Hobart Welding Products Trek 180 Owner's Manual
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Hobart Welding Products Trek 180 Owner's Manual

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Trekt 180
And H100L4-10 Gun
OM-232 661B
2010−02
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Battery Powered Arc Welding
Power Source And Wire Feeder

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Summary of Contents for Hobart Welding Products Trek 180

  • Page 1 OM-232 661B 2010−02 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Battery Powered Arc Welding Power Source And Wire Feeder Trekt 180 And H100L4-10 Gun...
  • Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − ELECTRICAL DIAGRAM ............SECTION 10 −...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 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.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−08 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 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.

  • Page 11: 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 12: 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-232 661 Page 10...

  • Page 15: Section 3 − Battery Safety Precautions - Read Before Using

    SECTION 3 − BATTERY SAFETY PRECAUTIONS - READ BEFORE USING Ref. rom _2009−08 Protect yourself and others from injury — read and follow these precautions. 3-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 16: Section 4 − Definitions

    SECTION 4 − DEFINITIONS 4-1. Symbols And Definitions Amperage Voltage Hertz Negative Direct Current Positive Single Phase Input (DC) Output Voltage Input Do Not Switch Gas Metal Arc Wire Feed Battery While Welding Welding (GMAW) Temperature Trigger Battery Charging Work Connection SECTION 5 −...

  • Page 17: Duty Cycle And Overheating

    5-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. WELD TIME WHILE USING BATTERIES ONLY If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Let unit cool until Over Temperature light goes out.

  • Page 18: Volt-Ampere Curves

    5-4. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. DC AMPERES 236 786-A Notes Work like a Pro! Pros weld and cut safely.

  • Page 19: Section 6 − Installation

    SECTION 6 − INSTALLATION 6-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 6-2.

  • Page 20: Assembling Work Clamp

    6-3. Assembling Work Clamp Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld perfor- mance and excessive heating of the work clamp. Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable.

  • Page 21: Changing Polarity

    6-5. Changing Polarity Jumper Link Connections For Direct Current Electrode Negative (DCEN) Jumper Link Connections For Direct Current Electrode Positive (DCEP) Always read and follow wire manufacturer’s recommended po- larity. See Process/Polarity Table in Section 6-6. Close door. Tools Needed: 3/8 in.

  • Page 22: Installing Gas Supply

    6-7. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

  • Page 23: Selecting A Location And Connecting Input Power

    6-8. Selecting A Location And Connecting Input Power Do not move or operate unit where it could tip. 18 in. (460 mm) 18 in. (460 mm) 244 703 115 V, 15 A Grounded Receptacle acle. Select 16 AWG extension cord for rating of 1000 −...

  • Page 24: Installing Wire Spool And Adjusting Hub Tension

    6-9. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool Tension is set when a slight force is needed to turn spool. Tools Needed: 244 707 OM-232 661 Page 20...

  • Page 25: Installing Contact Tip And Nozzle

    6-10. Installing Contact Tip And Nozzle Turn off welding power source. Nozzle (See Items 4 And 5 Below) Remove nozzle. Contact Tip Tip Adapter Thread welding wire through gun (see Section 6-11). Slide contact tip over wire and tighten tip into tip adapter.

  • Page 26: Threading Welding Wire

    6-11. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly. Make sure feed roll is set to correct groove to Pull and hold wire;...
  • Page 27 Use pressure indicator scale to set a desired drive roll pressure. (Start Tighten with a setting of 2 or 3 on the scale.) Pressure Indicator Scale Be sure that wire is positioned in proper feed roll groove. Remove gun nozzle and contact tip. Close and tighten pressure assembly, and let go of wire.

  • Page 28: Section 7 − Operation

    SECTION 7 − OPERATION 7-1. Controls Unplug trigger cable be- fore transporting or stor- ing unit. Weld Controls Voltage Control 50 60 Use control to select weld voltage. The higher the selected number, the thicker the material that can be welded. (See weld parameter label in welding power source or in Section 7-4.) Wire Speed Control...

  • Page 29: Status Light Explanations

    7-2. Status Light Explanations Status Light Condition Explanation Charge Ready Over Temp Status Battery Unit was turned off or has automatically timed out and shut itself off to preserve batteries. The unit will shut off after 15 minutes of inactivity. Turn unit off and then on again to reset unit after automatic timeout.

  • Page 30: Charging The Internal Batteries

    7-3. Charging The Internal Batteries Unplug trigger cable before transporting or storing unit. Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section Do not charge internal batteries if batteries show signs of dam- age.
  • Page 31 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org OM-232 661 Page 27...

  • Page 32: Weld Parameter Chart

    7-4. Weld Parameter Chart Selecting Wire, Gas and Control Settings Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation and multiple passes. Material Wire Type, Suggested Diameter Being Shielding Gases of Wire Welded Polarity Setting 20–30 cfh Flow Rate Being Used...
  • Page 33 Selecting Wire, Gas and Control Settings Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded Number on Left is Voltage Setting / Number on Right is Wire Feed Setting 24 gauge 22 gauge 20 gauge 18 gauge 16 gauge 14 gauge 12 gauge...

  • Page 34: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe condi- tions. Reference n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent 3 Months l Damaged Or Unreadable Labels l Repair Or Replace...

  • Page 35: Changing Drive Roll Or Wire Inlet Guide

    8-4. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Remove guide by pressing on barbed area or by cutting off one end (near housing) and pulling it out of the hole. Push new guide into hole (from rear) until it snaps into place.

  • Page 36: Cleaning Or Replacing Gun Liner

    8-6. Cleaning Or Replacing Gun Liner Disconnect gun from unit. Head Tube 10 mm Remove liner. 8 mm Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. Blow out gun casing. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner.

  • Page 37: Replacing Switch And/Or Head Tube

    8-7. Replacing Switch And/Or Head Tube Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure.

  • Page 38: Troubleshooting Table

    8-8. Troubleshooting Table Trouble Remedy Place Power switch in On position (Section 7-1). No weld output; wire does not feed; Ready light is off. Unit shuts down after 15 minutes of activity. Reset unit by turning unit off and then on again. (The Ready light goes on.) Have a Factory Authorized Service Agent check fuse F3.
  • Page 39 Trouble Remedy Erratic welding arc, discolored weld Verify gun is fully seated in drive assembly and securing knob is tight (Section 6-2). bead, and insufficient gas coverage when welding with solid wire and shield- ing gas. Remove spatter from gun nozzle. Check gas supply, hose, regulator, and connections, and ensure gas is flowing (no leaks).

  • Page 40: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM 236 783-B Figure 9-1. Circuit Diagram OM-232 661 Page 36...

  • Page 41: Section 10 − Mig Welding (Gmaw) Guidelines

    SECTION 10 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 10-1. Typical 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 42: Typical Mig Process Control Settings

    10-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A)

  • Page 43: Holding And Positioning Welding Gun

    10-3. 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 44: Conditions That Affect Weld Bead Shape

    10-4. 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. ° Push ° Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 45: Gun Movement During Welding

    10-5. 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 46: Troubleshooting − Excessive Spatter

    10-8. 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 47: Troubleshooting − Lack Of Penetration

    10-11. 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 48: Troubleshooting − Waviness Of Bead

    10-14. 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.

  • Page 49: Common Mig Shielding Gases

    10-16. Common 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 50 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
  • Page 51 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-232 661 Page 47...

  • Page 52: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 245 536-A Figure 11-1. Main Assembly OM-232 661 Page 48...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ... . +232600 Cover, Battery Compartment ......... .
  • Page 54 Hardware is common and not available unless listed. 232 613-C Figure 11-2. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-2. Wire Drive Assembly (Fig 11-1 Item 14) ... . . 203567 Screw, Shld Stl Pan .250−28 X .310 X 1.120 Shld .
  • Page 55 Hardware is common and not available unless listed. 232 618-A Figure 11-3. Wind Tunnel Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-3. Wind Tunnel Assembly (Fig 11-1 Item 17) ..240939 Circuit Card Assy, Battery Charger w/Program .
  • Page 56 243 842-A Figure 11-4. H100L4-10 Gun Item Dia. Part Mkgs. Description Quantity 243 864 Figure 11-4. H100L4-10 Gun ... . . 169 715 NOZZLE, slip type .500 orf flush ........

  • Page 57: Section 12 − Accessories/Consumables

    SECTION 12 − ACCESSORIES/CONSUMABLES 12-1. Accessories PART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max. 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max. 12-2.
  • Page 59 Water Coolant Systems exclusions set out above may not apply. This Limited Warranty Engines, batteries (except Trek 180) and tires are provides specific legal rights, and other rights may be available, warranted separately by the manufacturer.
  • Page 60 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Hobart Welding Products. 2010−01...

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H100l4-10

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