OM-947 212 149J 2011−06 Processes Flux Cored (FCAW) Welding MIG (GMAW) Welding (Optional) Description Arc Welding Power Source And Wire Feeder Handler 125 And H-9B Gun R File: Flux Cored (FCAW)
From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 9 − FCAW/GMAW WELDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Typical FCAW Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Typical GMAW (MIG) Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Typical Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 7 Protect yourself and others from injury — read and follow these precautions. 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. D If ventilation is poor, wear an approved air-supplied respirator.
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.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−01 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 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. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
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. A complete Parts List is available at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1.
. A complete Parts List is available at www.HobartWelders.com 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Output Amperes 200 135 100 80 NOTICE − Exceeding duty cycle can damage unit or gun and void warranty.
. A complete Parts List is available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Installing Work Clamp . Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. 1 2 3 4 5 Nut Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable. 3 1 6 Insulator Grip Slide one insulating grip over work cable before connecting to clamp.
. A complete Parts List is available at www.HobartWelders.com 5-2.
. A complete Parts List is available at www.HobartWelders.com 5-4. Installing Gas Supply . This Section only applies to MIG units or units equipped with MIG kit. 1 Tools Needed: 4 11/16, 1-1/8 in. 2 6 5 3 7 Shielding Gas 802 028 / Ref. 803 379-A Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Install regulator/flowmeter to cylinder valve. Be sure that gauge face is vertical for viewing and adjusting.
. A complete Parts List is available at www.HobartWelders.com 5-5. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter used with 8 in. (203 mm) spool only. . Only applies to units equipped with optional hub kit. When a slight force is needed to turn spool, tension is set. Retaining ring used with 8 in. (203 mm) spool only. Tools Needed: 1/2 in. Ref.
. A complete Parts List is available at www.HobartWelders.com 5-6. Serial Number And Rating Label Location The serial number and rating information for this product is located on 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. 5-7.
. A complete Parts List is available at www.HobartWelders.com 5-8. Installing Contact Tip And Nozzle ! Turn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). 2 3 Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. 1 Flux Nozzle MIG Nozzle Use with flux cored wire only. Narrow design allows access in tight spaces and provides better visibility of puddle during welding.
. 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: 1 2 3 6 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 ~ Inside Unit 7-2.
. A complete Parts List is available at www.HobartWelders.com 7-4. 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 7-5. Replacing Gun Contact Tip ! Turn Off power before replacing contact tip. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter, and install new contact tip. Reinstall nozzle. 2 3 1 Tools Needed: Ref.
. 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 2 8 mm / 10 mm 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) When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. 3/8 in (10 mm) Be sure that cable is straight. Tighten liner setscrew. Cut liner so that 3/8 in. (10 mm) sticks out of head tube. File down any sharp points on liner after cutting to length. Reassemble gun by placing head tube and cable into one half of handle.
. 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 230 950-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, (weld current), and voltage. thickness of base metal, wire feed speed . 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 1 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. 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) 195 158 MIG Conversion Kit For Gas Metal Arc Welding (GMAW) 195 216 Hub Kit For 8 in Wire Spool 195 186 Protective Cover Weatherproof Nylon 10-2. Consumables HOBART PART NO. DESCRIPTION REMARKS 196 134 Tip, contact scr .023 wire Pkg of 5 196 131 Tip, contact scr .030 wire Pkg of 5 196 132 Tip, contact scr .
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Effective January 1, 2011 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MB 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.
Owner’s Record Please complete and retain with your personal records. Model Name Protect Your Investment! Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Call 1-877-Hobart1 or visit our website at www.HobartWelders.
