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 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-925 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining...
Page 6 - WELDING can cause fire or explosion.
OM-925 Page 2 Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld. ARC RAYS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil-ter lenses to protect you...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-925 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 nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly sized, ...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc
OM-925 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro-cédure comporte...
Page 10 - peuvent
OM-925 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS D’ARC peuvent entraî-ner des br...
Page 11 - LIRE LES INSTRUCTIONS.; Proposition californienne 65 Avertissements
OM-925 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO-SION. D Ne pas placer l’appareil sur, au-dessus ouà proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité deproduits inflammables. D Ne...
Page 13 - SECTION 3 − DEFINITIONS; Symbols And Definitions; Hz; SECTION 4 − SPECIFICATIONS; Specifications
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V Voltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output Voltage Input Off On Do Not Switch While Welding Gas Metal Arc Welding (GMAW)...
Page 14 - Duty Cycle And Overheating; A or V; Output Amperes
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 10 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forun...
Page 16 - SECTION 5 − INSTALLATION; Installing Welding Gun; Installing Work Clamp
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 12 SECTION 5 − INSTALLATION 5-1. Installing Welding Gun 803 711-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew. Insert end ofgun through opening in frontpanel until it bottoms againstdrive assembly. T...
Page 17 - Process/Polarity Table; Changing Polarity
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 13 5-3. Process/Polarity Table Process Polarity Cable Connections Process Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield-ing gas DCEP − Reverse polarity Connect to positive (+) out-put terminal Connect to ne...
Page 18 - Installing Gas Supply
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 14 5-5. Installing Gas Supply Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve,and open valve ...
Page 19 - Selecting A Location And Connecting Input Power
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 15 5-6. Selecting A Location And Connecting Input Power 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual branchcircuit protected by time-delay fuses orcircuit breaker is required. 3 Plug From Unit Select e...
Page 20 - Installing Wire Spool And Adjusting Hub Tension
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 16 5-7. Installing Wire Spool And Adjusting Hub Tension When a slight force is neededto turn spool, tension is set. 1/2 in Tools Needed: Installing 8 in (203 mm) Wire Spool Installing 4 in (102 mm) Wire Spool When a slight for...
Page 21 - Installing Contact Tip And Nozzle
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 17 5-8. Installing Contact Tip And Nozzle Tools Needed: Ref. 802 399-A Y Turn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (seeSection 5-9). Slide contact tip ov...
Page 22 - Threading Welding Wire
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 18 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. Tools Needed: Pull and hold wire; cut off end. Open pressure...
Page 24 - SECTION 6 − OPERATION; Controls
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 20 SECTION 6 − OPERATION 6-1. Controls 1 Wire Speed Control Use control to select a wire feed speed. AsVoltage switch setting increases, wirespeed range also increases (see weldsetting label in welding power source orSection 6...
Page 25 - Notes; MATERIAL THICKNESS REFERENCE CHART
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 21 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA...
Page 26 - Weld Parameter Chart
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 22 6-2. Weld Parameter Chart
Page 28 - SECTION 7 − MAINTENANCE & TROUBLESHOOTING; Routine Maintenance
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 24 SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factory...
Page 29 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 25 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide SecuringScrew 2 Inlet Wire Guide Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw. 3 Drive Roll The drive roll consist...
Page 30 - Cleaning Or Replacing Gun Liner
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 26 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446-A 8 mm / 10mm Y Disconnect gun from unit. Tools Needed: To Reassemble Gun: Insert new liner. Install wire outlet guide so that 1/8in (3 mm) of liner sticks out. Handtighten ...
Page 32 - Troubleshooting Table
. A complete Parts List is available at www.HobartWelders.com OM-925 Page 28 7-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fandoes not run. Secure power cord plug in receptacle (see Section 5-6). does not run. Replace building line fuse or reset circuit breaker if ope...
Page 33 - SECTION 8 − ELECTRICAL DIAGRAM
OM-925 Page 29 SECTION 8 − ELECTRICAL DIAGRAM 230 952-A Figure 8-1. Circuit Diagram
Page 34 - Typical MIG Process Connections
OM-925 Page 30 SECTION 9 − MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. Wire Feeder/ Power Source Workpiece Gun Regu...
Page 35 - Typical MIG Process Control Settings; NOTE
OM-925 Page 31 9-2. 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 sure they comply tospecifications. NOTE 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200...
Page 36 - Holding And Positioning Welding Gun
OM-925 Page 32 9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing 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. NOTE 1 Hold Gun and Control GunTr...
Page 37 - Conditions That Affect Weld Bead Shape
OM-925 Page 33 9-4. 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. NOTE Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXTEN...
Page 38 - Gun Movement During Welding; Poor Weld Bead Characteristics
OM-925 Page 34 9-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide groove weld joints or bridging across gaps, a weave bead ormultiple stringer beads works better. NOTE 1 Stringer Bead − SteadyMovement Along Seam 2 We...
Page 41 - -14. Troubleshooting − Waviness Of Bead
OM-925 Page 37 9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not coverjoint 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) bey...
Page 42 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment
OM-925 Page 38 9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table. Application Gas Spra...
Page 44 - SECTION 10 − ACCESSORIES/CONSUMABLES
OM-925 Page 40 SECTION 10 − ACCESSORIES/CONSUMABLES 10-1. Accessories PART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max. 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max. 195 186 Protective Cover Weath...
Page 45 - Pros weld and cut
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.
Page 46 - Start Your Professional
Notes 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Your Professional Welding Career Now!
Page 48 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 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 ...
