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Manafacture: Hobart Welding Products File size: 1.29 mb File name: Language of manual:

Lay gun cable out straight before installing new liner. Head Tube 8 mm Remove liner. Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. Blow out gun casing. 10 mm 1 2 3 A complete Parts List is available at OM-925 Page 29 7-7. Replacing Switch And/Or Head Tube Ref. 800 795-C Tools Needed: 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector. Place head tube in vice and tighten until nuts are tight. Remove from vice. Reposition handle and install switch housing. Secure with handle locking nut. ! Turn Off welding power source /wire feeder and disconnect gun. Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. 1 3 2 4 5 8 6 7 . A complete Parts List is available at 7-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-6). Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protector (see Section 7-2). No weld output; wire does not feed; fan motor continues to run. Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when unit has cooled (see Section 4-2). Check Voltage range switch position. Rotate knob until it “clicks” into detent at desired range setting. Secure gun trigger leads (see Section 5-1). No weld output; wire feeds. Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 7-5). Check for proper polarity connections (see Section 5-4). Check thumbscrew securing gun end to feed head adapter and tighten if necessary. Low weld output. Connect unit to proper input voltage or check for low line voltage. Place voltage switch in desired position (see Section 6-1). Electrode wire feeding stops during welding. Straighten gun cable and/or replace damaged parts. Adjust drive roll pressure (see Section 5-9). Change to proper drive roll groove (see Section 7-4). Readjust hub tension (see Section 5-7). Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove. Replace contact tip if blocked (see Section 7-5). Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 or Section 7-6). Replace drive roll or pressure bearing if worn or slipping (see Section 7-4). Secure gun trigger leads or repair leads (see Section 5-1). Check and clear any restrictions at drive assembly and liner (see Section 5-9 or Section 7-6). Release gun trigger and allow gun and motor protection circuitry to reset (see Section 7-3). Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten if necessary. Have nearest Factory Authorized Service Agent check drive motor. OM-925 Page 30 OM-925 Page 31 SECTION 8 . ELECTRICAL DIAGRAM 230 952-A Figure 8-1. Circuit Diagram OM-925 Page 32 SECTION 9 . MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Wire Feeder/ Power Source Workpiece Gun Regulator/ Flowmeter Gas Hose Shielding Gas Work Clamp light mig 5/97 / Ref. 803 715-A OM-925 Page 33 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 to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 . 90 A 40 . 145 A 50 . 180 A Convert Material Thickness to Amperage (A) Material thickness determines weld parameters. .035 in Recommendation Wire Speed (Approx.) 1/8 or 0.125 in (0.001 in = 1 ampere) 0.125 in = 125 A Wire Size Amperage Range 0.023 in 0.030 in 0.035 in Select Wire Size Wire Size 0.023 in 0.030 in 0.035 in 3.5 in per ampere 2 in per ampere 1.6 in per ampere Select Wire Speed (Amperage) 125 A based on 1/8 in material thickness ipm = inches per minute Low voltage: wire stubs into work High voltage: arc is unstable (spatter) Set voltage midway between high/low voltage Select Voltage Ref. 803 710-C Voltage controls height and width of weld bead. Wire speed (amperage) controls weld penetration (wire speed = burn-off rate) 9-3. 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 Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension (Stickout) 1/4 to 1/2 in (6 To 13 mm) 5 Cradle Gun and Rest Hand o...

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