Table of Contents
Troubleshooting
Related Manuals for Hobart H200L4-15
Summary of Contents for Hobart H200L4-15
- Page 1 OM-235 281D 2013−05 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder ™ IronMan 230 And H200L4-15 Gun File: MIG (GMAW) www.HobartWelders.com...
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Page 2: Table Of Contents
............. . . Hobart is registered to SECTION 7 −... -
Page 3: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. - Page 4 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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Page 5: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging D Do not install unit near flammables. -
Page 6: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer. -
Page 7: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 8 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 9: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser. -
Page 10: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent... -
Page 11: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com). - Page 12 OM-235 281 Page 10...
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Page 13: Section 3 − Definitions
A complete Parts List is available on-line at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. -
Page 14: Section 4 − Specifications
A complete Parts List is available on-line at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. -
Page 15: Section 5 − Installation
A complete Parts List is available on-line at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Use running gear or lifting forks to Location And Airflow Special installation may be move unit. -
Page 16: Connecting To Weld Output Terminals
A complete Parts List is available on-line at www.HobartWelders.com 5-3. Connecting To Weld Output Terminals Tools Needed: 3/4 in. (19 mm) Do not place anything between weld cable terminal and copper bar. Correct Installation Incorrect Installation 803 778-A Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper... -
Page 17: Installing 2 Lb Wire Spool And Adjusting Hub Tension
A complete Parts List is available on-line at www.HobartWelders.com 5-6. Installing 2 lb Wire Spool And Adjusting Hub Tension Keyed Washer Wire Spool (2 LB) Keyed Washer Compression Spring Washer Assemble components in numer- ical order as shown. Hand tighten nut to create a slight drag while rotating wire spool. -
Page 18: Installing Gas Supply
A complete Parts List is available on-line at www.HobartWelders.com 5-9. Installing Gas Supply DO NOT use Argon/Mixed gas regulator/ flowmeter with CO shielding gas. See Accessories/Consumables for optional gas regulator/flowmeter. Tools Needed: 1-1/8, 5/8 or 11/16 in. Argon Gas Or Mixed Gas Rear Panel 242 687-B... -
Page 19: Electrical Service Guide
A complete Parts List is available on-line at www.HobartWelders.com 5-11. Electrical Service Guide Elec Serv 2011−08 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. -
Page 20: Connecting 1-Phase Input Power
A complete Parts List is available on-line at www.HobartWelders.com 5-12. Connecting 1-Phase Input Power =GND/PE Earth Ground Tools Needed: 230 VAC, 1 input4 2012−05 − Ref. 803 766-C / Ref. 242 691-A / Ref. 802 286-E 5-12. Connecting 1-Phase Input Power (Continued) Input Power Cord Connect input conductors L1 and L2 to dis- Installation must meet all National and... -
Page 21: Threading Welding Wire
A complete Parts List is available on-line at www.HobartWelders.com 5-13. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight before threading wire. Tools Needed: Hold wire tightly to keep it from unraveling. -
Page 22: Installing Optional Dp 3545 Spool Gun To Welding Power Source
A complete Parts List is available on-line at www.HobartWelders.com 5-14. Installing Optional DP 3545 Spool Gun To Welding Power Source Turn Off unit, and disconnect input power. Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. -
Page 23: Section 6 − Operation
A complete Parts List is available on-line at www.HobartWelders.com SECTION 6 − OPERATION 6-1. Controls Wire Speed Control Control varies the rate of wire being fed through the welding gun. Voltage Control Control varies the voltage level of the welding arc. The voltage range is 1 (minimum) to 12 (maximum). -
Page 24: Weld Parameters
A complete Parts List is available on-line at www.HobartWelders.com 6-2. Weld Parameters OM-235 281 Page 22... -
Page 25: Section 7 − Maintenance And Troubleshooting
A complete Parts List is available on-line at www.HobartWelders.com SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every... -
Page 26: Removing Knob From Front Panel
A complete Parts List is available on-line at www.HobartWelders.com 7-4. Removing Knob From Front Panel Turn Off power. Front Panel Knob Spring Clip Control Shaft Slot Slide Rotate knob to allow access to slot. Knob Insert Allen wrench (or stiff piece of wire) into slot, and while depressing spring clip, slide knob off control Depress... -
Page 27: Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing
A complete Parts List is available on-line at www.HobartWelders.com 7-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Turn off welding power source/wire feeder. Nozzle Contact Tip Tip Adapter Head Nozzle Adapter Tube Wire size stamped on tip − check and match wire size. -
Page 28: Welding Troubleshooting Table
A complete Parts List is available on-line at www.HobartWelders.com 7-9. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 5-12). Place Power switch in the ON position. Place MIG/Spool Gun switch in the proper position. Check and replace Power switch if necessary. -
Page 29: Section 8 − Gmaw Welding (Mig) Guidelines
SECTION 8 − GMAW WELDING (MIG) GUIDELINES 8-1. Typical GMAW (MIG) Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/... -
Page 30: Holding And Positioning Welding Gun
8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece... -
Page 31: Gun Movement During Welding
8-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −... - Page 32 8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
- Page 33 8-11. Troubleshooting − 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 proper welding wire extension and arc characteristics.
- Page 34 8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand.
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Page 35: Troubleshooting Guide For Semiautomatic Welding Equipment
8-16. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. - Page 36 Problem Probable Cause Remedy Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder. Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line.
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Page 37: Section 9 − Electrical Diagram
SECTION 9 − ELECTRICAL DIAGRAM 240 907-A Figure 9-1. Circuit Diagram For Welding Power Source OM-235 281 Page 35... -
Page 38: Section 10 − Accessories/Consumables
Protective Cover Weatherproof Nylon For use with 100% CO Shielding Gas. Use with replacement 237 702* Regulator/Flowmeter gas hose 144 108. *Available at Hobart/Miller welding distributors. 10-2. Consumables Item Hobart Part No.* Miller Part No.** Contact Tips .023/.025 in. (0.6 mm) - Page 39 Effective January 1, 2013 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MD or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
- Page 40 Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy...
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