Hobart Handler Manual

Hobart Handler Manual
 HOBART
LL i
OWNERS MANUAL
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
Specifications covered by this manual:
OWNER'S MANUAL NO. OM-690
The Handler Single Phase MIG Welding Machine
MODEL HANDLER TT
This manual covers units displaying any
one of the following specification num-
6969-1
6969-2
DO NOT DESTROY
HOBART BROTHERS COMPANY, TROY, OHIO 45373, U.S.A.
Manufacturers of Arc Welding Systems/Aircraft Ground Power Equipment/industrial Battery Chargers
HOW TO USE THIS MANUAL - This manual, identified by an "OM" prefixed number, usu-
ally covers just the underlined specification or assembly numbers ín the listing
below. If none of the numbers are underlined, they are all covered.
EQUIPMENT IDENTIFICATION - The unit's identification number (either a Specifi-
cation number, or an Assembly number), model, and serial number usually appear on
a nameplate attached to its control panel. Equipment which does not have a con-
trol panel, such as gun and cable assemblies, are identified only by Spec. (or
six-digit assembly) numbers printed on the outside of the shipping container.
Record this number for future reference.
A "specification number” starts out with a "series number” (first four-digit num-
ber with a possible letter suffix). A "dash number” (-1, -2, etc.) must follow
the series number to make a complete "Specification number”. For example,
1234A-1, 1234A-2, etc. In the same manner, a “dash number” (-1, -2, etc.) must
follow a six-digit assembly number, to identify specific equipment. See below
for identifying equipment covered by this manual.
OWNER'S MANUAL NO. OM-690
The Handler Single Phase MIG Welding Machine
MODEL HANDLER
This manual covers units displaying any
one of the following specification num-
bers with exceptions as noted in the
first paragraph above.
6969-1
6969-2
~ Issued: Aug 14/87 _
Revised: Aug 22/90
Page
DATA SHEET
SAFETY INSTRUCTIONS AND WARNINGS
INSTRUCTIONS
RECEIPT OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
General
Rated Conditions
Miscellaneous Features
Description of Controls/Outlets
Volt-Ampere Curves
Duty Cycle
Functional Block Diagram
INSTALLATION
Location
Safety
Grounding
Electrical Input Requirements
00000000 00 QR LN F~ La NII bt ime = i=
~J
~ 2" „° >
= TFABLE-OF-CONFTENTS—CCONTINUED)—— = =
Page
Installation of Shielding Gas Process 8
Threading Wire Into Feedhead and Welding Gun 10
Polarity Changeover | 13
WELDING GUN DESCRIPTION AND MAINTENANCE 14
General 14
Removing The Gun From The Machine 14
Replacing the Gun Liner 16
Gun Head Maintenance 17
OPERATION 17
General 17
Gas Metal-Arc Welding (GMAW) | 17
Flux-Cored Arc Welding (FCAW) 18
Shutdown Procedures | 18
Welding Guide 18
TROUBLESHOOTING 20
MAINTENANCE OF POWER SOURCE 23
Cleaning of the Unit 23
Cleaning of the Drive Rolls 23
WELDING GUIDELINES 23
General 23
Weld Starting Procedure 24
Check List Before Starting 24
Welding Techniques 24
Welding Gun Positions 24 =
MIG Welding (GMAW) Variables 25
Preselected Variables 25
Primary Adjustable Variables 25
Secondary Adjustable Variables 26
Establishing the Arc and Making Weld Beads 26
Preweld Procedure 27
Welding Procedure 27
Reference Tables 27
PARTS LIST
DIAGRAMS
WARRANTY
NOTE
As you read through this Operator's Manual, be alert for the
words WARNING, CAUTION, and NOTE. Pay particular attention
to the information provided under these headings. WARNING
gives information of possible personal injury. CAUTION re-
fers to possible equipment damage. NOTE offers helpful in-
formation before and during certain operating procedures.
— — чине == | = —_———————
= нет от. ос — ВЫ ыы a = нони нае TD —]—
HOW TO PREPARE YOUR HOBART HANDLER FOR WELDING
THE I
ANDLE
PLUGS IN THE WALL...WELDS IT ALL!
1
Open side of unit using quarter-
turn latches.
2
Remove wire spool retaining nut.
Unload wire spool, remove pro-
tective packaging, reload wire
spool with free end unreeling
from front, left to right. Secure
with retaining nut.
3
Release upper feed roller.
4
Thread wire through guide
between rollers and into wire
cable.
Clamp upper feed roller.
Plug unit into 120 VAC grounded
wall outlet.
Turn input switch on. Set weld
voltage range switch to “1.” Ad-
vance wire to end of cable with
gun trigger. CAUTION: WIRE IS
ELECTRICALLY HOT WHEN
TRIGGER IS PULLED.
Set voltage and wire feed speed
using wire settings guide on
inside of case.
R
}
Attach ground cable clamp to
work to be welded.
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10
Connect gas to coupling at rear
of case.
For gas-shielded solid wire, be
sure #B cable is attached to
negative ( —) terminal, and #A
cable is attached to positive (+)
terminal. Unit will be shipped
this way. To use Handler with
self-shielding tubular wire,
change polarity by attaching #8
cable to positive (+) terminal,
and #À cable to negative (— )
terminal. Close case.
ALWAYS WEAR PROPER
SAFETY EQUIPMENT. Pull
trigger and weld.
DM-633
HOBART
ARC WELDING SYSTEMS
HOBART BROTHERS COMPANY, TROY, OHIO 45373, U.S.A.
PHONE: (513) 332-4000 e TELEX: 28-8265 HOBROCO TRYO
J-29165
OPTIONS:
202858 Tubular wire kit. In-
cludes 21% Ib. roll Fabshield 21B
045 diameter, 3 contact tips
: and 1 liner.
202858-1 .030 Solid wire kit.
includes 3 contact tips, 1 drive
roll and 1 liner.
202858-2. .035 Solid wire kit.
Includes 3 contact tips, 1 drive
roll and 1 liner.
Always consult operator's man-
ual before operating this unit.
LITHO IN USA
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
Hobart Brothers Company
Troy, Ohio 45373
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
4 WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER |
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/ INSTRUC-
TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Certain of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitied: SAFETY IN WELDING AND CUTTING. This publication and
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can Kill. 6. Тит off all equipment when not in use. Disconnect power to
Touching live electrical parts can cause fatal shocks equipment ¡fit will be left una ed or aut of service.
| or severe burns. The electrode and work circuit is 7. Use fully insulated electrode holders. Never dip holder in water
electrically live whenever the output iis on. The input to cool it or lay it down on the ground or the work surface. Do
power circuit and machine internal circuits are also not touch holders connected to two welding machines at the
live when power is on. In semiautomatic or auto- same time or touch other people with the holder or electrode.
matic wire welding, the wire, wire reel, drive roll 8. Do not use wom, damaged, undersized, or poorly spliced ca-
housing, and all metal parts touching the welding bles.
wire are electrically live. Incorrectly installed or im- 9. Do not wrap cables around your body.
properly grounded equipment is a hazard. 10. Ground the workpiece to a good electrical (earth) ground.
1. Do not touch live electrical parts. 11. Do not touch electrode while in contact with the work (ground)
2. Wear dry, hole-free insulating gloves and body protection. 12 Use ol ly well-maintained , Repair or replace dam
| | . . . only well-mai equipment. Repair or -
3. Insulate yourself from work and ground using dry insulating aged parts at once.
mats or covers.
. ; . , . 13. In confined spaces or damp locations, do not use a welder with
4. Disconnect in power or stop erigine before installing or ng . .
servicing this a кос! input ' disconnect он АС output unless it is equipped with a voltage reducer. Use
open, or remove line fuses so power cannot be turned on equipment with OC output. —
accidentally. | 14. Wear a safety harness to prevent falling if working above ficor
5. Properly install and ground this equipment according to its level.
Owner's Manual and national, state, and local codes. 15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
1. Wear a welding heimet fitted with a proper shade of filter (see
ANS! Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
Arc rays from the welding process produce intense 3. Use protective screens or barriers to protect others from flash
heat and strong ultraviolet rays that can burn eyes and glare; warn others not to watch the arc.
and Sian. Noise from some processes can damage 4 Wear protective clothing made from durable, flame-resistant
9. material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A5.2-73. |
wl
Electrode Size Filter _ Electrode Size Filter
Weiding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade
ration or Welding Current No. Operation ___ or Welding Current | №. _
Torch soldering - 2 Gas metal-arc welding (MIG)
Torch brazing — 30r4 Non-ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3or4|i Gastungstenarc welding (TIG) All 12
Medium 1 to 6 in, 25-150 mm 4or5|| Atomic hydrogen welding Al 12
Heavy Over 6 in., 150 mm Sor6|{ Carbon arc welding All 12
Gas welding Plasma arc welding All 12
Light Under 1/8 in., 3mm 4 or 51) Carbon arc air gouging
Medium 1/8 to 1/2in., 3-12 mm S5or6 Light 12
Heavy Over 1/2 in., 12 mm бог 8 Heavy 14
Shielded metal-arc welding Under 5/32 in., 4 mm 10 Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 4t0 6.4mm| 12 Light Under 300 Amp 9
Over 1/4 in, 6.4 mm 14 Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
March 24, 1993 2-1
Replaces April 1, 1992
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
Hobart Brothers Company
Troy, Ohio 45373
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer's instruction for metals, consumables, coatings,
and cleaners.
. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors
to form highly toxic and irritating gases.
. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work-
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
)
RE
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
. Do not use welder to thaw frozen pipes.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. 10. Remove stick electrode from holder or cut off welding wire at
If this is not possible, tightly cover them with approved covers. . contact tip when not in use.
4. Be alert that welding sparks and hot materials from weldingcan 11. Wear oil-free protective garments such as leather gloves, heavy
easily go through small cracks and openings to adjacent areas. shirt, cuffless trousers, high shoes, and a cap.
A FLYING SPARKS AND HOT METAL can
am | Cause injury. 1. Wear approved face shield or safety goggles. Side shields
Chipping and grinding cause flying metal. As weids recommended.
cool, they can throw off slag. 2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged. 3. Keep cylinders away from any welding or other electrical cir-
cuits.
Shield а | h 4. Never allow a welding electrode to touch any cylinder.
ielding gas cyiinders contain gas under high pres- — 5. Use only correct shielding gas cylinders, regulators, hoses, and
sure. If damaged, a cylinder can explode. Since gas fittings designed for the specific application; maintain them and
pim are normaily part of the welding process, associated parts in good condition.
Sure to treat stully. 6. Tum face away from valve outlet when opening cylinder valve.
— ‚ 7. Keep protective cap in place over valve except when cylinder is
1. Protect compressed gas cylinders from excessive heat, me- in use or connected for use.
chanical shocks, and arcs. 8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
A WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
ENGINES can be hazardous.
№ю —
. Use equipment outside in open, well-ventilated areas.
. lf used in a closed area, vent engine exhaust outside and away
from any building air intakes.
2-2
April 1, 1992
Replaces June 2, 1987
Hobart Brothers Company
Troy, Ohio 45373
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
(AO,
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
| X
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for main-
tenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect neg-
ative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can bum
eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and --) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before comnletely removing cap.
"NOTE: Considerations About Weiding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects
Magnetic Fields — Background OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet ailow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
About Pacemakers:
4. Keep welding power source and cables as far away from body as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, S50 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
‘D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Amer-
ican Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Cas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code tor Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada MSW 183.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANSI Standard ZB7.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 518, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
March 24, 1993
Replaces April 1, 1992
2-3
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
This page intentionally left blank.
Hobart Brothers Company
Troy, Ohio 45373
2-4
April 1, 1992
Replaces June 2, 1987
A a A AAA a A a
HOBART
E
Instructions
0M-690
RECEIPT OF EQUIPMENT
Check the equipment received against
the Hobart Brothers Company invoice
to make certain that the shipment is
complete and undamaged. If the
equipment has been damaged in trans-
it, notify the carrier (railroad,
trucking company, etc.) at once and
file a claim for damages. If you
require assistance with a damage
claim, furnish Hobart Brothers Com-
pany with full information about the
claim. If the shipment is in error,
contact: Order Department, Hobart
Brothers Company, 600 West Main
Street, Troy, Ohio 45373.
Give the MODEL, SPECIFICATION, and
SERIAL numbers of the equipment, and
a full description of the parts in
error. Refer to EQUIPMENT IDENTIFI-
CATION on front sheet of this manual
for an explanation of the specifica-
tion numbers.
Best results will be obtained with
this equipment ONLY if the respon-
DESCRIPTION OF
GENERAL
The Hobart Handler Machine is a 90-
Amp single-phase input welding ma-
chine which comes equipped with the
following:
1. Built-in Wire Feeder and Wire
Spool Hub
2. GAL-90 Gun
3. Work Cable and Clamp
4. Input Cord and Plug
5. Spare Parts Kit for Gun (3 tips
and 1 fuse)
6. 2.5 Lbs. of .024" Diameter HB-28
Wire
7. Operational Manual
The welding system is designed for
use with the following processes:
l. GMAW - Gas metal arc welding
(MIG). Requires the use of a
shielding gas and regulator.
Aug 14/87
sible operating and maintenance per-
sonnel have access to this manual,
and are familiar with the instruc-
tions contained herein. Additional
copies may be obtained at a small
cost per copy by writing to: Hobart
Brothers Company, 600 West Main
Street, Troy, Ohio 45373. Be sure
and give the SPECIFICATION, SERIAL,
and MODEL numbers of your equipment,
and the OM number of this manual, or
PL number of Parts Lists, and number
of copies desired when ordering ad-
ditional manuals or parts lists.
Generally, it is good practice to
move the equipment to the site of
installation before uncrating. Use
care in uncrating in order to avoid
damage to the equipment when bars,
hammers, etc., are used. A lifting
handle on the top of the case has
been provided so that the equipment
may be carried or lifted with a
crane or hoist.
EQUIPMENT
2. FCAW - Flux—cored arc welding -
Does not require the use of a
shielding gas.
As delivered from the factory the
welding machine is set up for .024"
diameter solid wire. Optional kits
are available to convert the gun and
feed system to use the following
wires. Refer to OPTIONAL EQUIPMENT
LIST PRECEDING PARTS LIST AT END OF
THIS MANUAL.
le 045" Self-Shielded Wire (Mild
Steel)
2. 030" Solid Wire (Mild Steel and
Stainless Steel)
3. 035" Solid Wire (Mild Steel)
Page 1
l.
2.
3.
— e
A _6M=690
“ =. | Pe — — —
RATED CONDITIONS 10. Input cord length - 6.0 ft.
(1.83 m)
Rated output amperage - 90 amps 11. Shielding gas - CO» or C25
DC 12. Maximum wire spool size - 8 in.
Rated output voltage - 19 volts (203 mm)
DC 13. Work cable length - 10 ft.
Rated duty cycle - 30% (3.05 m)
Maximum open circuit voltage -
27.0 volts MISCELLANEOUS FEATURES
5e
= -—
2.4 kW for any reason. It automatically
Welding gun length - 8.5 ft. resets after the machine has
(2.6 m) cooled.
23 Ygin. Qin.
(600mm) (254mm)
=i ——] —_ Zn
ISin. 2
(381 mm) ”
|| | и
27 ©
CT T
CTF CF ‘7 — J
o _ Weight -62 Lbs. (28 Kg.) Net, includes gun and cables. 353
Specifications
Lee ner aan oo Figure 1
- Page -2… — nn ___ Revised Oct 15/87_
Input voltage rating -
S-6969-1 — 120 volts AC
S-6969-2 — 220-230 volts AC
Input current at rated load -
S-6969-1 - 24 amps
S-6969-2 —- 14 amps
Input frequency-phases -
S-6969-1 - 60 Hz, single phase
S-6969-2 - 50/60 Hz, single phase
Input kilowatt at rated load -
1. The power source contains output
welding terminals to conveniently
change the polarity of the welding
output.
2. A thermal overload device will
turn the machine off automatically
if the duty cycle of the machine is
exceeded or if the machine overheats
pe = от бт ——— —
mE ти М wes R= A rd ——
OM-690
Figure 2
DESCRIPTION OF CONTROLS/OUTLETS
(POWER SOURCE AND WIRE FEEDER)
l. Wire Feed Speed Control — Adjusts
the wire feed speed which changes
the welding amperage.
2. Weld Voltage Range Switch - Se-
lects voltage setting. 4 steps
(ranges) are provided; 1 through
4. A zero "0" setting is pro-
vided which turns off the welding
output but allows the cooling fan
to run.
3. Input Power Switch - Turns the
input power on or off.
4. Wire Spool Hub - Wire spool
mounting location.
5. Feedhead Assembly - The wire
threads through this assembly and
is driven through the gun with
the motor-driven feed roll.
Mar 9/88 Revised
Negative (-) Welding output ter-
minal.
10.
11.
12.
Positive (+) Welding output ter-
minal.
Fuse = Protects feed motor cir-
cuit. 4-Amp slow blow.
Gun Switch Connector - Gun
switch leads connect at this
point.
Gun Connector Inlet Hole - Weld
power gun connector inserts
through this hole and into the
feedhead assembly.
Gun Switch Leads and Gas Hose
Hole - Gun switch leads and gas
hose are routed through this
hole.
Work Cable and Clamp - Connects
to item being welded.
Page 3
0M-690
DESCRIPTION OF CONTROLS/OUTLETS 14. Gas Valve - Controls the flow of
(POWER SOURCE AND WIRE FEEDER) shielding gas when using the
(Continued) GMAW process. It is not used
with the FCAW process.
15. Identification Nameplate.
13. Gun Holder — When completing
welding, the gun head can be VOLT-AMPERE CURVES (Figure 3)
placed in this holder as a con- The volt-ampere curves show the min-
venient storage place for a hot imum and maximum voltage and amper-
gun head. age output capabilities of the unit.
30
25
un 20
|--- RANGE 4
À
СЭ RANGE 3
> 15
RANGE 2
а бам
O RANGE 1
a
18
5
0 25 50 75 190 125
Volt-Amperes Curves
Figure 3
Page 4 Aug 14/87
DUTY CYCLE (Figure 4)
Duty cycle
each ten-minute
is
the percentage of
period
of time
that the welding machine may be
operated under rated load
For example,
tions.
of 30%
can be
Aug 14/87
means
operated at
WELD AMPERES
159
125
condi-
a duty cycle
that the machine
0 15
rated load
28 25 30
% DUTY CYCLE
0M-690
for an average of 3 minutes of
each 10 minute period of operation.
During the remaining 7 minutes,
the machine must idle to permit
proper cooling. Figure 4 enables
the operator to determine the
duty cycle at various welding
amperages.
47 59 ES 860 100
Duty Cycle Chart
Figure 4
Page >
_ SN 0
pa > M0
+7 =— pa >
INPUT
CONTACTOR #
Ki
. OUTPUT
INPUT POWER POWER DIODES
— SWITCH -» TRANSFORMER >
POWER Ti CR2
Se CR3
VOLTAGE
RANGE L
SWITCH |
о Si CONTROL
T RECTIFIER |
FAN = a OUTPUT FILTER
MOTOR REACTOR [1 CAPACITOR |
во Li el
Y
> VA CONTROL WIRE FEED
TRANSFORMER RHEOSTAT
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EN
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OVERTEMP. < CONTACTOR FUSE
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GAS WELDING WELDING
VALVE . WIRE FEED OUTPUT OUTPUT
— - Bi
TO GUN
SWITCH A-375
Functional Block Diagram - S-6969-1
Figure 5
чик нете с —— —
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Revised Oct 15/87
— — - — мен | не
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ail —— INPUT
CONTACTOR H
K1
POWER [7] SWITCH
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VOLTAGE
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T SWITCH
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FAN
MOTOR
B2
24 VAC CONTROL
TRANSFORMER
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THERMOSTAT COIL
53 Ki
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Functional Block Diagram - 5-6969-2
Figure 5A
-— E wen — =
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POWER DIODES
{>| TRANSFORMER >
T1 CR2
CRI
CONTROL
RECTIFIER y
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REACTOR f«1 CAPACITOR
Li Cl
WIRE FEED
RHEOSTAT
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Fi
WELDING WELDING
WIRE FEED OUTPUT OUTPUT
MOTOR
B1
A-400
Page 7
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TTT INSTALLATION
LOCATION the welding power source. This unit
For best operating characteristics has a 30% duty cycle (3 minutes of
and longest unit life, take care in
selecting an installation site.
Avoid locations exposed to high hu-
midity, dust, high ambient tempera-
‘ture, or corrosive fumes. Moisture
‘can condense on electrical com-
‘ponents, causing corrosion or short-
ing of circuits. Dirt on components
helps retain this moisture and also
increases wear on moving parts.
Adequate air circulation is needed
at all times in order to assure
proper operation. Provide a minimum
of 12 inches (305 mm) of free air
space at both right side and rear of
the unit. Make sure that the venti-
lator openings are not obstructed.
SAFETY
Refer to additional installation in-
structions under SAFETY INSTRUCTIONS
AND WARNINGS in front of this man-
ual.
GROUND ING
The internal frame of this welding
machine should be grounded for per-
sonnel safety. Where grounding is
mandatory under state or local
codes, it is the responsibility of
the user to comply with all ap-
plicable rules and regulations.
Where no state or local codes exist,
it is recommended that the National
Electrical Code be followed.
ELECTRICAL INPUT REQUIREMENTS
A cord with plug attached is pro-
vided on this unit. Connect the
plug to a properly grounded and рго-
tected (fuses or circuit breakers)
120 V AC receptacle capable of
handling 15 amperes.
The National Electrical Code
(Article 630B., 1987 Edition) pro-
vides standards for amperage
handling capability of supply con-
ductors based on the duty cycle of
== == оным омлет ln
every 10 minutes can be used for
welding); therefore the cord and
plug supplied with this unit comply
with these standards. Ensure that
the building supply and receptacle
comply with NEC standards and any
additional state and local codes.
NOTE
The supply wiring for the
welding power source must
be capable of handling a
15 ampere load. The weld-
ing power source must be
the only load connected to
the supply circuit. Poor
unit performance or fre-
quently opening line fuses
or circuit breakers can
result from an inadequate
or improper supply.
INSTALLATION OF SHIELDING GAS (GMAW)
PROCESS - See Figure 6
NOTE
Shielding gas is mot re-
quired if unit is used
with the FCAW (flux cored
arc welding) process. The
shielding gas cylinder,
regulator/flowmeter and
gas hose are not included
as part of the welding
package. Contact your
local Hobart distributor.
GAS CYLINDER - Two types of gas
are generally used with Gas Metal
Arc Welding (GMAW) of thin gauge
sheet steel. Carbon dioxide (C05)
is the gas recommended for use with
this welding power source/gun com-
bination. A mixture of 75 percent
argon and 25 percent carbon dioxide
(C25) also can be used. Obtain a
cylinder of selected shielding gas.
честен не — — a.
Revised Nov 11/88
-—
- «*
-
=
A
— — wom man
— Oct 15/87 Revised
INSTALLATION OF SHIELDING GAS UCMAW)
-— —— — | кто 1.
dirt
— —]]] — — = — —— | че ay
that may have "accumulated
around the valve-éeat.
P
ROCESS (Continued)
Chain the
other Support to
cylinder from falling over. If an
optional portable mounting is used
follow the instructions provided
with it. |
REGULATOR/FLOWMETER - Regulator/
flowmeters provide a constant
shielding gas pressure and flow rate
during the welding process. Because
gases have different properties,
each regulator/flowmeter is designed
to be used with a specific gas or
mixture of gases. egulator/flow-
meters cannot be changed from one
gas to another unless the proper
adapters are installed. Be sure to
obtain the proper regulator/flow-
meter for the type of gas used. |
With the cylinder securely in-
stalled, remove the cylinder cap,
stand to one side of cylinder valve,
and open valve slightly. When gas
is emitted from cylinder, close
cylinder to a wall or
prevent the
valve. This will blow out dust or
- "Flowmeter
= et
7 ei (=)
£
7 Fiow
a
Áciusimen A
©
Gas Hase Connection
(5-18 male fitting required) —
„=
CO, instaligtion
Flowmeter
Flow
. Adjustment
, Gas Hose Connection
* (5/2-18 male fitting required)
Regutator
Regulator
The regulator/flowmeter must be
properly equipped with a stem, nut
connectors, and gasket for use with
either CO9 cylinders or
С inert gas
type cylinders.
Install gas regulator/flowmeter onto
gas cylinder valve; keep the face of
the regulator/flowmeter auge in
vertical position and tighten stem
nut securely to gas cylinder valve.
GAS HOSE - Obtain good quality
5/8 ine. (16 mn) 0.D. S.A. . gas
hose, and install 5/8-18 right-hand
thread fittings on both ends of
ose.
Install one end of gas hose | to
fitting on rear of welding power
source.
Install remaining end of gas hose to
fitting on regulator/flowmeter. Be
sure the gas hose is not kinked or
twisted.
Gos Cylinder
ви Volve
CO» Cylinder
Cop
Gas Cylinder
CA Y Valve
С
_— Argon or ArgonMix
Cylinder
E-54
Argon or Argon Mix installation ( C 25)
TT Typical Regulator/ Flowmeter fustattation
Figure 6
N a a = sa sea pe— = —
— o …
Page 9—
= DO A O CR A ALE o AA de еее.
== = = ее сете
THREADING WIRE INTO THE FEEDHEAD AND
WELDING GUN |
For operator convenience, the weld-
ing gun - has been installed at the
factory. A 2.5 1b. sample spool of
wire is included in the materials
supplied with the machine.
WARNING
ELECTRIC SHOCK CAN KILL!
Make certain the machine
is unplugged from the pow-
er receptacle. Do not
plug machine in until told
to do so in these instruc-
tions.
INSTALLATION OF WELDING WIRE
SPOOL — (See Figure 8)
l. Open the door on the case of the
machine.
2. Remove all packing from the
spool of wire.
3. Grasp the spool nut and turn it
counterclockwise, removing it from
4. Slide the wire spool onto the
hub, loading it so that the wire
will feed off of the spool as the
spool rotates counterclockwise.
5. Make sure that the locating pin
on the spool hub lines up with the
hole in the spool.
6. When spool of wire is in place,
replace the spool nut, and tighten
"snug" by hand.
NOTE
|The hub tension has been
preadjusted at the fac-
tory.
— —rs ir A —]———;—]——— ;Ñ*;“"“—];—l — i. ——D—]—]]É—;—.D«_—[—— ]—]]—]——]——
THREADING WIRE (See Figure 8)
CAUTION
Use care in handling the
spooled wire as it will
tend to “unravel” when
| loosened from the spool.
Grasp the end of the wire
firmly, and don't let go
of it. Make sure end of
wire is free of any burrs,
and is straight.
l. Place end of wire into the Inlet
Wire Guide, feeding it through the
rear guide and over the drive roll
groove. Make certain the =— proper
groove is being used.
or
It is best if the Drive
Roll Pressure Arm is in
the UP" position, when
threading the wire into
the feedhead.
a - я"
‘045 Groove EN I и 024 Groove | ,
Restraining Motor Shaft
Screw —]
Stamped .024 Stamped .045
—
Figure 7 ea
The drive roll consists of two dif-
ferent sized grooves. As delivered
from the factory, the drive roll is
installed to feed .024 inch di-
ameter wire. As shown in Figure 7,
the stamped marking on the end sur-
face of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to
the motor shaft is the proper groove
to thread.
me ——]] — a
—— ———— -— Revised Oct—15/87 ————
Te ee ti, |: mm bi i | - rm eat er
THREADING WIRE INTO THE FEEDHEAD AND
WELDING GUN (Continued)
THREADING WIRE (Continued)
This also applies to any optional
drive roll for other wire sizes.
To change the drive roll, simply re-
move the restraining screw, and re-
install drive roll with proper
groove next to motor shaft.
2. Pass the wire into the Input
Guide of the gun that is in the
Feedhead.
3. Close the Drive ‘Roll Pressure
Arm, and lock in position. Tighten
plastic nut on pressure arm to a
"snug" condition.
4. Plug the welding power source in-
to 120-volt receptacle.
WARNING
ELECTRIC SHOCK CAN KILL!
With the gun switch (lo-
_ Oct 15/87 Revised
cated on the gun) acti-
vated, welding power is
applied to the output ter-
minals, feed roll, ground
clamp, gun cable connec-
tion and welding wire. Do
not touch these parts with
the gun switch activated.
5. Turn the welding machine ON with
the Power Switch on the front panel,
and set the Wire Feed Speed to "5".
Activate the Gun Switch until the
wire feeds out past the gun nozzle.
Cut off wire within about 1/4 inch
(6 mm) from nozzle.
WARNING
If ground connection clamp
is in place on the work-
piece, the wire will arc
with the workpiece. The
electrode is electrically
"hot" when gun switch is
activated.
6. Turn the Welding Machine OFF and
unplug input cord.
Page 11
LI
(7
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/ ta OM-690 =
~~ ~ Ш Pe >
Feed Motor Screw F x
Securing w For
Drive Roll Inout Guid
Drive Roll Pressure Arm Gun Input Guide
Bearing Cable Connection
input Guide in
. Gun
Inlet Wire
Guide Gun Securing Nut
and Washer
|
L£————— Gun Cable
| J, Gas Hose .
— - a .
Gun Switch Leads.
joo
|
© |
I
|__—— Control Panel
Front of Plastic Case
/ YN, 1)
A = a » a 9 = \
Fuse and Work Lead
Fuseholder C-355
Threading Wire Into Feedhead and Gun
Figure 8
——— Revised Oet-15/87— ——
a - wm
> -~ _ < > un
+7 > 7 > ~. - pe >
ne To TT ATT 7 - OM-690
A — et >,
POLARITY CHANGEOVER (See Figure 9) l and Figure 9 for proper connec-
tions of cables to output terminals.
As delivered from the factory, the The output terminals are located in-
output polarity is connected for side the door of the side panel of
DCEP (reverse polarity). See Table the power source.
CABLE CONNECTIONS
CABLE A - CABLE B -
TO GUN TO WORK
PROCESS POLARITY
1. GMAW — Solid Wire 1. DCEP —- Reverse | 1. Connect to | 1. Connect to
with Shielding Gas Polarity (+) output (=) output.
terminal terminal
2. FCAW — Self-shield- 2. DCEN - Straight | 2. Connect to 2. Connect to
ing wire - No Polarity (=) output (+) output
shielding gas terminal terminal
Polarity Changeover
Table 1
Gun Connection
Cable B-to Work Clamp С J
Polarity Changeover
Figure 9
Adam. m urn hv dete -——
Oct 15/87 Revised __ Page 13
- -— бен жет сене ео“ = o ; жж me mem — — ее a кл ее. =
WELDING GUN DESCRIPTION AND MAINTENANCE
Hondle
GunTube -
- mé
Spring
N Switch
Actuator
Slip On
Nozzte
==
lo? Ny
*
Power and Gas
able
Liner ©.
A
| Gun Switch .
Pushbutton
Switch Leads
C-358
Welding Gun Description and Maintenance
Figure
GENERAL (See Figure 10)
The GAL-90 welding gun is installed
into the power source at the factory.
It is set up for .024-inch diameter
10
in turn activates the power source
and wire feed motor.
REMOVING THE GUN FROM THE MACHINE
solid wire. The gun and cable length
is 8.5 ft. (2.6 m). The power and
gas cable assembly connects inter-
nally in the gun handle. Gun switch
control leads are also contained in
the cable and make connection with
the pushbutton switch with push-on
terminals.
The switch actuator (when depressed)
activates the pushbutton switch which
—Eer a ———]—]] | е
(See Figure 11)
The gun must be removed from the ma-
chine to install a new or different
liner or a new gun.
WARNING
Make certain the machine is
unplugged from the input
receptacle before removing
gun.
mm ——
— Tm E A A il EE EE a | че
— -
Revised Oct 15/87
= ma Er EER SE AU A AE
Gun Switch Leads
> _ ни the > Вай
„^^ N „о
| > _ LA ~~
e II -OM-690
intet Guide
Feedhead Screw
Gun Inlet Guide
Coble Conne 9” Spring Liner |
Washer Connection Block
и Threaded Support
i i — eX X
J) Gas Hose Borbed
— : Fitting
—Úo 1 -
Na N as Hose Co.
ole
Gun Switch
Receptacle
--
"Plastic Case - -
Removing The Gun From The Machine
| Figure ll
REMOVING THE GUN FROM. THE MACHINE
(Continued)
1. Loosen inlet guide screw.
2. Loosen locknut and remove it and
the washer from the threaded sup-
port. Let them both rest on the
connection block at this point.
3. Gently pull on gun until gun in-
let guide comes out of the feed-
head.
4. Stop pulling at this point and
disassemble the gun inlet guide
from the connection block. Remove
the cable connector.
5. Disconnect the gun switch leads
from the gun switch receptacle and
pull them gently through the hole
in the plastic case.
6. Remove the gas hose from the
barbed fitting on the gun.
7. Pull the gun the rest of the way
out of the case.
8. If the liner is to be changed,
leave the gun disassembled.
is to be
install the
the threaded
gun inlet
connection
92. If the removed gun
stored for later use,
washer and locknut onto
support and install the
guide back into the
block.
10. To reinstall the gun, simply re-
verse these directions.
“T
The cable connector must be
installed inside the case.
Be sure to place the lock-
nut and washer on the
threaded support prior to
making the cable connec-
tion. The gas hose barbed
fitting should be pointing -
down.
Oct 15/87 Revised
Page 15
O
a a —]—[][]z[—Ú——]]—]——]——;—T—D—l—]—y ———
REPLACING THE GUN LINER (See Figure
12)
1. Remove slip on nozzle, contact
tip, nozzle adaptor and contact tip
fitting from the gun. (Figure 12A)
2. Remove gun inlet guide. (Figure
12B)
3. Pull the liner straight out of
the cable from the rear of the gun.
4. To install a new liner, pull the
OM-690
of the gun
seats into
new liner into the rear
until the liner fitting
the connector block.
5. Reinstall the gun inlet guide to
hold liner in position.
6. At the front end of the gun, the
liner will extend out beyond the gun
tube. Cut the liner off at 7/8"
past the gun tube end. Cut off the
spring liner with side cutters ora
gun cable out straight and feed the hacksaw.
A
Slip-On Nozzle Contact Fitting Contact Gun Tube
Nozzle Adapter Tip /°
| Te
Front of Gun
B
Connector Block . : Liner Gun Inlet Guide
Gas Tube
(to valve)
Gun Switch
Leads
Rear of Gun
Liner Replacement and Gun Head Maintenance
Figure 12
Page 16
Revised May 31/88
REPLACING THE GUN LINER (Continued)
NOTE
Burrs or bent wire from
the spring may make it
difficult to feed wire
through the liner. Re-
move burrs.
7. Install and tighten contact tip
fitting and nozzle adapter.
8. Replace contact tip and nozzle.
GUN HEAD MAINTENANCE
1. To inspect or replace nozzle
parts, see Figure 12A. Pull off noz-
OM-690
zle and unscrew contact tip. Unscrew
nozzle adapter and contact tip
fitting. Replace needed parts and
reassemble.
2. To inspect or replace parts in
handle, see Figure 10. Remove the
three #6-32 x 1/2-inch screws in
handle. Separate the two halves of
handle, opening the internal parts
to view.
3. If pushbutton switch is to be re-
placed, grasp the terminals of the
switch leads and pull them off. Do
not pull on the wires. Replace
switch if defective.
OPERATION
GENERAL
WARNING
|ELECTRIC SHOCK CAN KILL!
Do not operate the ma-
chine with the door
open.
CAUTION
Do not pull the machine
with the gun. Damage can
occur to the gun, gun
liner and machine. Avoid
bending the gun cable
with a sharp radius. Dam-
age can occur to the gun
liner.
GAS METAL-ARC WELDING (GMAW) - See
WELDING GUIDELINES in back part of
this manual.
1. Make all necessary connections as
instructed in the Installation sec-
tion.
Oct 15/87 Revised
—
2. Place the Weld Voltage Range
Switch (see Figure 2) at the desired
setting.
3. Rotate the WIRE SPEED Control to
the desired position.
4. Plug the input cord into a 120-V,
15-Amp receptacle.
5. Open the gas cylinder valve to
supply shielding gas to the gun.
6. Connect the WORK clamp to the
workpiece (material to be welded.)
7. Place the welding machine Power
ON/OFF switch on the ON position.
8. Extend wire from gun, and cut to
proper stick-out for that type wire
(when welding, always maintain this
distance). See Figure 19 under
WELDING GUIDELINES section in back
part of this manual.
Page 17
>”
>
nn
A a la =
GAS METAL-ARC WELDING (GMAW) (Con-
tinued)
WARNING
Be sure to put on proper
protective clothing and
eye safeguards (welding
coat, apron, gloves, and
welding helmet, with prop-
er lenses installed). See
SAFETY 1 INSTRUCTIONS AND
WARNINGS in front part of
this manual. Neglect of
these precautions may re-
sult in personal injury.
9. Position gun to where it is at
approximately right angles to the
workpiece, with proper wire stick-
out, lower your welding helmet, and
pull the gun switch (trigger).
10. Travel at a speed to maintain a
bead width from 1/8 to 1/4 inch, de-
pending on the thickness of the ma-
terial. For material that may re-
quire larger weldments, either
change to a larger diameter filler
wire, or use multi-pass beads. On
some applications, it may be neces-
sary to adjust the voltage range to
stabilize the arc.
ll. Upon completion of weld, release
the gun switch trigger, raise your
hood, and visually examine the
weld.
NOTE
To help you overcome any
problems that might arise,
you will find useful in-
formation in the WELDING
dm a о
690 —
7 >
| GUIDELINES section, and in
particular under WELDING
TECHNIQUES in that sec-
tion.
FLUX-CORED ARC WELDING (FCAW)
Follow the same general procedure as
with the GMAW process above. Shield-
ing gas is not required for this pro-
cess. For differences in the process,
see WELDING GUIDELINES section in the
back part of this manual. Also in-
cluded is information to solve any
problem related to the: Flux-Cored Arc
Welding process.
SHUTDOWN PROCEDURES
1. Close gas cylinder valve. (GMAW
process only)
2. Press Gun Switch to vent gas line.
(GMAW process only)
3. Place the welding machine Power
ON/OFF Switch in the OFF position.
4. Unplug the machine from the 120-V,
15-Amp receptacle.
WARNING
After releasing gun switch,
the wire will remain elec-
trically hot for several
seconds.
WELDING GUIDE
Refer to Table 2 for the parameters
for welding with the HANDLER single-
phase welding machine.
— — — | в
——— Revised-0ct—+5/87———
кое = — = сене вы dma mE A ее =
WELDING GUIDE
Settings are approximate. Adjust as required.
Wire
Speed
Wire Gas Voltage
1 5.
20
СЕН
DCEP
Carbon
Steel
— L
less 308L
Steel Stain-
less
E-/1T-11
Fab-
Carbon FCAW Shield
Steel 21B
24 ga. =.022", 18 ga. = 3/64”, 16 ga. = 1/16", 10 ga. = 1/8"
CO = Carbon Dioxide DCEP=DC Volts Wire Positive
Cys =25% Carbon dioxide + 75% Argon DCEN=DC Volts Wire Negative
Table 2
Oct 15/87 Revised Page 19
TROUBLESHOOTING
The following chart contains information which can be used to diagnose and cor-
rect unsatisfactory operation or failure of the various components of the weld-
ing machine.
and procedures to correct them.
Each symptom of trouble is followed by a list of probable causes
TROUBLE
POSSIBLE CAUSE
REMEDY
Fan motor runs
slow
Output normal;
fan motor does
not run
No output; fan
motor does not
run
No open-circuit
voltage; fan
motor runs and
wire feeds
Wire does not
feed; fan motor
runs and open-
circuit voltage
is normal
Erratic weld
output
jr wm ve —
Low primary voltage
Fan motor defective
Loose connections to fan
motor
Power switch defective
Line fuse open or circuit
breaker tripped
Loose primary connections
Contactor points defective
Contactor coil defective
Fuse open
Wire speed adjustment con-
trol open
Rectifier defective
Wire drive motor is de-
fective
Check leads and contacts
of voltage range switch
Capacitor defective
a.
be
be
Ce
be
Connect welding power
source to proper input
voltage. В
Replace fan motor.
Check connections to fan|
motor.
Replace power switch.
Replace line fuse if
necessary or reset
circuit breaker.
Check tightness of all |
primary connections.
Replace contactor.
Replace contactor.
Check and replace fuse.
Check rheostat.
Replace rectifier.
Replace motor.
Discoloring of brass
contacts could indicate
heating caused by loose
connections. Replace
switch if necessary.
Replace capacitor.
a E A с к
—-—-—-—-—-— -—
———— Revised Oct-15/87
PO — = = п = .
— те ес = ан с
— — [ — лее
и” AS
— Se em... 0M-690
- ET ss
_ Di ~~
TROUBLE "POSSIBLE CAUSE REMEDY
Erratic weld ce Loose connections on Ce Secure connections.
output (Cont'd) output terminals
d. Ground clamp loose at WORK | d. Check ground clamp for
connection secure attachment.
e. Gun liner dirty e. Check gun liner and re-
place if necessary.
f. Voltage and wire feed f. Readjust as necessary.
settings are not correct
Wire feed motor a. Too little pressure on wire| a. Increase pressure ad-
operates, but feed roll justment.
wire does not |
feed b. Incorrect wire groove be Check wire size stamped
on outside of feed roll.
Match to wire size. See
Figure 7.
ce Restriction in gun or cable| c. Examine cable, gun, and
assembly current contact tip
for damage and correct
size. Make sure correct
contact tip and liner is
being used.
Wire wraps a. Too much feed roll pressure| a. Decrease the pressure
around the drive adjustment on the drive
roll roll pressure arm.
b. Incorrect liner or contact b. Make sure that liner
tip and/or contact tip is
correct for the size
of wire being fed.
No speed control| a. Broken or loose wires in a. Correct by checking all
wire feed control circuit. connections.
b. Rheostat is open. b. Replace the rheostat.
c. Knob loose on rheostat c. Tighten knob.
d. Fuse blown d. Replace fuse.
Wire feeds but | a. Failure of gas valve sole- | a. Replace.
no gas flows noid
b. Loose or broken wires to be Check all connections.
gas valve solenoid
Oct 15/87 Revised
— — — === | нете O == са =
Zn _ 7
27 > “ и
TROUBLE POSSIBLE CAUSE REMEDY
Wire feeds but
no gas flows
(Continued)
Welding current
not stable
Jerky or erratic
wire feeding
Welding current
stops during
welding
Ce
d.
eo
fe
as
Ce
ee
De
Ce
as
Gas cylinder valve not open
or flow meter not adjusted
Gas cylinder empty
Restriction in gas line
Gun nozzle plugged
Wire slipping in rolls
Restriction in gun cable
or gun
Wrong size liner or contact
tip.
Incorrect voltage adjust-
ment for selected wire
speed on the welding ma-
chine
Loose connection on the
welding leads or WORK
table
Liner dirty or damaged
Worn or damaged contact
tip
Wrong groove used on drive
roll
Overtemperature device
trips
Input circuit breaker or
fuses clear
Ce
Е.
as
b.
Ce
de
fuses.
Open gas valve at cylin-
der and adjust flow
meter.
Replace.
Check gas hose between
flow meter and machine,
and gas hose in gun and
cable assembly.
Clean gun nozzle.
Readjust pressure on the
drive roll pressure arm.
Check Welding Gun.
Match liner and contact
tip to electrode wire
size.
Readjust. See Welding
Guide in Operation sec-
tion.
Check and tighten all
connections.
Replace liner.
Replace contact tip.
Use correct groove or
correct drive roll.
Allow machine to cool
for several minutes
and resume welding.
Reset breaker or replace
Revised Oct 15/87 —— —
— — —— ——]—
шнек мк = NL ET - er ue
— — — — A
== се ыы еее A — == + —
MAINTENANCE OF
CLEANING OF THE UNIT
Periodically remove from the plastic
case the inside metal constructed
portion of the power source. Blow
out the interior with clean, dry,
compressed air of not more than 25
PSI air pressure. Do not strike any
components with the air hose noz-
zle.
POWER SOURCE
CLEANING OF THE DRIVE ROLLS
Clean the wire groove on the drive
roll at frequent intervals. This
cleaning operation can be done by us-
ing a small wire brush. To clean the
wire groove, loosen the nut and lift
the drive roll pressure arm. Remove
all wire from the feedhead. Wipe off
the bearing roll (top roll).
WELDING GUIDELINES
GENERAL
Two different welding processes are
covered in this section, with the
intention of providing the very
basic concepts in using the semi-
automatic mode of welding, where a
welding gun is hand-held, and the
electrode (welding wire) is fed into
a weld puddle, and the arc is
shielded by a gas or gas mixture.
GAS METAL ARC WELDING (GMAW) -
This process, also known as MIG
welding, CO, welding, Micro Wire
Welding, short arc welding, dip
transfer welding, wire welding,
etc., is an electric arc welding
process which fuses together the
parts to be welded by heating. them
with an arc between a solid, contin-
uous, consumable electrode and the
work. Shielding is obtained from an
externally supplied gas or gas mix-
ture. The process is normally ap-
plied semiautomatically; however,
the process may be operated auto-
matically and can be machine
operated. The process can be used
to weld thin and fairly thick steels
and some nonferrous metals in all
positions.
GMAW Process
Figure 13
FLUX-CORED ARC WELDING (FCAW) -
This process, also known as ]Dual-
Shielded, Innershield, FAB Shield,
FabC0, etc., is an electric arc weld-
ing process which fuses together the
parts to be welded by heating them
with an arc between a continuous flux
filled electrode wire and the work.
Shielding is obtained through decom-
position of the flux within the
Page 23
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na
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= - mm >
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LE = 777.777 70M=690 4
о > Pa
FLUX-CORED ARC WELDING (Continued) "o
tubular wire. Additional shielding |See Table on inside of
may or may not be obtained from an the welding machine.
externally supplied gas or gas mix-
ture. The process is normally ap- ELECTRODE WIRE STICKOUT - See
plied semiautomatically, but can be Figure 19 or Welding Guide, Table 2.
applied automatically or by machine.
It is commonly used to weld medium
to thick steels using large diameter
electrodes in the flat and horizon-
tal position and small electrode
diameters in all positions. The WELDING TECHNIQUES
process is used to a lesser degree
for welding stainless steel and for The Hobart Pocket Welding Guide will
overlay work. give you pictorial examples of good
and bad welds, and causes of common
welding troubles. It contains a
wealth of information for the weld-
1 | ing operator. Copies of the Pocket
leg Nozzle Optional) po14ins Guide may be obtained at min-
imal cost from:
Gas (Optional)
Molten Metal
“= -.
. Solidified
: Weld Metal
EN , Molten Hobart Brothers Company
- Stag Slog P. 0. Box EW-609 a.
Troy, Ohio 45373
| Ji
- N a
| WELDING GUN POSITIONS
FCAW Process The welding gun should be held at an
Figure 14 angle to the weld joint. See para-
graph 3 in Secondary Adjustable Var-
WELD STARTING PROCEDURE iables below, and also Figures 15,
Follow these instructions only after 16, 17, 18, 19, 20, and 21.
referring to the SAFETY INSTRUCTIONS |
AND WARNINGS in the front of this Hold the gun so that the welding
manual, and instructions in the IN- seam is viewed at all times. Always
STALLATION section. wear the welding helmet with proper
filter lenses.
CHECK LIST BEFORE STARTING
CAUTION
POLARITY (DCEP - Direct Current
Electrode Positive) or (DCEN - Do not pull the welding
Direct Current Electrode Nega- gun back when the welding
tive). arc is established. This
WIRE FEED SPEED (1 to 10) will create excessive wire
VOLTAGE RANGE SETTING (1 thru 4) extension (stickout) and
GAS FLOW RATE (15 to 25 CFH) make a very poor weld.
Page 24 ___ ] E Revised Nov 28/88
= rr ————] —]M——;—;—— LE E E
A A a A nt Std
<< Erp ING GUN POSTTIONS (Continued)
The electrode wire is not energized
until the gun switch trigger is de-
pressed. The wire may therefore be
placed on the seam or joínt prior to
lowering the helmet.
5° to 15°
— LONGITUDINAL
ANGLE
Butt and Horizontal Welds
Figure 15
10 to 209 LONGITUDINAL —
ANGLE
I 10° |
LONGITUDINAL
ANGLE
“т
60°
TRANSVERSE
ANGLE
DIRECTION OF TRAVEL"
Vertical Up Vertical Up
Figure 16
5° to 15°
LONGITUDINAL ANGL
Co 30° to 60°
Г 2 TRANSVERSE ANGLE |
“= RECTION OF
RAVE
Horizontal Fillet Weld
--—— Figure 17
-———They-are-
ET aes
= >
DIRECTION OF TRAVEL |
Overhead
Figure 18
MIG WELDING (GMAW) VARIABLES
Most of the welding done by all pro-
cesses is on carbon steel. The
items below describe the welding
variables in short—-arc welding of 24
gauge to 3/16 inch mild sheet or
plate. The applied techniques and
end results in the GMAW process are
controlled by these variables.
PRESELECTED VARIABLES
Preselected variables depend upon
the type of material being welded,
the thickness of the material, :the-
welding position, the deposition
rate and the mechanical properties.
These variables are:
l. Type of electrode wire
2. Size of electrode wire
3. Type of gas (not applicable to
self-shielding FCAW)
4. Gas flow rate (not applicable to
self-shielding FCAW)
Tables 3,
4, and 5 are references
for the new MIG welding process
user. |
PRIMARY ADJUSTABLE VARIABLES
These control the process after pre-
selected variables have been found.
They control the penetration, bead
width, bead height, arc stability,
deposition rate, and weld soundness.
Page 25
с в чт
pa
>
M698
zs _ _ >s
PRIMARY ADJUSTABLE VARIABLES (Cont'd)
l. Arc voltage
2. Welding (wire
speed)
current feed
3. Travel speed
SECONDARY ADJUSTABLE VARIABLES
‘These variables cause changes in pri-
mary adjustable variables which in
turn cause the desired change in the
bead formatiom.
‘They are:
1. Stickout (distance between the end
of the contact tube [tip] and the end
of the electrode wire). See Figure
19. Maintain about 3/8" (9.5 mm)
stickout.
2. Wire Feed Speed. Increase in wire
feed speed increases weld current.
Decrease in wire feed speed decreases
weld current.
3. Nozzle Angle. Refers to
sition of the welding gun in relation
to the joint, as shown in Figures 16-
18, 20, and 21. The transverse angle
is usually one-half the included
angle between plates forming the
joint. The longitudinal angle is the
angle between the center line of the
welding gun and a line perpendicular
to the axis of the weld.
The longitudinal angle is generally
called the nozzle angle, and is shown
in Figure 21 as either trailing
(pulling) or leading (pushing).
Whether the operator is left-handed
or right-handed has to be considered
to realize the effects of each angle
in relation to the direction of
travel.
za — — —
the po-
. Gas Nozzle Contact Tip (Tube)
- Tip To Electrode Wire
‚ Work Distance Actual Stickout
N
=
"le m aa 4 ew - o ay mek Comm vam a
Electrode Stickout
Figure 19
| “Fransverse
! Angle
AN A o
E
Longitudinal
и Angle Г || -
"Axis of wid
+.
. у
- Ш ' ’
. . = - * п
7 = : N . —
? - - -
` “ - - = - а
. " - * | . —
‘ x .
Transverse and Longitudinal Вы
Nozzle Angles
Figure 20
Direction.of Gun Travel
>—
90°
Leading or “Pushing”
Troiling or' Pulting
Angle (Forward Pointing)
Angle (Backward В спо)
[B-105] a ль
Nozzle Angle, Right-Handed Operator
Figure 21
ESTABLISHING THE ARC AND MAKING WELD
BEADS
Before attempting to weld on a fin-
ished piece of work, it is recom-
mended that practice welds be made
on sample metal of the same material
as that of the finished piece.
== оо и =
— ——— Revised Oct 15/87
= ке am ams mes A = eam a -
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-== ~~ “ESTABLISHING THE ARC AND MAKING WELD — — to start —the wire feeding, amd es=
BEADS (Continued)
The easiest welding procedure for
the beginner to experiment with in
MIG welding is the flat position.
The equipment is capable of flat,
vertical, and overhead positions.
For practicing MIG welding, secure
some pieces of 16 or 18-gauge mild
steel plate 6 inches x 6 inches.
Use .024 wire supplied with machine
and CO shielding gas.
PREWELD PROCEDURE
1. Check the OPERATION section of
this manual for details on equip-
ment.
2. Set the weld voltage range at po-
sition l or 2.
3. Set the Wire Feed Speed Control
on about the number 6 setting. Re-
adjust as necessary.
4. Adjust the gas flow rate to about
20 cubic feet per hour.
5. Recess the contact tip from the
front edge of the nozzle from 0 to
about 1/8 inch.
6. Review standard safe practice
procedures in ventilation, eye and
face protection, fire, compressed
gas and preventive maintenance. See
Safety Instructions and Warnings in
the front of this manual.
WELDING PROCEDURE
l. Maintain the tip-to-work distance
(stickout) at 5/16 to 3/8 inch (8 to
9 mm) at all times. See Figure 19.
2. For transverse and longitudinal
nozzle angles, see welding gun posi-
tions.
3. Hold the gun about 3/8 inch from
the work, lower the helmet by shak-
tablish the arc.
“o
lt is the best practice to
form the habit of shaking
the helmet down, rather
than using the hands,
since one hand must hold
the gun, and the other is
often needed to hold
pieces to be tacked or
positioned.
4. Make a single downhand. (pulling)
stringer weld bead.
5. Practice welding beads. Start at
one edge and weld across the plate
to the opposite edge.
“T
[When the equipment is
properly adjusted, a rap-
idly crackling or hissing
sound of the arc is a good -
indicator of correct arc
length.
6. Practice stopping in the middle
of the plate, restarting into the
existing crater and continuing the
weld bead across the plate.
or
When the gun trigger is
released after welding,
the electrode forms a ball -
on the end. To the new
operator, this may present
a problem in obtaining the
penetration needed at the
start. This can be cor-
rected by cutting the ball
off with wire cutting
pliers.
REFERENCE TABLES
The following tables are provided
for an aid to the user of the MIG or
FLUX CORED Welding Mode. Also see
--__. . ing—the-head-and squeeze-the -trigger … Table 2 under OPERATION.
_-__ Oet-15-/87-Revised—- —————— Page 27
-— — "=; - — mms мнт жет нете се = =
- ss pt
- “< ~ - >
= — то < —0M-690 = _
LL ——— . e
WELDING ELECTRODE SELECTION
AWS CLASS DESCRIPTION AND APPLICATION HOBART DESIGNATION
E71T-11 Fabshield 21B (AWS E71T-11) A good general Fabshield 21B
purpose self shielded flux cored wire
suited to a broad line of general applica-
tions including galvanized and sheet metal.
A good all position wire.
ER70S-6 HB-28 (AWS ER70S-6) A unique solid wire| ‘ HB-28
with powerful deoxidizers for CO, welding
where poor fit up, rusty or oily material
may be used. Recommended for general shop
fabrication.
ER-308-L HB-308L (AWS-ER-308-L) A good general pur- 308L
pose solid stainless steel wire suited for
welding types 304, 308, 321, and 347 steels.
Table 3
Type of Gas Typical Mixtures Primary Uses
Carbon Dioxide Mild and Low Alloy Steel
Argon- 75hAr-25% CO Mild and Low Alloy Steels
Carbon Dioxide Stainless Steel
Table 4
45 = .
чо = = — =
=
> 7 >
~ - > >
„” ~~ ^^ A ss,
A ~ _ ~~ Ds
Ee == —— —— = реб —— Об _
Li > CT >,
STIO—OUTI
OR
NOZZLE |TIP-TO-WORK | WIRE GAS
ANGLE DISTANCE SIZE TYPE |
3Trailing 2pecrease |?Smaller* 400»
Penetration Max. 25
Shallower lDecrease YLeading 2Tncrease |Larger* 4AR+CO5
Penetration |
Larger lnerease |?Decrease 3Increase*
Bead |
Smaller lpecrease |2Increase Зрестеаве*
Bead Bead
Height |
. and Higher lpecrease 2Trailing Increase
Bead |Narrower
Width | Bead
Flatter |lIncrease | 290 or SDecrease
Wider : Leading
Bead
Faster l Increase 2Tncrease* |3Smaller
Deposition Rate
Slower Inecrease 2Necrease* Larger
Deposition Rate
ор ть лены ны | ва
—
KEY: (1) First Choîce, (2) Second Choice,
(4) Fourth Choice, (5)
(3) Third Choice,
Fifth Choice
NOTE: Same adjustment is required for
wire feed speed.
remains constant.
ness.
Table 5
= нм ен нс E EE E ARA не EA
— Oct 15/87 Revised
*When these variables are changed, the wire feed
speed mist be adjusted so that the welding current
See deposition rate of welding
variables section. his change is especially
helpful on materials 20 gage and smaller in thick-
Page 29 —
- TE SEL rr My 1 RE dr aa hang носом | LT Lol
~~
~ -
.
a „” a
-
- ' я
—
= o O.
; _ e - | В Ч
“OPTIONAL EQUIPMENT LIST FOR VARIOUS WIRE SIZES AND TYPES — °
DRIVE ROLLS
HOBART PART NO. WIRE DIAMETER INCHES (mm)
WELDING GUNS (FOR REPLACEMENT OR IN ADDITION TO STANDARD GUN)
HOBART PART NO. LENGTH FEET (m) WIRE SIZE INCHES (mm)
177057-2 8.5 (2.6) 030 (.8)
177057-3 8.5 (2.6) „035 (.8 or .9)
177057-8 8.5 (2.6) 045 (1.2)
KITS TO CONVERT GUN AND MACHINE TO OPTIONAL WIRE SIZES.
WIRE SIZE
HOBART PART NO. | INCHES (mm) ITEMS INCLUDED IN KIT
| 3 Contact Tips, 1 Gun Liner,
202858 045 (1.2) 1 Drive Roll, and a 2.5 Lb. =
Sample of FABSHIELD 21B.
202858-1 .030 (.8) 3 Contact Tips, 1 Gun Liner,
1 Drive Roll
202858-2 .035 (.9) 3 Contact Tips, 1 Gun Liner,
1 Drive Roll
If individual parts are required, see parts list following this page for
part numbers to order.
— mm vem =
Page 306 —————— ————.-—Revised Oct-15/87—— ——
.— de CE o E A E met — - —— ==
жен a =
“Parts List
-
mm Em ——]] iE a Eh mer EAE mm BA EF mi MES meh bm bmg mf ET mam ver Wr My «окон memes 1-5 mt
EQUIPMENT IDENTIFICATION - An identification plate on the unit's control panel
shows its model number, serial number, and specification number. Whenever or-
dering parts or making inquiries, furnish all these numbers.
NOTE: A "specification number” must have a “dash number”
suffix (-1, -2, -3, etc.) in order to be a complete number.
HOW TO USE THIS PARTS LIST - The part mame listings may be indented to show
part relationships as indicated in the following example.
TA E As = — PE [— — = я с — pra
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2| No. No, No. Description Assembly Code
1- 123456 Assembly (Not Shown) 1
234567 . A detail of assembly 1
345678 . A sub-assembly 1
456789 . . A detail of sub-assy (item 2) 1
567891 . . A sub-assembly of item 2 1
678910 . . . A detail of sub—assy (item 4) 1
in + Wwe >
The parts list contains a breakdown of the equipment into assemblies, subassem-
blies, and detail parts. All parts of the equipment are listed except standard
hardware items, bulk items such as wire, cable, sleeving, tubing, etc., and
permanently attached parts which lose their identity by being welded, soldered,
riveted, etc.
Locate the specification number below that appears on your unit, and note the
"APPLICATION CODE" letter adjacent to it. (If no application code appears be-
low, the parts list is applicable to only the one specification number that ap-
pears below.) After locating the desired part in the following figures and
parts lists, if the "Application Code” column says "All", proceed to order the
part. If there are several part numbers after the same “Item No.”, order only
the part number corresponding to the "Application Code” letter that you se-
lected above.
SPECIFICATION NUMBER APPLICATION CODE
6969-1 A
6969-2 B
HOW TO SELECT RECOMMENDED SPARES —- The parts list has a column heading entitled
"Recomm. Spares, Class 1 and Class 2”. Class 1 recommended spare parts are
parts that are consumed or may need replacement in two years or less, depending
on operating hours. Class 2 spares are parts that may need replacement under
unusual service conditions or because of additional operating hours. The
quantities listed are suggested quantities based on expected usage or the mini-
mum quantity package. Class 1 spares are repeated under Class 2 but the
quantities may be larger to allow for the additional operating hours. Contact
your Hobart equipment dealer for assistance in establishing a spare parts pro-
gram based on your needs.
- ——— hm ES SE im. e = = -- -
+ ее не 2000 == = et mm = = tm me em vas ni ленин -
Oct 15/87 Revised Page 1
ME = ноет ня = не — us om — te re Bear del
= = неее ее == антены = ан ен ен ное нео a
Page
Figure 1. Ce ma
~~ PL~690
© Aug 14/87
oC _ __ Quantity
Fe A LL EL Sal En a LD llr
~
a A en rt | nt BR iin py ma hE Cf mmm AER A KA E A E A AA w— — 2 кн сено
A7
-
L
Tow
-
“e,
-— PL-690
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 | No. No. No. Description Assembly Code
1- S-6969-1 Handler - Single Phase Mig
Welding Machine, 60 Hz 1 A
S-6969-2 Handler - Single Phase Mig
Welding Machine, 50/60 Hz 1 B
1 Ref. . Welder & Case (For Details
See Fig. 2) Ref. All
1 2 177057-1 - Gun € Cable Assembly (For
Details See Fig. 4) 1 All
"Oct 15/87 Revised | TU Page 3
PL-690
Figure 2
Revised May 31/88
Page 4
PL-690
Quantity
Re comm.
Spares — Quantity
Cl ass Fig. Item Part per Application
1{ 2 | No. No. No. Description Assembly Code
2- 1 Ref. Cable - Input Ref. All
2 No Number Connector — Strain Relief 1 All
3 200548 Adapter - Gas 1 All
4 Delete
1 | 5 201234-3 Cable — Ground 1 All
200567-1 Case - Assembly 1 All
6 409472-1 e Case - Plastic 1 All
7 407849 - Handle - Carrying 1 All
8 200571 « Bracket - Handle 1 All
9 376379 « Holder - Gun 1 All
10 No Number . Screw — 8-18 x 3/4, Туре В
Sf. Tap. 1 All
11 Delete
12 No Number « Foot - Rubber 4 All
13 407850 . Latch - Door 2 All
14 400562-41. . Spring - Compression 2 All
15 No Number +. Washer - Flat, ST. 5/16 2 All
16 No Number » Washer —- Retainer, Split 2 All
17 407851 « Receptacle - Leaf Spring 2 All
18 200563 - Vent - Screen l All
18А 202859 « Hinge — Assembly 1 All
19 200574 Vent - Air Outlet 1 All
20 200568-1 Welder - Assy (For Details
See Fig. 3) 1 A
200568-2 Welder —- Assy (For Details
See Fig. 3) 1 B
202796 Summary - Label 1 All
21 405999 . Label - Warning, Electric
Shock 1 All
22 405970 e Label - Warning, Arc Welding 1 All
23 407099 « Label - Warning, Electric
Shock 1 All
24 406636 . Label - Moving Parts 1 All
25 409285 Label - Ident. 2 All
26 200577 Bracket - Lifting 1 All
Aug 22/90 Revised Page 5
“e ale we Tam EE A A Md к =
PL-690__—-
Figure 3
© ат rm ie ie O EE a
_ Revised Oct 15/87
——]—] WER LEMS Ep fr a ger m— eh + Whe AD bpm com ome mm == = + ln dm 1 ==
———— 4 ———
PL-690
Quantity.
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 | №. №. No. Description Assembly Code
3- 200568-1 Welder - Assembly Ref. A
200568-2 Welder - Assembly Ref. B
1 405377 « Nut — Hub, Wire Spool 1 All
2 No Number . Screw - 1/4-20 x 1/2, HHC, ST. 4 All
3 No Number >. Washer - LK, 1/4, Std. 2 All
4 W-11242-30 . Washer - Flat, 1/4 (Special) 1 All
5 409615-1 . Washer - Spring, Finger 1 All
6 409475 . Hub - Wire Spool 1 All
7 200562 . Shaft - Hub 1 All
8 No Number . Washer - 1К, ТЕТ, 1/4 1 All
9 200556 » Tray - Upper 1 All
1 10 409520 . Motor - Feed 1 All
11 40947 3A . Head - Feed 1 All
1 12 407230-4 » Roll - Feed 1 All
13 200572 » Cover — Welder 1 All
14 No Number . Screw — 8-18 x 3/8, HWH,
Sf-~Tap 8 All
15 No Number . Nut - 1/4-20, Hex, Keps 9 All
16 No Number . Washer — FL, ST, 1/4 10 All
17 No Number . Washer - FL, ST. 4 All
18 406319-1 . Grommet — Mtg. 2 ~All
19 No Number >. Rod - Threaded, 1/4-20 x a
2, Brass 2 All
20 402658 . Holder — Fuse 1 All
2 21 16DA-4252-3 . Fuse - 4 Amp, Slow Blow 1 All
22 405576-1 « Bushing - Terminal 1 All
23 200570 . Bracket - Fan 1 All
24 No Number . Insulator 2 All
1 25 W-9746-18 . Resistor - 25 W, Fixed Type 1 All
1 26 409474 . Fan - W/Motor, Assembly 1 A
1 26A 409952-1 . Motor - Fan/Control Transf. 1 B
409953 . Fan — Blade 1 B
1 27 404065-2 .» Rectifier - Silicon 1 All
28 No Number . Clamp — Wire, 1" 2 All
29 200561 se Reactor - Filter, Assembly 1 All
1 30 4094761 . Relay - Power 1 All
31 No Number + Connector - Right Angle 2 All
32 200557 . Tray - Lower 1 All
33 200494-1 . Panel - Control 1 All
1 34 W-9712-14 . Rheostat — H. 25 A, 10 Ohm 1 All
35 406806 . Knob - Control, 1-3/8 2 All
36 402662 e Switch - Toggle, DPST 1 All
1 37 409477 e Switch - Rotary 1 All
38 16DA-3134 + Transformer - Stepdown 1 A
39 405548 . Label - Frame Ground 1 All
Aug 22/90 Revised
Not Illustrated
Page 7
и В В О PL-690
Page 8 1110 a Aug 14/87
PL-690
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 !2 | No. No. No. Description Assembly Code
1 | 3- 40 4052/8-10 » Capacitor - Electrolytic 1 All
41 No Number + Insulator —- Mylar 1 All
42 No Number » Clamp - Capacitor 1 All
1 43 367703-6 .» Resistor - W/Lug Assembly 1 All
1 44 404162-1 .» Valve - Solenoid 1 All
45 No Number . Tubing - Tygon 1 All
46 402927-1 . Connector - Male 1 All
47 No Number . Spacer 2 All
48 200560 » Transformer —- Power Assembly 1 A
202865 . Transformer - Power Assembly 1 B
49 200558 . Heat Sink - Assembly 1 All
1 50 406170-2 . Diode - Silicon, Positive Base 2 All
- 368705-20 » Capacitor - Assembly
W/Leads and Terminal 2 All
l 51 404044-7 e Thermostat - Overload 1 All
52 No Number +» Spacer — Flanged Nylon 2 All
53 No Number . Insulator —- Spacer Nylon 2 All
54 375432-9 . Cable - Assembly, Input
Power 1 A
202901-1 e Cable - Assembly, Input
Power 1 B
55 No Number » Terminal - Quick Connect 2 All
— 406185-1 . Terminal - Male 1 All
- 406186-1 . Terminal - Female 1 All
- 402197-1 . Terminal 2 A
- | 400480—2 se Terminal 4 B
56 409828 Label - Welding Guide 1 All
- 407961A-1 Form - Production Info. 1 А11
- Not Illustrated
Mar 1/88 Revised Page 9
PL-690
Figure 4
Revised Aug 26/87
Page 10
и >
Le ~ A
Le = 7 TT PL-690
al mm <” >.
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 | No. No. No. Description Assembly Code
4— 177057-1 Gun & Cable Assy —- Gal-90
«024 H, 8-1/2 Ft. A
177057-2 Gun é Cable Assy - Gal-90
.030 H, 8-1/2 Ft. (Optional) B
177057-3 Gun & Cable Assy —- Gal-90
.035 H, 8-1/2 Ft. (Optional) С
177057-8 Gun & Cable Assy — Gal-90
.045 H, 8-1/2 Ft. (Optional) D
5 1 379718 . Nozzle —- Slip-On, Assy. 1 All
5 2 379708 . Adapter — Nozzle 1 All
10 3 379587 . Tip - Contact .024 Dia. 1 A
10. 379304 » Tip - Contact .030 Dia.(Opt) 1 B
10 379314 » Tip - Contact .035 Diía.(Opt) 1 С
10 379315 e Tip - Contact .045 Dia.(Opt) 1 D
5 4 379717 « Fitting - Contact Tip 1 All
5 409243-1 » Cable —- Assy. Gal-90 1 A
409243-2 . Cable - Assy. Gal-90 (Opt) 1 B
409243-3 » Cable - Assy. Gal-9%0 (opt) 1 C
409243-8 » Cable - Assy. Gal-9%0 (opt) 1 D
6 379389 « « Actuator - Switch Assy. 1 All
1 7 406196 e e Switch - Pushbutton 1 All
8 379363 « « Handle —- Gun, Left 1 All -
9 379362 . « Handle - Gun, Right 1 All
10 W-11126-2 » e. Screw - 46-32 x 1/2,
MH, BND, Hd. ST. l All
2 - 409737-1 e « Liner — .024 (for Replace-
| ment) Ref. A
2 409737-2 e « Liner - .030 (for Replace-
ment) (Opt) Ref. B
2 409737-3 ‚ « Liner - .035-.045 (for
Replacement) (Opt) Ref. CD
11 379436 Kit - Handles (Includes
Items 8, 9, and 10) 1 All
12 407723-11 Label - Gun 1 Al].
- Not Illustrated
Note: The above application code applies to gun and cable assembly
тнт нам a
only.
— ss === | =
Oct 15/87 Revised
Page 11
— — — —_ —
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Diagrams
l. Note the specification number shown on the equipment nameplate.
2. Locate these numbers in the specification number columns below.
3. Use only those diagrams and instructions that are applicable.
MODEL SPECIFICATION CONNECTION
NUMBER NUMBER DIAGRAM
Handler 6969-1 200566
6969-2 202902
Oct 15/87 Revised
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IMPORTANT"!
FILL OUT REGISTRATION CARD AT ONCE
AND RETURN TO HOBART BROTHERS CO.
IMMEDIATE RETURN OF THIS CARD
ESTABLISHES WARRANTY COVERAGE.
HOBART - WELDER REGISTRATION CARD -
SERIAL #: SPEC. #
OWNERS NAME:
ADDRESS PHONE #: (
CITY: STATE: ZIP:
DATE PURCHASED: RECEIVED IN SATISFACTORY ORDER:
PURCHASED FROM (Distributor Name):
ADDRESS
CITY: STATE: ZIP:
BUSINESS REPLY MAIL
FIRST CLASS MAIL PERMIT NO. 12 TROY, OHIO
POSTAGE WILL BE PAID BY ADDRESSEE
Hobart Brothers Company
600 West Main Street
Troy, Ohio 45373-9933
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
CalrokobrboradlaBusalna botolortolano rl bno sVIrolosh!
®
“POWER PROTECTION”
3 YEAR WARRANTY
1. General: Hobart's products are warranted for three (3) years following date of shipment to the original user with the exceptions of
items listed in paragraphs 2 through 8.
2. Parts and Labor For: Motor driven guns; High frequency/Capacitor Discharge units; Running gears/Trailers; Field options,
are warranted for one (1) year.
3. Expendable items: Primary and secondary switch contacts, cable connectors, carbon brushes, fuses, bulbs, filters, nozzles,
contact tips, liners, cutting tips and wire feed rolls are worn or consumed in the normal process of welding or cutting and are there-
fore warranted only if found to be defective prior to use.
4. Replacement parts: Replacement and exchange parts are warranted for the remainder of the original equipment warranty or for
a period of ninety (90) days, whichever is greater.
5. Semiautomatic Items: Mig welding guns and cables and plasma cutting torches, tig torches and cables and remote controls
and accessory kits are warranted for ninety (20) days.
6. Engines, Tires, and Batteries: Hobart does not warrant items fumished by Hobart but manufactured by others, including with-
out limitation, gasoline or diesel engines, engine electrical equipment, batteries, and tires. Such items are warranted directly by the
manufacturer, and Hobart may periodically inform customers of such warranty coverage; however, Hobart does not guarantee the
accuracy or completeness of its information regarding such warranties.
7. Exclusive Remedies: In case of Hobart's breach of warranty or any other duty with respect to the quality of any product or serv-
ice, the sole and exclusive remedies therefore shall be:
As to PRODUCTS, (1) repair, (2) replacement, or (3) where authorized by Hobart, payment of or credit for the purchase price (less
reasonable depreciation based on its actual use) upon return of the product, and as to SERVICES (including repair under war-
ranty), the sole and exclusive remedies therefore shall be payment or credit for Hobart's actual charge therefore or, in the absence
of any actual charge, the customary or reasonable charge for such services, and if such breach also involves impairment of Hobart
products, the remedies available for breach of warranty with respect to the product.
8. Modification and Misuse: This warranty does not apply to products which have been modified in any way by any party other
than Hobart; nor to products which have not been installed and operated in accordance with applicable industry standards; nor to
products which have been used other than under the usual conditions for which designed; nor to products that have not received
proper care, lubrication, protection, and maintenance under supervision of competent personnel. Use of a product after discovery of
a defect voids all warranties.
DISCLAIMER OF WARRANTIES
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF, EXCEPT AS SPECIFI-
CALLY PROVIDED IN THE EXPRESSED WARRANTIES SET FORTH ABOVE, ALL PRODUCTS ARE SOLD “AS IS”. HOBART
MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
WARNING
At all times, safety is an important consideration in the installation, servicing, and operation of the
product, and skilled, qualified technical assistance should be utilized at all times. Specific recom-
mendations are included in “Safety in Welding and Cutting”, American National Standard No. Z-49-1.
Hobart Brothers Company October 1989
Troy, Ohio 45373 U.S.A. 910516
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