Hobart Welding Products 217 694E, OM-925 manual Troubleshooting Table, Trouble Remedy

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.A complete Parts List is available at www.HobartWelders.com

7-8. Troubleshooting Table

 

 

 

 

 

 

 

 

 

 

 

Trouble

 

 

Remedy

 

 

No weld output; wire does not feed; fan

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 Section 6-1).

 

 

 

 

 

Reset welding power source supplementary protector (see Section 7-2).

 

 

No weld output; wire does not feed; fan

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when

motor continues to run.

unit has cooled (see Section 4-2).

 

 

 

 

 

Check Voltage range switch position. Rotate knob until it “clicks” into detent at desired range setting.

 

 

 

 

 

Secure gun trigger leads (see Section 5-1).

 

 

No weld output; wire feeds.

Connect work clamp to get good metal to metal contact.

 

 

 

 

 

Replace contact tip (see Section 7-5).

 

 

 

 

 

Check for proper polarity connections (see Section 5-4).

 

 

 

 

 

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

 

 

Low weld output.

Connect unit to proper input voltage or check for low line voltage.

 

 

 

 

 

Place voltage switch in desired position (see Section 6-1).

 

 

Electrode wire feeding stops during

Straighten gun cable and/or replace damaged parts.

welding.

 

 

 

Adjust drive roll pressure (see Section 5-9).

 

 

 

 

 

 

 

Change to proper drive roll groove (see Section 7-4).

 

 

 

 

 

Readjust hub tension (see Section 5-7).

 

 

 

 

 

Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.

 

 

 

 

 

Replace contact tip if blocked (see Section 7-5).

 

 

 

 

 

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4or Section 7-6).

 

 

 

 

 

Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).

 

 

 

 

 

Secure gun trigger leads or repair leads (see Section 5-1).

 

 

 

 

 

Check and clear any restrictions at drive assembly and liner (see Section 5-9or Section 7-6).

 

 

 

 

 

Release gun trigger and allow gun and motor protection circuitry to reset (see Section 7-3).

 

 

 

 

 

Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten

 

 

if necessary.

 

 

 

 

 

Have nearest Factory Authorized Service Agent check drive motor.

 

 

 

 

 

OM-925 Page 30

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Contents Description Arc Welding Power Source Wire FeederProcesses OM-925217 694E 2008−10From Hobart to You Protect Your InvestmentTable of Contents − ACCESSORIES/CONSUMABLES Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsWelding can cause fire or explosion Fumes and Gases can be hazardousARC Rays can burn eyes and skin Flying Metal or Dirt can injure eyesFalling Unit can cause injury Welding Wire can cause injuryFire or Explosion hazard Moving Parts can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésIndique des instructions spécifiques LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion Risque D’INCENDIE OU D’EXPLO- Sion LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées LA Chute DE L’APPAREIL peut blesserLES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Information EMF Principales normes de sécuritéEn ce qui concerne les implants médicaux OM-925 Specifications − SpecificationsSymbols And Definitions − DefinitionsOutput Duty Cycle % WarrantyDuty Cycle And Overheating Can damage unit or gun and void15.0 Volt-Ampere CurvesVoltage 10.0 100 110 120 130 140 150 160Installing Work Clamp − InstallationInstalling Welding Gun Be sure that gun end is tight against drive assemblyProcess/Polarity Table Changing PolarityFeedhead Pressure Assembly Closed Installing Gas SupplyFeedhead Pressure Assembly Open Do not use Argon/Mixed gas regulator/flowmeterSelecting a Location And Connecting Input Power Do not move or operate unit Where it could tipAlign locking hole in spool with locking pin on spool hub Installing Wire Spool And Adjusting Hub TensionRetaining ring used with 8 in 203 mm spool only Turn off welding power source Installing Contact Tip And NozzleUse with solid or flux cored wire Hold wire tightly to keep it from unraveling Threading Welding WireLay gun cable out straight Tighten With a setting of 2 or 3 on the scalePressure Indicator Scale Desired drive roll pressure. Start− Operation Source or -2. Do not switch under loadControls Material Thickness Reference Chart Weld Parameter Chart 217 618-A Overload Protection − Maintenance & TroubleshootingRoutine Maintenance Drive Motor ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Stamped Stamped .030/.035Disconnect gun from unit Cleaning Or Replacing Gun LinerTo Reassemble Gun Replacing Switch And/Or Head Tube Troubleshooting Table Trouble Remedy− Electrical Diagram Circuit DiagramTypical MIG Process Connections Wire Feeder Power Source Shielding Gas− MIG Welding Gmaw Guidelines Regulator Flowmeter001 in = 1 ampere Typical MIG Process Control SettingsWire Size Amperage Range 125 in = 125 aHolding And Positioning Welding Gun Groove WeldsShort Normal Long Conditions That Affect Weld Bead ShapePush Perpendicular Drag Slow Normal FastGood Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Burn-Through Base metal to move Troubleshooting − Waviness Of BeadTroubleshooting − Distortion DirectionCommon MIG Shielding Gases Troubleshooting Guide For Semiautomatic Welding EquipmentApplication Welding power source Welding arc not stable Wire slipping in drive rollsReadjust welding parameters Drive rolls if necessaryReplacement Drive Rolls − ACCESSORIES/CONSUMABLESAccessories ConsumablesSupport ServiceAssistance Contact your Distributor for Hobart Welding Products