OM-249 202A 2012−05 Processes MIG (GMAW) Welding Description Wire Feeder Spool Gun SpoolRunner 100 File: Wire Feeder www.HobartWelders.
TABLE OF CONTENTS SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7 (MIG) 2011-10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
1-3. Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-4.
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT UTILISATION SR7(MIG)_2011−10fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
LES PIÈCES CHAUDES peuvent provoquer des brûlures. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Laisser refroidir le pistolet avant de le toucher. D Ne pas toucher d’objets métalliques chauds. D Abriter les objets métalliques contre tout contact par les personnes à proximité. D Éloigner les mains et le corps de la buse du pistolet après avoir appuyé sur la gâchette. LIRE LES INSTRUCTIONS. Le BRUIT peut endommager l’ouie.
SECTION 3 − INSTALLATION 3-1. Specifications Wire Diameter Range .030 Thru .035 in. (0.8 Thru 0.9 mm) Aluminum Wire Or Flux Cored Wire .023 Thru 035 in. (0.6 Thru 0.9 mm) Solid Wire Approximate Wire Feed Range 60 To 660 ipm (1.5 To 16.8 mpm) Cooling Method Air Cooled Maximum Spool Size Weld Circuit Rating Overall Dimensions Weight 4 in. (102 mm) Diameter 100 Volts, 150 Amperes, 60% Duty Cycle Using Argon Shielding Gas Length: 11-1/2 in. (291 mm) Width: 2-1/4 in. (57 mm) Height: 8 in. (203 mm) 5.
3-3. Connecting Spool Gun To Handler 7 Spool Gun ÇÇ ÇÇ ! Turn off and disconnect input power. 1 2 3 4 Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew. 5 Spool gun must be inserted completely to prevent leakage of shielding gas. 5 6 MIG Gun 6 1 3 2 4 3 Exposed O-rings will cause shielding gas leakage. Spool Gun/MIG Gun Switch Place switch in Spool Gun position.
3-4. Installing Wire Spool And Threading Welding Wire Tools Needed: 6 7 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover. 8 3 4 5 Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool. 4 2 1 3 9 10 Hub Tension Nut Wire Spool 5 Push Roll/Lower Drive Roll 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever (Red) 8 Wire Inlet Guide 9 Contact Tip 10 Nozzle Remove nozzle and contact tip.
SECTION 4 − OPERATION 4-1. Controls . Spool Gun/MIG Gun switch on Handler must be in Spool Gun position for spool gun to operate. 2 1 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 Valve Open valve on cylinder just before welding. Close valve on cylinder when finished welding. 3 Spool Gun/MIG Gun Switch Switch must be set in Spool Gun position for spool gun to operate.
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months l Unreadable Labels ~ Weld Terminals nl Cords nl Gun Cables Every 6 Months Disconnect power before maintaining. . Maintain more often during severe conditions.
5-2. Changing Drive Rolls ! Turn off and disconnect input power. 1 Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer, and lift out drive roll. To install drive roll: 4 Slide drive roll onto shaft and secure with washer and screw. 3 2 It may be necessary to remove drive roll side of gun case to change lower drive roll.
5-3. Changing Liner ! Turn off and disconnect input power. 1 2 3 Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. 3 2 1 Tools Needed: Ref. 804 687-A 5-4. Troubleshooting Trouble Gun tube assembly loose. Remedy Tighten nut at base of gun tube assembly. No weld output; gun/feeder does not Place Power switch on welding power source in the On position (see welding power source Owner’s work. Manual). Check Spool Gun/MIG Gun switch for correct position. Erratic weld output.
5-5. GMAW (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires different techniques than MIG welding mild steel. A. Before You Start Welding S Material thickness that can be welded with MIG process or aluminum are 14 ga. [0.074 in. (1.9 mm)] or heavier. (How heavy depends on the output capacity of the welder being used.) To MIG weld aluminum thinner than 14 ga.
S Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2. Gas Nozzle Contact Tube Recessed 1/8 in. (3.2 mm) Inside The Nozzle ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÉÉÉ ÉÉÉ Contact Tip To Work Distance 3/4 in. (19 mm) Figure 5-2. Contact Tube Position And Tip-To-Work Distance S Avoid large weave beads on aluminum.
SECTION 6 − ELECTRICAL DIAGRAMS 186 451 Figure 6-1.
SECTION 7 − PARTS LIST . Hardware is common and not available unless listed. 249 535-A Figure 7-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Complete Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 36 36 37 38 39 40 41 . . . PB1 . . . . . 186 416 . . TRIGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effective January 1, 2012 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MC or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281.
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