OM-243 712D 2014−02 Processes Flux Cored (FCAW) Welding MIG (GMAW) Welding Description Arc Welding Power Source and Wire Feeder R Auto Arc 130 And H-9B Welding Gun
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 7 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. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California 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. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 7 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. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé. D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. Les PIÈCES MOBILES peuvent causer des blessures. D Ne pas s’approcher des organes mobiles.
2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
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. A complete Parts List is available at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions . Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. Safe32 2012−05 3-2. Miscellaneous Symbols And Definitions . Some symbols are found only on CE products.
. A complete Parts List is available at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.
. A complete Parts List is available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Selecting A Location 18 in. (460 mm) ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. ! Do not move or operate unit where it could tip. 1 Grounded Receptacle 1 2 Locate unit near correct input power supply. 18 in. (460 mm) 803 443-C 5-2. Installing Work Clamp . Connection hardware must be tightened with proper tools.
. A complete Parts List is available at www.HobartWelders.com 5-5. Installing Gas Supply . This Section only applies to MIG units or units equipped with MIG kit. 2 5 7 4 Tools Needed: 3 8 11/16, 1-1/8 in. 1 6 9 Shielding Gas 247 832-A 1 Cylinder 5 Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.
. A complete Parts List is available at www.HobartWelders.com 5-7. Connecting 115 Volt Input Power ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 2 1 For 115 volts AC input power, a 20 ampere individual circuit protected by time-delay fuses or circuit breaker is required.
. A complete Parts List is available at www.HobartWelders.com 5-9. Threading Welding Wire 1 2 3 4 5 6 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Cable Lay gun cable out straight. 4 Tools Needed: 6 1 2 3 5 . Hold wire tightly to keep it from unraveling. 6 in. (150 mm) Open pressure assembly. Tighten Pull and hold wire; cut off end. 4 in. (102 mm) Push wire thru guides into gun liner; continue to hold wire. .
. A complete Parts List is available at www.HobartWelders.com SECTION 6 − OPERATION 6-1. Controls 1 Voltage Switch Use control to select the weld voltage range. As the thickness of material increases, a higher voltage range must be selected (see weld setting label in welding power source or Section 6-3 as applicable). Do not switch under load. 2 . Switch must “click” into detent position for weld output. 2 Wire Feed Control Use control to select a wire feed speed.
. A complete Parts List is available at www.HobartWelders.com 6-3.
. A complete Parts List is available at www.HobartWelders.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Reference l = Replace 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable ~ Clean And Tighten Weld Terminals 6 Months OR ~ Drive Rolls ~ Inside Unit 7-2.
. A complete Parts List is available at www.HobartWelders.com 7-5. Changing Drive Roll Or Wire Inlet Guide 1 2 Pressure Adjustment Knob Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly up. 3 4 5 6 Pivot Tube Plate Securing Screws Pressure Arm Pivot Tube Inlet Wire Guide Remove screws and pivot tube plate. Lift out pressure arm pivot tube, and slide inlet wire guide out of tube. 2 Slide replacement wire guide into tube, and place tube back into drive assembly.
. A complete Parts List is available at www.HobartWelders.com 7-6. Cleaning Gun Liner ! Turn Off welding power source. 1 Nozzle 2 Contact Tip 3 Adapter Head Tube 1 2 3 8 mm Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip adapter. Open pressure assembly. Retract wire from liner onto spool. . Hold wire tightly to keep it from unraveling. Secure end of wire at spool. Remove screws (3) from cover, and remove cover from wire drive assembly.
. A complete Parts List is available at www.HobartWelders.com 7-7. Replacing Gun Liner ! Turn Off welding power source. Tools Needed: Head Tube 1 8 mm / 10 mm 2 3 8 mm Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip adapter. Remove screws (3) from cover, and remove cover from wire drive assembly. Open pressure assembly. Retract wire from liner onto spool. Loosen liner setscrew. . Hold wire tightly to keep it from unraveling. Secure end of wire at spool.
. A complete Parts List is available at www.HobartWelders.com 7-7. Replacing Gun Liner (Continued) 13/16 in. (21 mm) 8 mm When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. Insert retaining nut into adapter, and adjust liner stickout as shown. Tighten retaining nut. Reinstall cable end into drive housing with retaining grooves inserted into the two retaining ribs. Be sure to position gas hose up.
. A complete Parts List is available at www.HobartWelders.com 7-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-7). does not run. 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 if open. No weld output; wire does not feed; fan Thermostat TP1 open (overheating).
SECTION 8 − ELECTRICAL DIAGRAM 247 077-A Figure 8-1.
SECTION 9 − FCAW/GMAW WELDING GUIDELINES 9-1. Typical FCAW 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 Gun Work Clamp Workpiece Self-Shielding Flux Core Wire FCAW/GMAW1 2011−03 − Ref. 803 444-A 9-2. Typical GMAW (MIG) Process Connections ! Weld current can damage electronic parts in vehicles.
9-3. Typical Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) (0.001 in. = 1 ampere) 0.125 in. = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in. 30 − 90 A 0.030 in. 40 − 145 A 0.035 in. 50 − 180 A Recommendation Wire Speed (Approx.) 0.023 in.
9-4. 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 2 3 4 1 5 3 2 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) Solid Wire − 3/8 to 1/2 in. (9 to 13 mm) Flux Cored Wire − 1/2 to 5/8 in.
9-5. 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. . The Drag or Pull technique is generally recommended when welding with flux-cored tubular wire.
9-6. 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 or multiple stringer beads works better. 1 2 3 Stringer Bead − Steady Movement Along Seam Weave Bead − Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 1 2 3 S-0054-A 9-7.
9-9. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool 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. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
9-11. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Excessive heat input. Corrective Actions Select lower voltage range and reduce wire feed speed. Increase travel speed. 9-12. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal.
9-14. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. 9-15. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
9-17. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Problem Probable Cause Remedy Wire feeds, but no gas flows (GMAW). Gas cylinder empty. Replace empty gas cylinder. Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line. Check gas hose between flowmeter and wire feeder, and gas hose in gun and cable assembly. Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
SECTION 10 − ACCESSORIES/CONSUMABLES 10-1. Accessories Part No. Description Remarks 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) 195 216 Hub Kit For 8 in Wire Spool 195 157R H-9B Replacement Gun 8 ft (2.4 m) length/.030-.035 (0.8-0.9 mm) Wire Size 770717 Preset Mixed Gas Regulator/Hose Kit For Argon and Argon mixed shielding gas. Use with replacement hose 183 581 10-2. Consumables Item Hobart Package Part No. .023/.025 in. (0.
Effective January 1, 2013 3/1 WARRANTY applies to all Auto Arc welding equipment and plasma cutters with a serial number preface of MD or newer. This limited warranty supersedes all previous Auto Arc warranties and is exclusive with no other guarantees or warranties expressed or implied. Auto Arc products are serviced by Hobart or Miller Authorized Service Agencies. LIMITED WARRANTY − Subject to the terms and conditions below, Hobart Brothers Co., Troy, Ohio and Miller Electric Mfg. Co.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. Service You always get the fast, reliable response you need.
