Page 2 - From Hobart to You; Register your product at:; Protect Your Investment!
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local Hobartdistributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.
OM-235 281 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009 − 07 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible h...
Page 6 - FUMES AND GASES can be hazardous.; ARC RAYS can burn eyes and skin.; WELDING can cause fire or explosion.; BUILDUP OF GAS can injure or kill.
OM-235 281 Page 2 Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove...
Page 7 - ARC WELDING can cause interference.
OM-235 281 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly s...
Page 9 - SECTION 2; CONSIGNES DE SÉCURITÉ; UNE DÉCHARGE ÉLECTRIQUE peut
OM-235 281 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la m...
Page 12 - -4. Proposition californienne 65 Avertissements
OM-235 281 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer de...
Page 15 - -2. Welding Power Source Duty Cycle And Overheating; A or V; WELD AMPERES
OM-235 281 Page 11 SECTION 3 − INTRODUCTION 3-1. Specifications Rated Output Max. Open Circuit Voltage Amps Input at Rated Output, 60 Hz, Single-Phase 200 V 230 V KVA KW 175 A at 25.5 VDC, 60% Duty Cycle 38 37.0 2.4* 32.5 2.3* 7.4 0.54* 6.3 0.30* * While idling Wire Type and Diameter No Load Wire Fe...
Page 16 - Voltage
OM-235 281 Page 12 3-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 − 240 913-A 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 0 50 100 150 200 250 300 Voltage Ampe...
Page 18 - -5. Connecting To Weld Output Terminals
OM-235 281 Page 14 3-5. Connecting To Weld Output Terminals 803 778-A ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3...
Page 19 - Changing Polarity; -8. Installing 2 lb Wire Spool And Adjusting Hub Tension
OM-235 281 Page 15 3-7. Setting Gun Polarity For Wire Type Tools Needed: 3/4 in Ref. 242 145-A Shown as shipped - Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or fluxcore with gas wires (GMAW). Electrode Negative (DCEN): Reverse lead connections at terminals from thatshown ...
Page 20 - -9. Installing 10 lb Wire Spool And Adjusting Hub Tension; -10. Installing 33 lb Wire Spool And Adjusting Hub Tension
OM-235 281 Page 16 3-9. Installing 10 lb Wire Spool And Adjusting Hub Tension 242 147-A 1 Spool Hub 2 Spool Hub Adapter 3 Spool Hub Nut 4 Keyed Washer (2) 5 Compression Spring 6 Washer 7 Nut Assemble components in numer- ical order as shown.Slide spool hub adapter up on hub for the smaller spool mak...
Page 24 - -14. Selecting A Location And Connecting Input Power
OM-235 281 Page 20 3-14. Selecting A Location And Connecting Input Power Ref. 242 691-A / 802 286-E ! Do not move or operate unit where it could tip. 18 in (457 mm) of space for airflow ! Installation must meet all National and Local Codes − have only quali- fied persons make this installation. ! Sp...
Page 26 - -16. Installing Optional DP 3545 Spool Gun To Welding Power Source
OM-235 281 Page 22 SPOOL GUN MIG GUN 3-16. Installing Optional DP 3545 Spool Gun To Welding Power Source 242 143-A / 242 154-A ! Turn Off unit, and disconnect input power. 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew. Insert gun end through opening until it bott...
Page 30 - -3. Replacing Drive Roll And Wire Inlet Guide
OM-235 281 Page 26 5-3. Replacing Drive Roll And Wire Inlet Guide 242 533-A 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.3 Drive Roll The drive roll consists of two differ- ent sized grooves. The stamped markings on t...
Page 33 - Casing
OM-235 281 Page 29 5-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 242 207-A ! Turn off welding power source/wire feeder. 1 Nozzle 2 Contact Tip 3 Tip Adapter 4 Nozzle Adapter . Wire size stamped on tip − check and match wire size. Head Tube Tools Needed: 5/8,...
Page 34 - Troubleshooting Table
OM-235 281 Page 30 5-9. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-14). Place Power switch in the ON position. Place MIG/Spool Gun switch in the proper position. Check and replace Power switch if necess...
Page 35 - SECTION 6
OM-235 281 Page 31 SECTION 6 − MIG WELDING (GMAW) GUIDELINES Wire Feeder/ Power Source Workpiece Gun Regulator/ Flowmeter Gas Shielding Gas Work Clamp 6-1. Typical MIG Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehic...
Page 36 - Typical MIG Process Control Settings
OM-235 281 Page 32 6-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 2...
Page 37 - Holding And Positioning Welding Gun
OM-235 281 Page 33 6-3. Holding And Positioning Welding Gun . Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam. 1 Hold Gun and Control Gun...
Page 38 - Conditions That Affect Weld Bead Shape
OM-235 281 Page 34 6-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage. Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXT...
Page 42 - Waviness Of Bead; Distortion
OM-235 281 Page 38 6-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm...
Page 43 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment; Problem
OM-235 281 Page 39 6-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Ga...
Page 45 - Figure 7-1. Circuit Diagram For Welding Power Source
OM-235 281 Page 41 SECTION 7 − ELECTRICAL DIAGRAM 240 907-A Figure 7-1. Circuit Diagram For Welding Power Source
Page 56 - Hobart Welding Products; Please complete and retain with your personal records.; To locate a Distributor,; Contact your Distributor for:; Resources Available; For technical assistance:
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Hobart Welding Products. 2009 − 01 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1 Model Name Serial/Style Nu...
