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-227 978 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 adjoi...
Page 6 - WELDING can cause fire or explosion.
OM-227 978 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...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-227 978 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 siz...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc
OM-227 978 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 comp...
Page 10 - peuvent
OM-227 978 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 de...
Page 11 - LIRE LES INSTRUCTIONS.; Proposition californienne 65 Avertissements
OM-227 978 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. ...
Page 13 - SECTION 3 − DEFINITIONS; Symbols And Definitions; Hz; SECTION 4 − SPECIFICATIONS; Specifications
OM-227 978 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) Wire Feed Flux Cored Arc Welding (FCAW) SECTION 4 − SPECI...
Page 14 - Duty Cycle And Overheating; A or V; Output
OM-227 978 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 forunit to cool. Reduce amperage orduty cycle before welding. Y...
Page 15 - SECTION 5 − INSTALLATION; Installing Welding Gun; Installing Work Clamp
OM-227 978 Page 11 SECTION 5 − INSTALLATION 5-1. Installing Welding Gun 804 686-A 1 Drive Assembly 2 MIG Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew. Insert endthrough opening until it bottomsagainst drive assembly. Tightenthumbscrew. Welding gun must be insertedcompletely to prevent l...
Page 16 - Process/Polarity Table; Changing Polarity
OM-227 978 Page 12 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 negative (−) outputterminal FCAW − Self-shielding wire −no s...
Page 17 - Installing Gas Supply
OM-227 978 Page 13 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 slightly. Gas flowblows dust and dirt from valve.Close val...
Page 18 - Selecting A Location And Connecting Input Power
OM-227 978 Page 14 5-6. Selecting A Location And Connecting Input Power Y Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20. Y Installation must meet all Na-tional and Local Codes −have only qualified personsmake this installation...
Page 20 - Installing Contact Tip And Nozzle
OM-227 978 Page 16 5-9. 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 5-11). Slide contact tip over wire and tightentip into tip adapter. Install nozzle. ...
Page 23 - SECTION 6 − OPERATION; Controls
OM-227 978 Page 19 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 6-2, as applicable). 2 Power Switch 3 Voltage Switch The hi...
Page 24 - Weld Parameter Chart For 230 VAC Model
OM-227 978 Page 20 6-2. Weld Parameter Chart For 230 VAC Model /
Page 26 - SECTION 7 − MAINTENANCE &TROUBLESHOOTING; Routine Maintenance
OM-227 978 Page 22 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 Authorized Service Agent Reference Every l Unreadable Labe...
Page 27 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
OM-227 978 Page 23 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 Retaining Pin To remove drive roll, push drive rollin and rotate it (1/4 turn) to the opens...
Page 28 - Cleaning Or Replacing Gun Liner
OM-227 978 Page 24 7-6. Cleaning Or Replacing Gun Liner Ref. 804 692-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 outlet guide, and thentighten two full turns more. Cut lin...
Page 30 - Troubleshooting Table
OM-227 978 Page 26 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 open. Place Power switch in On position (see Section 6-1). Re...
Page 31 - Notes
Page 32 - SECTION 8 − ELECTRICAL DIAGRAM
OM-227 978 Page 28 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram
Page 34 - Typical MIG Process Connections
OM-227 978 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 ...
Page 35 - Typical MIG Process Control Settings; NOTE
OM-227 978 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 =...
Page 36 - Holding And Positioning Welding Gun
OM-227 978 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 G...
Page 37 - Conditions That Affect Weld Bead Shape
OM-227 978 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 E...
Page 38 - Gun Movement During Welding; Poor Weld Bead Characteristics
OM-227 978 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 ...
Page 41 - -14. Troubleshooting − Waviness Of Bead
OM-227 978 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)...
Page 42 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment
OM-227 978 Page 38 9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, butwire does not feed. Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. wire does not feed. Incorrect wire feed rolls. Check...
Page 44 - SECTION 10 − PARTS LIST
OM-227 978 Page 40 SECTION 10 − PARTS LIST . Hardware is common andnot available unless listed. 804 691-A 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 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 56 55 57 58 Figure 10-1. Main Assembly
Page 50 - Pros weld and cut
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.
Page 52 - 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 ...
