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Manual Hobart Welding Products OM-947

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  • Hobart Welding Products OM-947 - page 1

    OM-947 212 149G 2010 − 05 Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW) W elding (Optional) Flux Cored (FCA W ) W elding Handler 125 A n d H - 9 B G u n R File: Flux Cored (FCA W) ...

  • Hobart Welding Products OM-947 - page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H ...

  • Hobart Welding Products OM-947 - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . ...

  • Hobart Welding Products OM-947 - page 4

    T ABLE OF CONTENTS SECTION 9 − WIRE WELDING GUIDELINES 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical FCA W Process Connections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Connections 32 ...

  • Hobart Welding Products OM-947 - page 5

    OM-947 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010 − 03 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 ...

  • Hobart Welding Products OM-947 - page 6

    OM-947 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. 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 , ...

  • Hobart Welding Products OM-947 - page 7

    OM-947 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 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. F A ...

  • Hobart Welding Products OM-947 - page 8

    OM-947 Page 4 1-4. California Proposition 65 W arnings W elding 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 ...

  • Hobart Welding Products OM-947 - page 9

    OM-947 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2010 − 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. ...

  • Hobart Welding Products OM-947 - page 10

    OM-947 Page 6 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 ...

  • Hobart Welding Products OM-947 - page 11

    OM-947 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les i ...

  • Hobart Welding Products OM-947 - page 12

    OM-947 Page 8 Les PIÈCES MOBILES peuvent causer des blessures. 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 v ...

  • Hobart Welding Products OM-947 - page 13

    OM-947 Page 9 2-5. P r inc ipa l es n or m es d e s éc ur it é Safety i n W elding, 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 W elding and Cutting, American Welding Society ...

  • Hobart Welding Products OM-947 - page 14

    OM-947 Page 10 ...

  • Hobart Welding Products OM-947 - page 15

    OM-947 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMAW) Wire Feed Flux Cored Arc W elding (FCAW) SECTION 4 − SPECIFICA TIONS 4-1. Specifications Rated Weldi ...

  • Hobart Welding Products OM-947 - page 16

    OM-947 Page 12 4-2. Duty Cycle And Overheating duty1 4/95 − 210 517-B Duty Cycle is percentage of 10 min- utes 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. NOTICE − Exceeding d ...

  • Hobart Welding Products OM-947 - page 17

    OM-947 Page 13 SECTION 5 − INST ALLA TION 5-1. Installing W ork Clamp 1 Nut 2 W ork Cable From Unit 3 W ork Clamp 4 Screw 5 W ork Clamp T abs Bend tabs around work cable. 6 Insulator Grip Slide one insulating grip over work cable before connecting to clamp. Slide insulating grips over handles. Ref. 802 456 . Connection hardware must be tightened ...

  • Hobart Welding Products OM-947 - page 18

    OM-947 Page 14 5-2. Process/Polarity T able Process Polarity Cable Connections Cable T o Gun Cable T o Work Clamp FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative ( − ) output terminal Connect to positive (+) output terminal GMA W* − Solid wire with shielding gas DCEP − Reverse polarity Connect ...

  • Hobart Welding Products OM-947 - page 19

    OM-947 Page 15 5-4. Installing Gas Supply . This Section only applies to MIG units or units equipped with MIG kit. Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly . Gas flow blows dust an ...

  • Hobart Welding Products OM-947 - page 20

    OM-947 Page 16 5-5. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in. T ools Needed: Ref. 802 971-C / 803 012 / 803 013 -B Installing 8 in. (203 mm) Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Retaining ring used with ...

  • Hobart Welding Products OM-947 - page 21

    OM-947 Page 17 5-6. Serial Number And Rating Label Location Th e 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. Selecting A Location And Connecting Inpu ...

  • Hobart Welding Products OM-947 - page 22

    OM-947 Page 18 5-8. Installing Contact T ip And Nozzle T ools Needed: Ref. 804 241-A ! T ur n off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. 1 2 3 Flux Nozzle MIG Nozzle Use with flux core ...

  • Hobart Welding Products OM-947 - page 23

    OM-947 Page 19 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Cable Lay gun cable out straight. T ools Needed: 6 1 Pull and hold wire; cut off end. 4 in. (102 mm) Remove gun nozzle and contact tip. Open pressure assembly . Push wire thru guides into gun liner; continue to hol ...

  • Hobart Welding Products OM-947 - page 24

    OM-947 Page 20 SECTION 6 − OPERATION 6-1. Controls 1 V oltage 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. . Switch must “click” into detent position f ...

  • Hobart Welding Products OM-947 - page 25

    OM-947 Page 21 Notes ...

  • Hobart Welding Products OM-947 - page 26

    OM-947 Page 22 6-3. W eld Parameter Chart ...

  • Hobart Welding Products OM-947 - page 27

    OM-947 Page 23 210 428 ...

  • Hobart Welding Products OM-947 - page 28

    OM-947 Page 24 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe condi- tions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked W e ...

  • Hobart Welding Products OM-947 - page 29

    OM-947 Page 25 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Pressure Adjustment Knob 2 Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly up. 3 Pivot T ube Plate 4 Securing Screws 5 Pressure Arm Pivot T ube 6 Inlet Wire Guide Remove screws and pivot tube plate. Lift out pressure arm pivot tube, and slide inlet wire ...

  • Hobart Welding Products OM-947 - page 30

    OM-947 Page 26 7-5. Replacing Gun Contact Tip T ools Needed: Ref. 804 241-A ! T urn Off power before replacing contact tip. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter , and install new contact tip. Reinstall nozzle. 1 2 3 ...

  • Hobart Welding Products OM-947 - page 31

    OM-947 Page 27 7-6. Cleaning Gun Liner 804 241-A / 803 838-A ! T urn Off welding power source. 1 Nozzle 2 Contact T ip 3 Adapter Head T ube T ools Needed: 8 mm La y gun cable out straight, and blow out liner . Remove nozzle. Cut of f wire at contact tip, and remove contact tip and tip adapter . . Thread wire according to Section 5-9. Reassemble dri ...

  • Hobart Welding Products OM-947 - page 32

    OM-947 Page 28 7-7. Replacing Gun Liner Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A T ools Needed: 8 mm / 10 mm Remove nozzle. Cut of f 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. T wist t ...

  • Hobart Welding Products OM-947 - page 33

    OM-947 Page 29 7-7. Replacing Gun Liner (Continued) When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. Slide locking rings over top and bottom of handle, and secure by twisting rings clockwise 1/4 turn. Place other half of handle over head tube and cable. Be sure that cable is s ...

  • Hobart Welding Products OM-947 - page 34

    OM-947 Page 30 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-7). 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 wel ...

  • Hobart Welding Products OM-947 - page 35

    OM-947 Page 31 SECTION 8 − ELECTRICAL DIAGRAM 230 950-A Figure 7-1. Circuit Diagram ...

  • Hobart Welding Products OM-947 - page 36

    OM-947 Page 32 SECTION 9 − WIRE WELDING GUIDELINES 9-1. T ypical FCA W Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce w or k cl am p as close to the weld as possible. Wire Feeder/ Power Source fcaw 1/2003 / Ref. 803 444-A Self-Shielding Flux Core Wire ...

  • Hobart Welding Products OM-947 - page 37

    OM-947 Page 33 9-3. T ypical Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A Convert Material ...

  • Hobart Welding Products OM-947 - page 38

    OM-947 Page 34 9-4. Holding And Positioning Welding Gun . W elding 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 e nd o f noz zle, and tip o f wir e is posi tion ed c orre ctly on s eam. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 El ...

  • Hobart Welding Products OM-947 - page 39

    OM-947 Page 35 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. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFILES ...

  • Hobart Welding Products OM-947 - page 40

    OM-947 Page 36 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 acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along Se ...

  • Hobart Welding Products OM-947 - page 41

    OM-947 Page 37 9-9. T roubleshooting − 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use sh ...

  • Hobart Welding Products OM-947 - page 42

    OM-947 Page 38 9-12. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining ...

  • Hobart Welding Products OM-947 - page 43

    OM-947 Page 39 9-15. T roubleshooting − W aviness Of Bead W aviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand o ...

  • Hobart Welding Products OM-947 - page 44

    OM-947 Page 40 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 803 446-B 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 42 20 21 22 23 24 25 26 27 28 29 32 30 31 33 34 35 36 37 38 39 40 41 43 Figure 9-1. Main Assembly ...

  • Hobart Welding Products OM-947 - page 45

    OM-947 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 210 432 CASE SECTION, front/bottom/rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 530 BLANK, snap-in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Hobart Welding Products OM-947 - page 46

    OM-947 Page 42 1 804 243-A 2 3 5 − See T able 9-1 4 6 7 7 Figure 9-2. H-9B Gun Description Part No. 195 157R Item No. Figure 9-2. H-9B Gun Quantity 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 226 190 NOZZLE, flux cored slip type 1 . . . ...

  • Hobart Welding Products OM-947 - page 47

    OM-947 Page 43 803 442-B 4 5 1 6 7 8 9 2 3 Figure 9-3. Wire Drive Assembly Quantity Description Part No. 209 532 Item No. Figure 9-3. Wire Drive Assembly 1 212 377 BEARING, idler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212 379 ROLL, drive .024-.030/. ...

  • Hobart Welding Products OM-947 - page 48

    Notes W o r k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual . ...

  • Hobart Welding Products OM-947 - page 49

    Notes ...

  • Hobart Welding Products OM-947 - page 50

    Notes ...

  • Hobart Welding Products OM-947 - page 51

    Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 2010 − 01 Service Y o u 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. The expertise of the distributor and Hoba ...

  • Hobart Welding Products OM-947 - page 52

    ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Hobart Welding Products. 2010 − 01 Hoba rt We lding Product s An Illinois T ool W or ks Comp an y 600 W est Main Stree t Tr oy , OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Liter atur e Or Nea re s t Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Dat ...

Manufacturer Hobart Welding Products Category Welder

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All of them are important, but the most important information from the point of view of use of the device are in the user manual Hobart Welding Products OM-947.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Hobart Welding Products OM-947, service manual, brief instructions and user manuals Hobart Welding Products OM-947. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Hobart Welding Products OM-947.

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A complete Hobart Welding Products manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Hobart Welding Products OM-947 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Hobart Welding Products OM-947, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Hobart Welding Products OM-947, that we can find in the current document
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5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Hobart Welding Products OM-947 in a specific country, if it was not possible to solve the problem on our own.

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