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.; FUMES AND GASES can be hazardous.
OM-355 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 6 - WELDING can cause fire or explosion.
OM-355 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 a welding helmet fitted with a proper shade of filter to protectyour face and eyes whe...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-355 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-355 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 mor...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-355 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 message...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-355 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 – INSTALLATION; Included with Your Unit; Selecting A Location
OM-355 Page 9 SECTION 2 – INSTALLATION 2-1. Included with Your Unit 1 12 ft (3.7 m) Work CableWith Clamp AndQuick-Connect 2 150 Amp TIG Torch with12-1/2 ft (3.8 m) Cable 3 Electrode Holder andQuick-Connect 4 Gas Hose 5 Gas Regulator 6 RFCS-14 Foot Control with20 ft (6 m) Cable 7 8 ft (2.4 m) Primary...
Page 14 - Dimensions And Weights; Specifications
OM-355 Page 10 2-3. Dimensions And Weights Dimensions Height 21 in (533 mm) Width 13-5/8 in (346 mm) Length 22-1/8 in (562 mm) A 21-5/16 in (541 mm) A B 13/16 in (21 mm) C 12-7/16 in (316 mm) D 1–1/16 in (27 mm) 4 Holes E E 1/2 (13 mm) Front B Weight ST-802 259 C D 210 lbs (95 kg) 2-4. Specification...
Page 15 - Weld Output Terminals And Selecting Cable Sizes
OM-355 Page 11 2-6. Volt-Ampere Curves ssb1.1 10/91 – ST-188 277 / ST-188 278 Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of weldingpower source. Curves of other set-tings fall between curves shown. AC MODE 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 300 3...
Page 16 - Remote 14 Receptacle; NOTE; Shielding Gas Connections
OM-355 Page 12 2-8. Remote 14 Receptacle Remote control device has complete control of amperage at all times whenconnected to Remote 14 receptacle. NOTE Socket* Socket Information A 24 volts DC. B Contact closure to A completes 24 volts DC contactor controlcircuit. C Command reference; 0 to +10 volt...
Page 18 - SECTION 3 – OPERATION; Controls
OM-355 Page 14 SECTION 3 – OPERATION 3-1. Controls Ref. ST-188 714-A 1 Output Selector Switch Y Do not use AC output in damp areas, ifmovement is confined, or if there isdanger of falling. Use AC output ONLYif required for the welding process, andthen use a remote control. Y Do not change position o...
Page 19 - Example of Front Panel Amperage Control For Stick (SMAW) Welding; Example of Remote Amperage Control For TIG (GTAW) Welding; or
OM-355 Page 15 3-2. Example of Front Panel Amperage Control For Stick (SMAW) Welding Select amperage. Select weld process. Select polarity. In Example: Remote weld amperage = 10–180 amps DC NOTE: Remote amperage control is active whenever a remote control is connected. If the remote device does not ...
Page 21 - Process and Material Thickness Guide Label; SECTION 4 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance
OM-355 Page 17 3-6. Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And 22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 11 ga 10 ga 6 ga 2 ga – 0.033 in 0.8 mm 0.036 in 0.9 mm 0.048 in 1.2 mm 0.06 in 1.5 mm 0.07 in 1.8 mm 0.1 in 2.5 mm...
Page 23 - SECTION 5 – ELECTRICAL DIAGRAM; Figure 5-1. Circuit Diagram For Welding Power Source
OM-355 Page 19 SECTION 5 – ELECTRICAL DIAGRAM SD-188 274-F Figure 5-1. Circuit Diagram For Welding Power Source
Page 24 - Welding Processes Using HF; Sources Of HF Radiation From Incorrect Installation
OM-355 Page 20 SECTION 6 – HIGH FREQUENCY (HF) 6-1. Welding Processes Using HF high_freq1 7/95 – S-0693 1 HF Voltage GTAW – helps arc jump air gapbetween torch and workpiece and/or stabilize the arc. SAW – helps arc reach workpiecethrough flux granules. 2 Flux 1 2 1 Gas Tungsten Arc Welding (GTAW) S...
Page 25 - Correct Installation
OM-355 Page 21 6-3. Correct Installation 1 HF Source (Welder With Built-In HF OrSeparate HF Unit) Ground metal machine case, work outputterminal, line disconnect device, inputsupply, and worktable. 2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpointbetween HF source and welding tor...
Page 26 - Selecting Tungsten Electrode
OM-355 Page 22 SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw2 7/97 For additional information, see your distributor for a handbook on the GasTungs t en Ar c Welding (G TAW ) pr oc es s . Wear clean glov es to pr ev entcontamination of tungsten electrode. NOTE 7-1. Selecting Tungsten El...
Page 27 - Preparing Tungsten For DC Electrode Negative (DCEN) Welding
OM-355 Page 23 7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Ref. S-0161 / Ref. S-0162 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit,hard abrasive wheel before weld-ing. Do not use wheel for other jobsor tungsten can become contami-nated causing lower weld ...
Page 28 - SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW); Positioning The Torch
OM-355 Page 24 SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. Positioning The Torch Ref. ST-161 892 Y Grinding the tungsten elec-trode produces dust and fly-ing sparks which can causeinjury and start fires. Use lo-cal exhaust (forced ventila-tion) at the grinder or wear anapproved respirator. Re...
Page 29 - Torch Movement During Welding
OM-355 Page 25 8-2. Torch Movement During Welding ST-162 002-B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove ...
Page 30 - Positioning Torch Tungsten For Various Weld Joints
OM-355 Page 26 8-3. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 31 - Notes
Page 32 - SECTION 9 – STICK WELDING (SMAW) GUIDELINES; Stick Welding Procedure
OM-355 Page 28 SECTION 9 – STICK WELDING (SMAW) GUIDELINES 9-1. Stick Welding Procedure stick 12/96 – ST-151 593 Y Weld current starts whenelectrode touches work-piece. Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp as...
Page 35 - Conditions That Affect Weld Bead Shape; Electrode Movement During Welding
OM-355 Page 31 9-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Ang...
Page 37 - -15. Troubleshooting – Excessive Spatter
OM-355 Page 33 9-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown.A good weld bends over but doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 9-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting from...
Page 39 - -20. Troubleshooting – Waviness Of Bead
OM-355 Page 35 9-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel ...
Page 40 - SECTION 10 – PARTS LIST
OM-355 Page 36 SECTION 10 – PARTS LIST Figure 10-1. Main Assembly ST-802 252-D . Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 30 31 32 33 34 35 36 37 38 39 40 24 25 41 42 43 29
Page 47 - (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 48 - 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...
