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 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...
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-1581 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This...
Page 6 - WELDING can cause fire or explosion.
OM-1581 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 a welding helmet fitted with a proper shade of filter to protectyour face and eyes wh...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-1581 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 8 - EMF Information
OM-1581 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining mo...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-1581 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 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. Y Identifie un messag...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-1581 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer des...
Page 13 - SECTION 2 – SPECIFICATIONS; Wire Feeder Specifications; Gun Specifications; Duty Cycle And Overheating
OM-1581 Page 9 SECTION 2 – SPECIFICATIONS 2-1. Wire Feeder Specifications Specification Description Type Of Input Power 115 Volts AC, 3 Amperes At 50/60 Or 100 Hz Power Control Circuit Voltage Provided At Gun 30 Volts DC Wire Feed Speed Range 70-875 ipm (1.9-22.2 mpm) Overall Dimensions Length: 19 i...
Page 14 - Read entire Section 3 before installing equipment.
OM-1581 Page 10 SECTION 3 – INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. SeeSection 5 to change parts as needed. See Section 7 for list of other availablecontact tips. NOTE Review Section 3-1 through Section 3-4 to determine how equipment will be ...
Page 16 - Removing Top Cover Of Gun
OM-1581 Page 12 3-4. Connections With A CC Welding Power Source And A 115 VAC/12 VDC SecondaryContactor 1 Constant Current (CC) Weld-ing Power Source 2 Workpiece 3 Voltage Sensing Lead 4 Gun 5 Wire Feeder 6 3-Conductor 115 VAC Cord 7 3-Conductor Contactor Con-trol Cord 8 5-Pin Plug 9 Secondary Conta...
Page 17 - Air-Cooled Gun Connections
OM-1581 Page 13 3-6. Air-Cooled Gun Connections 3 1 Gun Control Cable Insert plug into Gun Control recep-tacle, and tighten threaded collar. 2 Gas Hose Connect to Gas fitting on feeder. 3 Weld Cable 4 Weld Cable Terminal InFeeder Connect gun weld cable to weldcable terminal in feeder. 5 Wire Conduit...
Page 18 - Water-Cooled Gun Connections
OM-1581 Page 14 3-7. Water-Cooled Gun Connections 1 Gas Hose Connect to Gas fitting on feeder. 2 Water Hose Connect to Water To Gun fitting onfeeder (left-hand threads). 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew, and insertconduit through Wire opening untilit bottoms against...
Page 19 - Air-Cooled Feeder Connections
OM-1581 Page 15 3-8. Air-Cooled Feeder Connections 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose throughgrommet, and connect hose to rearof Gas fitting in feeder. Connectremaining end of hose toregulator/flowmeter. 4 Weld Cable To Welding PowerSource Selec...
Page 20 - Water-Cooled Feeder Connections
OM-1581 Page 16 3-9. Water-Cooled Feeder Connections Obtain coolant supply. 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose throughgrommet, and connect hose to rearof Gas fitting in feeder. Connectremaining end of hose toregulator/flowmeter. 4 Coolant Supply...
Page 23 - Twistlock Plug
OM-1581 Page 19 3-13. Replacing 115 VAC/Contactor Control Plug With Customer-Supplied 5-Pin Or Twistlock Plug 1 115 VAC/Contactor ControlPlug PLG5 2 Contactor Control Cord 3 115 VAC Cord Find and label cords by followingleads to back of PLG5: Contactor control cord connects topins A & B of PLG5 ...
Page 25 - -15. Threading Welding Wire Through Feeder
OM-1581 Page 21 3-15. Threading Welding Wire Through Feeder 1 Wire Spool Loosen wire from spool, cut off bentwire, and pull 6 in (150 mm) of wireoff spool. 2 Tension Arm 3 Mounting Arm To open pressure roll assembly,open tension arm and lift mountingarm. 4 Wire Inlet Guide 5 Drive Roll 6 Wire Condui...
Page 26 - CAUTION
OM-1581 Page 22 3-16. Threading Welding Wire Through Gun 1 Pressure Roll Assembly Lift arm and open pressure rollassembly. 2 Wire Conduit Lay wire conduit out straight. 3 Jog Switch Push Jog switch up to feed wirethrough wire conduit. 4 Drive Roll For wire sizes .035 in (0.9 mm) andsmaller use small...
Page 27 - -18. Adjusting Wire Feed Starting Speed
OM-1581 Page 23 3-18. Adjusting Wire Feed Starting Speed 1 2 Top Of PC1 Ref. 151 772-A / Ref. 142 054-B To adjust wire feed starting speed,proceed as follows: Turn Off wire feeder and weldingpower source. Open right sidepanel. 1 Motor Speed Control BoardPC1 2 Motor Start ControlPotentiometer R70 Tur...
Page 28 - SECTION 4 – OPERATION; Safety Equipment
OM-1581 Page 24 SECTION 4 – OPERATION 4-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 1 Voltage/Wire Speed Meter(Optional) 2 Voltage/Wire Speed Switch(Optional) 3 Run-In Speed Control 4 Jog Switch 5 Burnback Time Control(Optional) 6 Spot/Continuous Switch(Optional) 7 Remote Voltage Cont...
Page 30 - Power Switch
OM-1581 Page 26 4-7. Spot Controls (Optional) 1 Spot/Continuous Switch Use switch to select either an un-timed continuous weld cycle or atimed spot weld cycle. Both weldcycles consist of the followingsteps: run-in, weld (untimed or spottime), and burnback. 2 Time Range Switch Use switch to select sp...
Page 33 - SECTION 5 – MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Months
OM-1581 Page 29 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Turn Off all power before maintaining. 3 Months OR Blow Out Or Vacuum Inside Replace Unreadable Labels 6 Months Clean Drive Rolls 5-2 Clean And Tighten Weld Terminals 3-8 3 Months – – See Section 7 Tape Or Replace...
Page 34 - Changing Or Cleaning Gun Drive Roll
OM-1581 Page 30 5-2. Changing Or Cleaning Gun Drive Roll Turn Off wire feeder and weldingpower source. 1 Top Cover 2 Pressure Roll Assembly Cut off wire where it enterspressure roll assembly area. 3 Setscrew 4 Current Pick-Up Tab This tab helps prevent burnbackcaused by welding arcs inside thecontac...
Page 35 - Changing Feeder Drive Roll And Wire Inlet Guide
OM-1581 Page 31 5-3. Changing Feeder Drive Roll And Wire Inlet Guide Turn Off wire feeder and weldingpower source. Lay wire conduit outstraight. Open gun pressure roll assembly,and cut welding wire off at contacttip. 1 Pressure Roll Assembly 2 Wire Spool For welding power sources withoutcontactor, r...
Page 38 - Removing Contact Tip Adapter In Water-Cooled Models; WARNING; Replacing Hub Assembly
OM-1581 Page 34 5-8. Removing Contact Tip Adapter In Water-Cooled Models WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality. • Turn Off welding power source and water supply before working on gun. Stop engine on welding generators. • Always point gun downward when removing water-...
Page 40 - A. Wire Feeder Trouble
OM-1581 Page 36 5-13. Troubleshooting A. Wire Feeder Trouble Trouble Remedy Pressing gun trigger does not energizefeeder. Welding wire is not energized.Shielding gas flows. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 3-6). Secure 115 VAC input plug connectio...
Page 42 - SECTION 6 – ELECTRICAL DIAGRAMS; Figure 6-1. Circuit Diagram For Wire Feeder
OM-1581 Page 38 SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Wire Feeder 156 399-C
Page 44 - SECTION 7 – PARTS LIST
OM-1581 Page 40 SECTION 7 – PARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 20 21 22 23 24 25 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 59 61 62 71 Fig 7-2 72 73 74 75 76 77 78 79 Figure 7-1. Main Assembly Fig 7-3 63 64 65 66 67 ...
Page 55 - (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 56 - 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...
