Page 2 - From Hobart to You
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 catalog sheets.To locate your nearest distributor or service agency call 1-877-...
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-944 Page 1 Return To Table Of Contents SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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”; ...
Page 6 - WELDING can cause fire or explosion.
OM-944 Page 2 Return To Table Of Contents 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 p...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-944 Page 3 Return To Table Of Contents 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 supp...
Page 8 - Principal Safety Standards
OM-944 Page 4 Return To Table Of Contents 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparatio...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT; Signification des symboles; Dangers relatifs au soudage à l’arc
OM-944 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives. Y Id...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-944 Page 6 Revenez à la table des matières Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brûlures oculaires et cutanées.Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent cau-ser des br...
Page 12 - Principales normes de sécurité
OM-944 Page 8 Revenez à la table des matières 2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(téléphone : (305) 443−9353, site Web : www.aws.org). Recommended Safe Practices for ...
Page 13 - SECTION 3 − SPECIFICATIONS; Specifications
OM-944 Page 9 Return To Table Of Contents SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Rated Welding Output Amperage Range Maximum Open- Circuit Voltage DC Amperes Input at Rated Load Output 115 V, 60 Hz, Single- Phase KVA KW Weight W/ Gun Overall Dimensions 90 A @ 19 Volts DC, 20...
Page 14 - Duty Cycle And Overheating; A or V
OM-944 Page 10 Return To Table Of Contents 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage ordu...
Page 16 - SECTION 4 − INSTALLATION; Installing Welding Gun
OM-944 Page 12 Return To Table Of Contents SECTION 4 − INSTALLATION 4-1. Installing Welding Gun Ref. 802 440-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew. Insert gunend through opening until it bottomsagainst drive assembly. Tightenthumbscrew. 4 Gun Trigger Leads Insert l...
Page 17 - Process/Polarity Table; Changing Polarity
OM-944 Page 13 Return To Table Of Contents 4-3. 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 − S...
Page 18 - Installing Gas Supply
OM-944 Page 14 Return To Table Of Contents 4-5. 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 d...
Page 19 - Selecting A Location And Connecting Input Power For 115 VAC Model
OM-944 Page 15 Return To Table Of Contents 4-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individualbranch circuit protected by time-de-lay fuses or circuit breaker is re-quired. 3 Plug From Unit Select extension cord...
Page 20 - Selecting A Location And Connecting Input Power For 230 VAC Model
OM-944 Page 16 Return To Table Of Contents 4-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug (NEMA 6-50P) 3 Receptacle (NEMA 6-50R) Connect plug to receptacle. 4 Line Disconnect Device See Section 4-8. Y Special installation may ...
Page 21 - Electrical Service Guide For 230 VAC Model; Installing Wire Spool And Adjusting Hub Tension
OM-944 Page 17 Return To Table Of Contents 4-8. Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In AWG/Kcmil 14 Max Recommended Input Conductor Length In Feet ...
Page 23 - SECTION 5 − OPERATION; Controls
OM-944 Page 19 Return To Table Of Contents SECTION 5 − OPERATION 5-1. Controls 1 Voltage Switch The higher the selected number,the thicker the material that can bewelded (see weld setting label inwelding power source or Sections5-2 and 5-3, as applicable). Do notswitch under load. . Switch must “cli...
Page 24 - Weld Parameter Chart For 115 VAC Model; Welding
OM-944 Page 20 Return To Table Of Contents 5-2. Weld Parameter Chart For 115 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set...
Page 25 - olt Wire Welding
OM-944 Page 21 Return To Table Of Contents for 1 15 V olt Wire Welding Package DCEN DCEP Wire Speed listed is a starting value only − Wire Speed setting can be fine−tuned while welding. Wire Speed also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc....
Page 26 - Weld Parameter Chart For 230 VAC Model
OM-944 Page 22 Return To Table Of Contents 5-3. Weld Parameter Chart For 230 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set...
Page 28 - SECTION 6 − MAINTENANCE &TROUBLESHOOTING; Routine Maintenance; Months; Overload Protection; Drive Motor Protection
OM-944 Page 24 Return To Table Of Contents SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replaceunreadablelabels. Repair orreplacecrackedweld cable. Clean andtighten weldterminals. 6 Months Blow out orvacuum inside.During heavys...
Page 29 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
OM-944 Page 25 Return To Table Of Contents 6-4. 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 Drive Roll The drive roll consists of two differ-ent sized grooves....
Page 30 - Cleaning Or Replacing Gun Liner
OM-944 Page 26 Return To Table Of Contents 6-6. Cleaning Or Replacing Gun Liner Ref. 802 446 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 then tight-en two ...
Page 32 - Troubleshooting Table
OM-944 Page 28 Return To Table Of Contents 6-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fandoes not run. Secure power cord plug in receptacle (see Section 4-6). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On positi...
Page 33 - SECTION 7 − ELECTRICAL DIAGRAM; Figure 7-1. Circuit Diagram For 115 VAC Model
OM-944 Page 29 Return To Table Of Contents SECTION 7 − ELECTRICAL DIAGRAM 194 324-C Figure 7-1. Circuit Diagram For 115 VAC Model
Page 34 - Figure 7-2. Circuit Diagram For 230 VAC Model
OM-944 Page 30 Return To Table Of Contents 194 325-A Figure 7-2. Circuit Diagram For 230 VAC Model
Page 35 - Typical MIG Process Connections
OM-944 Page 31 Return To Table Of Contents SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. 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/ Pow...
Page 36 - Typical MIG Process Control Settings; NOTE
OM-944 Page 32 Return To Table Of Contents 8-2. 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...
Page 37 - Holding And Positioning Welding Gun
OM-944 Page 33 Return To Table Of Contents 8-3. 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 ...
Page 38 - Conditions That Affect Weld Bead Shape
OM-944 Page 34 Return To Table Of Contents 8-4. 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 EXTENSION...
Page 39 - Gun Movement During Welding; Poor Weld Bead Characteristics
OM-944 Page 35 Return To Table Of Contents 8-5. 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 − St...
Page 40 - Troubleshooting − Excessive Spatter
OM-944 Page 36 Return To Table Of Contents 8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Sele...
Page 41 - -11. Troubleshooting − Lack Of Penetration
OM-944 Page 37 Return To Table Of Contents 8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallowfusion between weld metal andbase metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparatio...
Page 42 - -14. Troubleshooting − Waviness Of Bead
OM-944 Page 38 Return To Table Of Contents 8-14. 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 ...
Page 43 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment
OM-944 Page 39 Return To Table Of Contents 8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing...
Page 45 - Notes
Page 46 - SECTION 9 − PARTS LIST
OM-944 Page 42 Return To Table Of Contents SECTION 9 − PARTS LIST . Hardware is common andnot available unless listed. 802 449-E 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 29 30 35 33 32 50 44 49 48 47 46 45 52 51 36 37 43 42 41 39 40 38 28 31 34 Figure 9-1. Main Assembl...
Page 49 - Quantity; Optional Drive Rolls; Options
OM-944 Page 45 Return To Table Of Contents Quantity Description Part No. 195 957 Item No. Figure 9-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP, contact scr .023 wire...
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 2003 Hobart Welding Products. 1/03 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...
