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Hobart Welding Products 140 manual

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Table of contents for the manual

  • Page 1

    Processes OM-925 217 694D 2007−06 Handler 140 And H-10 Gun Arc W elding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding R[...]

  • Page 2

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

  • Page 3

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

  • Page 4

    T ABLE OF CONTENTS SECTION 9 − MIG WELDING (GMA W) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical MIG Process Connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Control Settin[...]

  • Page 5

    OM-925 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messag[...]

  • Page 6

    OM-925 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (see[...]

  • Page 7

    OM-925 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F A[...]

  • Page 8

    OM-925 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F4[...]

  • Page 9

    OM-925 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy m bole graphique d’avertis sement ! Attention ! Cette pro- cédur e c omport e des risques poss ibles[...]

  • Page 10

    OM-925 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau. [...]

  • Page 11

    OM-925 Page 7 2-3 . Dangers s upplémenta ires en r elation ave c l ’installa tion, l e f onctionnement et l a maintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’[...]

  • Page 12

    OM-925 Page 8 2-5. Prin cipales nor mes d e sécu rité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding[...]

  • Page 13

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMA W) Wire Feed SECTION 4 − SPECIFICA TIONS[...]

  • Page 14

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 10 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle [...]

  • Page 15

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 1 1 4-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 217 624-A RANGE 4 RANGE 3 RANGE 2 RANGE 1 0 10 20[...]

  • Page 16

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 12 SECTION 5 − INST ALLA TION 5-1. Installing Welding Gun 803 71 1-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert end of gun through opening in front panel until it bottoms against drive assembly . Tighten thumbscrew . W elding gun must [...]

  • Page 17

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 13 5-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect to negative (−) output terminal FCAW − S[...]

  • Page 18

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 14 5-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt [...]

  • Page 19

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 15 5-6. Selecting A Location And Connecting Input Power 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. 3 Plug From Unit Select extension cord of 14 AWG for up t o 50 ft (15 [...]

  • Page 20

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 16 5-7. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in T ools Needed: Installing 8 in (203 mm) Wire Spool Installing 4 in (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. R[...]

  • Page 21

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 17 5-8. Installing Contact Tip And Nozzle T ools Nee d e d : Ref. 802 399-A Y T urn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter [...]

  • Page 22

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 18 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: Pull and hold wire; cut off end. Open pressure assembly. Make sure feed roll is set to correc[...]

  • Page 23

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 19 Remove gun nozzle and contact tip. Ref. 803 714-A WOOD Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close door . Press gun trigger until wire comes out of gun. (Keep gun cable as straight as possible.) Turn power on. Be s[...]

  • Page 24

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 20 SECTION 6 − O P E R A T I O N 6-1. Controls 1 Wire Speed Control Us e control to select a wire feed speed. As V oltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2 ). 2 Power Switch 3 V oltage [...]

  • Page 25

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 21 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 26

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 22 6-2. W eld Parameter Chart[...]

  • Page 27

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 23 217 618-A[...]

  • Page 28

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 24 SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions . n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3[...]

  • Page 29

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 25 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized gro[...]

  • Page 30

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 26 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446-A 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full tur[...]

  • Page 31

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 27 7-7. Replacing Switch And/Or Head T ube Ref. 800 795-C T ools Nee d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tu[...]

  • Page 32

    . A complete Parts List is available at www .HobartW elders.com OM-925 Page 28 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-6). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Se[...]

  • Page 33

    OM-925 Page 29 SECTION 8 − ELECTRICAL DIAGRAM 230 952-A Figure 8-1. Circuit Diagram[...]

  • Page 34

    OM-925 Page 30 SECTION 9 − MIG WELDING (GMA W) GUIDELINES 9-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Sh[...]

  • Page 35

    OM-925 Page 31 9-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A Co[...]

  • Page 36

    OM-925 Page 32 9-3. 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 Electrode E[...]

  • Page 37

    OM-925 Page 33 9-4. 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. NOTE Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFI[...]

  • Page 38

    OM-925 Page 34 9-5. 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along [...]

  • Page 39

    OM-925 Page 35 9-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use[...]

  • Page 40

    OM-925 Page 36 9-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining[...]

  • Page 41

    OM-925 Page 37 9-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand [...]

  • Page 42

    OM-925 Page 38 9-16. 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Circuit[...]

  • Page 43

    OM-925 Page 39 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed o n welding power sour[...]

  • Page 44

    OM-925 Page 40 SECTION 10 − ACCESSORIES/CONSUMABLES 10-1. Accessories P ART 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. 195 186 Protective Cover W eatherproof Nylon 10-2. Consumables Item Hobart [...]

  • Page 45

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

  • Page 46

    Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Pr ofessional W elding Career Now![...]

  • Page 47

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2007−01 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart[...]

  • Page 48

    PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 Hoba rt We lding Product s An I l li noi s T ool Works Company 600 W es t Main Street Troy , OH 45373 U SA For T echn i cal A ssistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered [...]