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; WARNING
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.
OM-1594 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 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-1594 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-1594 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-1594 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-1594 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 – DEFINITIONS; Warning Label Definitions
OM-1594 Page 9 SECTION 2 – DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 5 6 + 2.3 S-178 936 A. Warning! Watch Out! There are possible hazards asshown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage duringoperation – keep hand...
Page 14 - Hz; Rating Label For CE Products
OM-1594 Page 10 1 Read the Owner’s Manual. 2 Do not overtighten wire spoolbrake pressure. Tighten onlyuntil wire does not overspoolfrom wire supply spool. 3 Do not overtighten drive rollpressure. Tighten only untildrive roll will not slip (motorwill not stall) on a stationarywire. ST-178 794-A 50/60...
Page 15 - Symbols And Definitions; Note; IP; SECTION 3 – INTRODUCTION; Specifications
OM-1594 Page 11 2-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire Feed Jog Output Trigger Gun Press To Set Increase Trigger Hold On Trigger Hold Off Purge Spot Weld Ti...
Page 16 - Duty Cycle And Overheating
OM-1594 Page 12 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Y Exceeding duty cycle candamage unit and voidwarranty. sduty1 5/95 6 Minutes Welding 4 Minutes Resting Continuous Welding Air-Cooled Models Water-Cooled Model...
Page 18 - Air-Cooled Feeder Connections
OM-1594 Page 14 4-2. Air-Cooled Feeder Connections Ref. 801 578-A 1 Gas Fitting Route one end of 10 ft (3 m) gashose to rear of unit, and connecthose to gas solenoid fitting.Connect remaining end of hose toregulator/flowmeter. 2 Weld Cable To Welding PowerSource Select and prepare weld cableaccordin...
Page 19 - Air-Cooled Gun Connections
OM-1594 Page 15 4-3. Air-Cooled Gun Connections Ref. 801 577-A / 801 564 / Ref. 151 666-A 1 Gun Control Cable Insert plug into Gun Controlreceptacle, and tighten threadedcollar. 2 Gas Hose 3 Reed Relay 4 Weld Cable 5 Weld Cable Terminal InFeeder Route weld cable from weldingpower source through reed...
Page 20 - Water-Cooled Feeder Connections
OM-1594 Page 16 4-4. Water-Cooled Feeder Connections Ref. 152 431-A / Ref. 801 578-A Obtain coolant supply. 1 Gas Fitting Route one end of 10 ft (3 m) gashose to rear of unit, and connecthose to gas solenoid fitting.Connect remaining end of hose toregulator/flowmeter. 2 Weld Cable To Welding PowerSo...
Page 21 - Water-Cooled Gun Connections
OM-1594 Page 17 4-5. Water-Cooled Gun Connections Ref. 801 577-A / 801 563 / Ref. 151 666-A 1 Gun Control Cable Insert plug into Gun Controlreceptacle, and tighten threadedcollar. 2 Gas Hose 3 Reed Relay 4 Weld Cable 5 Weld Cable Terminal InFeeder Route weld cable from weldingpower source through re...
Page 22 - 4-Pin Plug Information; Voltage Sensing Lead Connections
OM-1594 Page 18 4-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. A J K I G Circuit common for 24 volts AC circuit. B I C L N H C +10 volts dc output to remote control with respect to sock...
Page 23 - Optional Meter Circuit Board Settings
OM-1594 Page 19 4-8. Optional Meter Circuit Board Settings Ref. 802 359 / Ref. 186 266 Tools Needed: 1/4 in 1 Meter Board PC2 2 DIP Switch S2 Set DIP switch S2 for type ofwelding power source, and desiredwire feed speed display. Reinstall hinged door and sidepanel. 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 ...
Page 24 - Adjusting Contact Tip Position
OM-1594 Page 20 4-9. Adjusting Contact Tip Position Ref. 801 556 / 150 434 / Ref. 150 431 / Ref. 151 666-A 1 Contact Tip 2 Nozzle Adjusting barrel changes contacttip location from 1/16 in (1.6 mm)out beyond end of nozzle to 1/4 in(6.3 mm) inside nozzle. 3 Nozzle Adapter Lock Nut 4 Nozzle Adapter To ...
Page 25 - -11. Removing Top Cover Of Pistol Grip Gun
OM-1594 Page 21 4-11. Removing Top Cover Of Pistol Grip Gun 1 Top Cover Push back and lift off as shown. To reinstall cover, set rear of coverin gun, and push cover back, down,and forward until it clicks intoposition. 802 528 1 4-12. Installing Wire Spool Ref. 801 578-A / Ref. 072 573-B / Ref. 801 5...
Page 26 - -13. Threading Welding Wire Through Feeder
OM-1594 Page 22 4-13. Threading Welding Wire Through Feeder Ref. 802 193-A Tools Needed: Pull and hold wire; cut off end. Hold wire tightly to keepit from unraveling. 6 in (150 mm) Open tension arm. Thread wire thru inlet guide, along drive roll groove, andinto wire conduit. Close tension arm. Adjus...
Page 28 - -15. Adjusting Wire Feed Starting Speed
OM-1594 Page 24 4-15. Adjusting Wire Feed Starting Speed To adjust wire feed starting speed,proceed as follows: 1 Motor Speed Control BoardPC1 2 Motor Start ControlPotentiometer R3 Remove protective white rubbercap before making adjustment.Adjust potentiometer using a smallnonconductive screwdriver....
Page 29 - -16. Setting Switches For Preflow And Postflow
OM-1594 Page 25 4-16. Setting Switches For Preflow And Postflow . Unit arrives from the factorywith preflow Off and postflowturned On. To set switches for preflow andpostflow, proceed as follows: 1 Motor Speed Control BoardPC1 2 DIP Switch S1 . Preflow and postflow have pre-set time values and canno...
Page 30 - -17. Adjusting Trigger Hold Actuation Time
OM-1594 Page 26 4-17. Adjusting Trigger Hold Actuation Time To adjust trigger hold actuationtime, proceed as follows: 1 Motor Speed Control BoardPC1 2 Potentiometer R50 . Trigger hold actuation timerange is from 0 to 4 seconds. To decrease trigger hold actuationtime, use a small nonconductivescrewdr...
Page 31 - SECTION 5 – OPERATION; Controls
OM-1594 Page 27 SECTION 5 – OPERATION 5-1. Controls 801 554 1 Voltage/Wire Speed Meter (Optional) 2 Voltage/Wire Speed Switch (Optional) When switch is in Voltage position, andoperator is welding, meter displays arcvoltage. Cable resistance and poorconnections may cause displayed voltage tovary slig...
Page 32 - Internal Controls
OM-1594 Page 28 5-2. Internal Controls Ref. 801 578 Open left side door. 1 Run-In Speed Control Use this control to set run-in wirefeed speed before arc initiation. After arc initiation, weld wire feedspeed is controlled by the wirespeed setting on the welding gun(see Section 5-3). The scale around ...
Page 34 - Sequence Of Gas Metal Arc Welding (GMAW) – Continuous Or Spot; SECTION 6 – MAINTENANCE & TROUBLESHOOTING; Months
OM-1594 Page 30 5-6. Sequence Of Gas Metal Arc Welding (GMAW) – Continuous Or Spot Begin Welding ssb6.1* 9/92 Install & Connect Equipment Put On Personal Safety Equipment Set Controls Turn On Gas And Water (If Applicable) Turn On Feeder And Welding Power Source SECTION 6 – MAINTENANCE & TROU...
Page 35 - Feeder Drive Assembly Maintenance
OM-1594 Page 31 6-1. Feeder Drive Assembly Maintenance 802 193-A Retract wire onto spool. 1 Pressure Roll Assembly 2 Drive Motor Shaft 3 Drive Roll 4 Screw Use wire brush to clean drive roll. 5 Drive Roll Idler 6 Shoulder Washers Use wire brush to clean idler. 7 Outlet Guide 8 Wire Inlet Guide Pull ...
Page 36 - Gun Drive Assembly Maintenance For An XR-Edge Gun
OM-1594 Page 32 6-2. Gun Drive Assembly Maintenance For An XR-Edge Gun Ref. 801 556 Retract wire onto spool. 1 Screw 2 Drive Roll Use wire brush to clean drive roll.Install drive roll with hex openingdown toward shaft hex, and securewith screw. . Apply conductive grease todrive roll post every 4 to ...
Page 38 - Replacing Gun Cable Liner
OM-1594 Page 34 Ref. 151 599-C / Ref. 802 652 / Ref. 801 556 / 801 564 / Ref. 151 666-A / Ref. 200 371 6-5. Replacing Gun Cable Liner Y Turn Off welding powersource and wire feeder. 1 Drive Roll 2 Collet Nut Lay gun cable out straight. Removedrive roll on gun and loosen colletnut on liner tube assem...
Page 45 - Notes
Page 46 - Figure 7-1. Circuit Diagram For Wire Feeder
OM-1594 Page 42 SECTION 7 – ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram For Wire Feeder
Page 50 - SECTION 8 – PARTS LIST
OM-1594 Page 46 SECTION 8 – PARTS LIST . Hardware is common andnot available unless listed. ST-802 230 49 – Figure 8-2 45 – Figure 8-3 1 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 28 29 30 31 32 33 34 35 36 37 38 39 40 42 41 43 44 50 51 52 53 57 46 47 48 54 55 56 58 Figure...
Page 67 - (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 68 - 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...
