HobartWelders OLYMPIC 30A HOBART Owner's manual

Brand: HobartWelders

Model: OLYMPIC 30A HOBART

Category: Welding System

Type: Owner's manual

Processes

OM-184 693A

September 1998

Olympic 30A

Description

MIG (GMAW) Welding

Feeder Gun

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Removing Top Cover 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Adjusting Contact Tip Position 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Installing Wire Spool And Threading Welding Wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Rotating Canister 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Connecting To BETA-MIG 251 Welding Power Source 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Installing Gas Supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Adjusting Drive Roll And Spool Brake Pressure 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Shielding Gas 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE & TROUBLESHOOTING 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Changing Contact Tip And Liner 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Gun Drive Assembly Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Replacing Canister Inlet Guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Replacing Spool Canister 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Replacing Contact Tip Adapter 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-184 693A

OM-184 693 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible

hazards with this procedure! The possible hazards are

shown in the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary

actions to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-4. Read and

follow all Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and work

circuit is electrically live whenever the output is on.

The input power circuit and machine internal

circuits are also live when power is on. In semiautomatic or

automatic wire welding, the wire, wire reel, drive roll housing, and all

metal parts touching the welding wire are electrically live. Incorrectly

installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the

work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according

to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal

in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding

conductor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the

breathing air is safe.

D 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.

D 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.

OM-184 693 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 RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks,

hot workpiece, and hot equipment can cause fires

and burns. Accidental contact of electrode to metal objects can

cause sparks, explosion, overheating, or fire. Check and be sure the

area is safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition

can cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D 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.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat,

mechanical shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-184 693 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.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE

handling boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut,

keep spark gaps at correct setting, and use grounding and

shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 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,

American 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 Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-184 693 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

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 your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-184 693 Page 5

SECTION 2 – INSTALLATION

2-1. Specifications

Wire Diameter

Range

Approximate

Wire Feed

Range

Cooling

Method

Maximum

Spool Size

Weld Circuit

Rating

Overall

Dimensions

Weight

.025 Thru 1/16 in

(0.6 Thru 1.6 mm)

Aluminum Wire

.025 Thru 045 in

(0.6 Thru 1.1 mm)

Hard Or Cored Wire

70 To 875 ipm

(1.7 To 22.2

mpm)

Air Cooled

4 in (102 mm)

Diameter

100 Volts, 200

Amperes,

100% Duty

Cycle Using

Argon Shielding

Gas

IP 23

Length: 15-3/8 in

(390 mm)

Width: 2-1/2 in

(64 mm)

Height: 10-3/4 in

(273 mm)

2.9 lb (1.3 kg)

Gun Only

14 lb (6.4 kg)

Gun With Cable

Use welding power source Owner’s Manual during gun installation. If contact tip,

liner, and drive roll groove are not correct for wire size and type, see Section 4 to

change parts as needed. See Parts List for other available contact tips.

NOTE

2-2. Removing Top Cover

Ref. 150 882-A

1 Top Cover

Push back and lift off as shown.

To reinstall cover, set rear of cover

in gun/feeder, and push cover

back, down, and forward until it

clicks into position.

2-3. Adjusting Contact Tip Position

150 434

1 Contact Tip

2 Nozzle

Adjusting barrel changes contact

tip location from 1/16 in (1.6 mm)

out end of nozzle to 1/4 in (6.3 mm)

inside nozzle.

For aluminum welding, contact tip

should be at least 1/8 in (3.2 mm)

inside nozzle. For steel welding,

contact tip should be flush with end

of nozzle.

3 Jam Nut

4 Barrel

To change contact tip location,

loosen jam nut, and turn barrel.

Tighten jam nut.

OM-184 693 Page 6

2-4. Installing Wire Spool And Threading Welding Wire

150 436

1 Top Cover

2 Canister

3 Canister Cover

4 Thumbscrew (Canister

Cover)

Loosen thumbscrew and remove

cover.

5 Wire Spool

Loosen wire from spool, cut off

bent wire, and pull 6 in (150 mm) of

wire off spool.

6 Pressure Roll Assembly

Lift arm and open pressure roll

assembly.

7 Canister Inlet Guide

8 Drive Roll Groove

9 Contact Tip

Thread wire through canister inlet

guide, along drive roll groove, and

out contact tip.

Install spool so wire feeds off

bottom.

10 Spool Brake Thumbnut

If necessary, turn thumbnut coun-

terclockwise slightly to install

spool.

11 Thumbscrew (Canister

Rotation)

Loosen thumbscrew to rotate

canister (see Section 2-5).

Close and secure pressure roll

assembly.

Reinstall top cover and canister

cover.

Tools Needed:

2-5. Rotating Canister

150 433-A

1 Canister

Loosen canister rotation thumb-

screw (see Section 2-4). Move

canister to desired position.

Tighten thumbscrew.

Rear View

OM-184 693 Page 7

2-6. Connecting To BETA-MIG 251 Welding Power Source

801 758

1 Spool Gun Control Module

See BETA-MIG 251 Owner’s

Manual for spool gun control

module installation instructions.

2 Gas Hose

3 10 ft (3 m) Gas Hose With

5/8 in Adapter Fitting

Connect fitting to gun/feeder gas

hose and remaining end to regula-

tor/flowmeter (see Section 2-7).

4 Trigger Control Cord

Insert plug into receptacle, and

tighten threaded collar.

5 Weld Cable

Connect to positive (+) weld output

terminal on welding power source

according to its Owner’s Manual.

Tools Needed:

1-1/8, 5/8 in

2-7. Installing Gas Supply

ssb3.1* 5/94 – 158 697-A

Obtain gas cylinder and chain to

running gear, wall, or other station-

ary support so cylinder cannot fall

and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of

valve, and open valve slightly. Gas

flow blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Gas Hose Connection

Fitting has 5/8-18 right-hand

threads.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic

feet per hour). Check wire man-

ufacturer’s recommended flow

rate.

Make sure flow adjust is closed

when opening cylinder to avoid

damage to the flowmeter.

7CO

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

Tools Needed:

1-1/8, 5/8 in

Gas

Argon Gas

OM-184 693 Page 8

2-8. Adjusting Drive Roll And Spool Brake Pressure

Ref. 151 112 / S-0651

1 Top Cover

2 Canister Cover

3 Thumbscrew

Loosen thumbscrew and remove

cover.

4 Spool

Cut welding wire off at contact tip.

Retract wire onto spool and

secure.

5 Spool Brake Thumbnut

Grasp spool in one hand and turn

while adjusting spool brake thumb-

nut. When a slight force is needed

to turn spool, tension is set. Do not

overtighten.

Reinstall canister cover. Thread

welding wire (see Section 2-4).

6 Drive Roll Tension Thumbnut

Turn On unit and check drive roll

pressure by feeding wire against a

wood board or concrete surface;

wire should feed steadily without

slipping.

Adjust drive roll tension thumbnut

if necessary. Do not overtighten.

Turn Off unit. Reinstall top cover.

Tools Needed:

WOOD

Adjusting Pressure

OM-184 693 Page 9

SECTION 3 – OPERATION

3-1. Controls

Ref. 147 741-A

1 Trigger

Press trigger to energize welding

power source, start shielding gas

flow, and begin wire feed.

For shielding gas preflow and post-

flow, lightly press trigger before

and after welding.

2 Trigger Hold Button

Use button to continually feed wire

without holding down the trigger.

Press button while pressing the

trigger, release trigger, and wire

continues to feed until trigger is

pressed again.

3 Wire Speed Control

Use control to adjust wire feed

speed. The numbers in the open-

ing are not a wire feed speed and

are for reference only.

4 Rating Label Location

3-2. Shielding Gas

sb5.1* 6/92 – S-0621-C / Ref. 147 741-A

1 Shielding Gas Cylinder

2 Valve

3 Gun Trigger

Open valve on cylinder just before

welding.

Gun trigger turns weld output and

gas flow on and off. For shielding

gas preflow and postflow, lightly

press trigger before and after

welding.

Close valve on cylinder when

finished welding.

OM-184 693 Page 10

SECTION 4 – MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

3 Months

Replace

Damaged Or

Unreadable

Labels

Replace

Damage

Gas Hose

Clean

And

Tighten

Weld

Terminals

Repair Or Replace

Cracked Cables

And Cords

6 Months

Blow Out Or

Vacuum Inside

Clean

Drive

Rolls

4-2. Changing Contact Tip And Liner

150 437

Remove top cover and open pres-

sure roll assembly as shown in

Section 4-3.

1 Contact Tip Wrench

Insert wrench into nozzle over

contact tip.

2 Compression Nut

Loosen nut. Pull out contact tip.

3 Contact Tip

4 Nozzle

Pull wire out nozzle and liner

should slide out. If necessary, tilt

nozzle down to remove liner.

Close pressure roll assembly.

Reinstall top cover.

Install new liner and contact tip

over wire. Cut off wire at end of

contact tip.

Tighten nut just until contact tip is

secure. Overtightening nut will

damage adapter.

Tools Needed:

OM-184 693 Page 11

4-3. Gun Drive Assembly Maintenance

Ref. 149 967-B / Ref. 800 945-A

Retract wire onto spool.

1 Setscrew

2 Current Pick-Up Tab

This tab helps prevent burnback

caused by welding arcs inside the

contact tip. This tab may be re-

moved to provide an insulated

drive roll. (If tab is removed, a

smaller diameter contact tip is rec-

ommended. See options in Parts

List.) Lightly grease top of tab be-

fore reinstalling.

3 Drive Roll

Use wire brush to clean drive roll.

Install drive roll with desired groove

down, and turn drive roll so one

setscrew faces flat side of shaft.

4 Bearing

Use wire brush to clean bearing.

Line up drive roll groove with bear-

ing groove and liner opening.

Tighten setscrews.

Thread welding wire through gun

(see Section 2-4). Close and se-

cure pressure roll assembly. Adjust

drive roll pressure (see

Section 2-8). Reinstall top cover.

Tools Needed:

5/16 in

OM-184 693 Page 12

4-4. Replacing Canister Inlet Guide

Ref. 150 436 / Ref. 149 967-B

1 Top Cover

2 Pressure Roll Assembly

Cut off welding wire where it enters

pressure roll assembly area.

3 Nozzle

Pull wire out nozzle.

4 Thumbscrew

5 Canister Cover

Loosen thumbscrew and remove

cover.

6 Wire Spool

7 Spool Brake Thumbnut

Loosen thumbnut, retract wire onto

spool, secure, and remove spool.

8 Canister Inlet Guide

Turn counterclockwise to remove.

Install new guide.

Reinstall spool and thread welding

wire (see Section 2-4).

Close pressure roll assembly. Ad-

just spool brake pressure and drive

roll pressure if necessary (see

Section 2-8).

Reinstall covers.

Tools Needed:

OM-184 693 Page 13

4-5. Replacing Spool Canister

Ref. 149 967-B

1 Top Cover

2 Pressure Roll Assembly

Cut off welding wire where it enters

pressure roll assembly area.

3 Nozzle

Pull wire out nozzle.

4 Thumbscrew (Canister

Rotation)

Turn thumbscrew counterclock-

wise three full turns.

5 Spool Canister

Remove as shown. Push new can-

ister into wire drive housing until

fully seated. Tighten thumbscrew.

Install spool and thread welding

wire (see Section 2-4).

Close pressure roll assembly. Ad-

just spool brake pressure and drive

roll pressure as necessary (see

Section 2-8).

Reinstall covers.

Tools Needed:

4-6. Replacing Contact Tip Adapter

150 430-B

1 Barrel Extension

Remove as shown.

2 Contact Tip

3 Compression Nut

To remove, see Section 4-2.

4 Liner

5 Contact Tip Adapter

6 O-Ring

7 Head Tube

8 Head Tube Setscrew

Loosen setscrews and remove

adapter.

Install new o-ring and adapter, and

tighten setscrews. Reinstall con-

tact tip, compression nut, and

nozzle.

Tools Needed:

3/32 in

OM-184 693 Page 14

4-7. Troubleshooting

Trouble Remedy

No weld output; gun/feeder does not

work.

Place Power switch on welding power source in the On position (see welding power source Owner’s

Manual).

Erratic weld output. Tighten and clean all connections.

Pressing gun/feeder trigger does not

energize welding power source; weld-

ing wire is not energized; shielding gas

does not flow.

Secure plug from gun/feeder trigger cord into 10-socket receptacle on welding power source (see

Sections 2-6).

Wire feeds, shielding gas flows, bu

welding wire is not energized.

Secure control cable leads in welding power source (see welding power source Owner’s Manual).

welding wire is not energized.

See Troubleshooting section in welding power source Owner’s Manual.

Wire feeds erratically. Check and correct drive roll pressure (see Section 2-8).

Clean drive roll or replace drive roll (see Section 4-3).

Decrease spool brake pressure (see Section 2-8).

OM-184 693 Page 15

SECTION 5 – ELECTRICAL DIAGRAMS

138 956-B

Figure 5-1. Circuit Diagram For Gun/Feeder

OM-184 693 Page 16

SECTION 6 – PARTS LIST

Figure 6-1. Complete Assembly

143 116-J

*Includes Items 6 & 7

**Includes Item 71

. Hardware is common and

not available unless listed.

69**

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HobartWelders OLYMPIC 30A HOBART Owner's manual

Brand: HobartWelders

Model: OLYMPIC 30A HOBART

Category: Welding System

Type: Owner's manual

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HobartWelders OLYMPIC 30A HOBART Owner's manual

HobartWelders OLYMPIC 30A HOBART Owner's manual

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