuit breaker continues to open, contact Factory Autho- rized Service Agent.[...]

  • Page 27

    OM-130 098 Page 23 6-2. Optional Auxiliary Power Receptacles Ref. ST-188 449 / ST -174 408  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord.  Auxiliary power is not affected by weld output. If a circuit breaker continues to open, contact Factory Autho- rized Service Agent. GFCI Receptacle Option 1 120 V 15 A AC G[...]

  • Page 28

    OM-130 098 Page 24 6-3. Connecting Optional Auxiliary Power Plant Ref. S-188 059-A  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 [...]

  • Page 29

    OM-130 098 Page 25 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. * T o be done by Factory Authorized Service Agent. 8 h Wipe Up Spills. Check Fluid Levels. Se[...]

  • Page 30

    OM-130 098 Page 26 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[...]

  • Page 31

    OM-130 098 Page 27 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 ai r cle[...]

  • Page 32

    OM-130 098 Page 28 7-4. Servicing Fuel And Lubrication Systems Ref. ST-801 739 / Ref. ST -188 449  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 manu[...]

  • Page 33

    OM-130 098 Page 29 7-5. Adjusting Engine Speed Ref. ST-801 179 / Ref. ST -801 739 / 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 Adjustm[...]

  • Page 34

    OM-130 098 Page 30 7-6. Overload Protection Ref. ST-156 199-B / ST -801 740  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[...]

  • Page 35

    OM-130 098 Page 31 7-8. Inspecting And Cleaning Optional Spark Arrestor ST-800 523 / Ref. ST -188 449  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 e[...]

  • Page 36

    OM-130 098 Page 32 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 [...]

  • Page 37

    OM-130 098 Page 33 SECTION 8 – ELECTRICAL DIAGRAM SC-190 649-A Figure 8-1. Circuit Diagram For Welding Generator[...]

  • Page 38

    OM-130 098 Page 34 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 engi[...]

  • Page 39

    OM-130 098 Page 35 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[...]

  • Page 40

    OM-130 098 Page 36 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 [...]

  • Page 41

    OM-130 098 Page 37 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. [...]

  • Page 42

    OM-130 098 Page 38 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 elec[...]

  • Page 43

    OM-130 098 Page 39 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 28[...]

  • Page 44

    OM-130 098 Page 40 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts 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 i[...]

  • Page 45

    OM-130 098 Page 41 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 startin[...]

  • Page 46

    OM-130 098 Page 42 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 Disconnec[...]

  • Page 47

    OM-130 098 Page 43 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) [...]

  • Page 48

    OM-130 098 Page 44 SECTION 1 1 – P ARTS LIST Figure 1 1-1. Main Assembly 3 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 82 83 84 85 86 87 88 89 90 91 92 94 93 95 96 97 98 99 100 101 102 103 104(Fig.1 1 – 2) 105 106 107 108 109 11 0 111 11 2 11 3 11 4 11 5 11 6 11 7 11 8 71(Includes 72 – 77) 72 73 74 75 76 77 78 79 80 81 99[...]

  • Page 49

    OM-130 098 Page 45 ST-801 653-F 18 20 19 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 31 39 40 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 FIG 1 1 – 4 66 67 68 69 70 44[...]

  • Page 50

    OM-130 098 Page 46 Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly 1 134 771 PLUG, protective .640sq 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 107 972 T ANK, fuel (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 51

    OM-130 098 Page 47 Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) 51 127 994 BALL JOINT , .250-28 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 175 936 ROD, throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 52

    OM-130 098 Page 48 102 +173 317 P ANEL, front lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) 103 CR2 044 588 RELA Y , encl 12VDC 3PDT 1 . . . . . . . . . . . . . . . . . . . .[...]

  • Page 53

    OM-130 098 Page 49 Optional Equipment Description Quantity Part No. 043 096 RECEPT ACLE KIT , 120V GFCI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE PROTECTION P ACKAGE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 042 318 AUTOMA TIC SHUTDOWN, l[...]

  • Page 54

    OM-130 098 Page 50 1 Fig 1 1 -3 ST-801 652-B 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 27 Figure 1 1-2. Panel, Front w/Components[...]

  • Page 55

    OM-130 098 Page 51 Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-2. Panel, Front w/Components (Fig 1 1-1 Item 104) 1 S3 1 14 193 SWITCH, range (Fig 1 1-3) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R1 605 960 RHEOST A T , WW 300W 34 ohm 1 . . . . . . . . . . . . . .[...]

  • Page 56

    OM-130 098 Page 52 Figure 1 1-3. Generator 7 8 9 10 11 14 15 16 17 18 12 21 22 19 23 24 25 26 27 1 2 4 5 6 4 3 12 28 20 ST-1 10 922-D 13[...]

  • Page 57

    OM-130 098 Page 53 Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-3. Generator (Fig 1 1-1 Item 65) 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 58

    OM-130 098 Page 54 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 . . . . . . . . . . . . . . . .[...]

  • Page 59

    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[...]

  • Page 60

    PRINTED IN USA  2001 Hobart Welding Products. 1/01 Hoba rt W elding Product s An I l li noi s T ool W orks Company 600 West M ain St reet Troy , OH 45373 US A For Technical Assi stance: Call1-800-332-3281 For Lit erat ure Or Neares t Deal er: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]