Page 1
Expert Series Auto-Darkening Helmets
Model: XVX
OM-240 362B
2008−11
For more information, visit www.HobartWelders.Com
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS −READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATING INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Helmet Controls 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Reset Button And Low Battery Indicator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Lens Delay Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Variable Shade Control (No. 9 − 13) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Sensitivity Control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − ADJUSTING HEADGEAR 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − REPLACING THE LENS COVERS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Replacing Outside Lens Cover 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Replacing Inside Lens Cover 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − REPLACING THE BATTERY 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 11. . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − LIMITED WARRANTY 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-240 362 Page 1
SECTION 1 − SAFETY PRECAUTIONS −
READ BEFORE USING
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
This group of symbols means Warning! Watch
Out! ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols
and related instructions below for necessary
actions to avoid the hazards.
. Indicates special instructions.
DANGER! − Indicates a hazardous
situation which, if not avoided, will
result in death or serious injury. The
possible hazards are shown in the
adjoining symbols or explained in
the text.
NOTICE − Indicates statements not related to
personal injury.
Indicates a hazardous situation
which, if not avoided, could result in
death or serious injury. The possible
hazards are shown in the adjoining
symbols or explained in the text.
1-2. Hazards
ARC RAYS can burn eyes and skin.
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.
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). Refer to Shade and Sensitivity charts in Sections 3-4
and 3-5.
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 HELMETS do not provide unlimited eye, ear and
face protection.
D Use impact resistant safety spectacles or goggles and ear protection at all
times when using this welding helmet.
D Do not use this helmet while working with or around explosives or
corrosive liquids.
D Do not weld in the overhead position while using this helmet.
D Inspect the auto-lens frequently. Immediately replace any scratched,
cracked, or pitted cover lenses or auto-lenses.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
D Wear approved ear protection if noise level is high.
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OM-240 362 Page 2
SECTION 2 − SPECIFICATIONS
Viewing Field 97 x 60mm/3.875 x 2.375 in
Reaction Time 0.0000500sec (1/20,000)
Available Shades Darkened State: No. 9 − No. 13 / Light State: No. 4
provides continuous UV and IR protection
Sensitivity/Grind Mode Control Adjusts for varying ambient light and welding arc
Delay Control Slows lens dark-to-light state between 0.1 and
1.0 seconds
Automatic Power Off Shuts lens Off 15−20 minutes after last arc is struck
Low Battery Indicator Red LED light illuminates to indicate 2−3 days
remaining battery life
Power Supply CR2450 Lithium Batteries (Hobart Part No. 770 284)
Sensors Independent/Redundant (Four)
Operating Temperature 14_F to 131_F / −10_C to +55_C
. When stored in extremely cold temperatures, warm
helmet to ambient temperature before welding.
Storage Temperature −4_F to 158_F / −20_C to +70_C
. When stored in extremely cold temperatures, warm
helmet to ambient temperature before welding.
Total Weight 510.3 g (1 lb 2oz)
Standards ANSI Z87.1-2003 and DIN/CSA/TUV
Warranty 2 years from date of purchase (see Section 11)
. The helmets in this manual are covered by one or more of the following patents:
U.S. Patent − No. 6,552,316, No. 6,483,090, No. 6,614,409
U.S. Patent Application − No. 29/223,100, No. 11/053,977
DE. Patent − No. 199 59 944 C2, No. 199 59 945 C2
FR. Patent − No. 9916004
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OM-240 362 Page 3
SECTION 3 − OPERATING INSTRUCTIONS
3-1. Helmet Controls
1 Reset Button (See Section 3-2)
2 Low Battery Indicator
(See Section 3-2)
3 Variable Shade Control (See
Section 3-4)
4 Sensitivity Control
(See Section 3-5)
5 Lens Delay Control
(See Section 3-3)
1 23 4 5
804 847
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OM-240 362 Page 4
3-2. Reset Button And Low Battery Indicator
. The auto-darkening lens turns on
(darkens) automatically when
welding begins and turns off 15 −
20 minutes after welding stops.
1 Reset Button
Press Reset button to check if the lens
is working properly.
When the Reset button is pressed, the
lens should darken twice and return to
the clear state. Do not use the helmet
if the lens does not function as described. (See Section 9, Troubleshooting.)
2 Low Battery Indicator
The low battery indicator lights when
2−3 days of battery life remain.
If battery power is low, replace with
CR2450 lithium batteries (2 required)
(Hobart Part No. 770 284) (see Section 6).
1 2
3-3. Lens Delay Control
1 Lens Delay Control
The lens delay control is used to adjust the time for the lens to switch to
the clear state after welding.
The delay is particularly useful in
eliminating bright after-rays present
in higher amperage applications
where the molten puddle remains
bright momentarily after welding.
Lens delay adjusts from min (0.10
second) to max (1.0 second.).
1
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OM-240 362 Page 5
3-4. Variable Shade Control (No. 9 − 13)
1 Variable Shade Control
(No. 9 − 13)
Use the control to adjust the lens
shade in the darkened state. Use
the table below to select proper
shade control setting based on
your welding process.
Start at shade 12 and adjust lighter
to suit the welding application and
your personal preference.
1
Application Welding Arc Current in Amperes Protective Shade No.
Stick Electrodes Less than 40
40−80
80−175
175−300
300−500
9
10
11
12
13
MIG Less than 100
100−175
175−300
300−500
10
11
12
13
Gas Tungsten Arc Welding
(TIG)
Less than 50
50−100
100−200
200−400
10
11
12
13
Air Carbon Less than 500
500−700
12
13
Plasma Arc Cutting 60−150
150−250
250−400
11
12
13
Plasma Arc Welding Less than 50
50−200
200−400
9
10
12
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OM-240 362 Page 6
3-5. Sensitivity Control
1 Sensitivity Control
Weld Mode
Use control to make the lens more responsive to different light levels in various welding processes. Use a Mid-Range or
30−50% sensitivity setting for most ap-
plications.
It may be necessary to adjust helmet sensitivity to accommodate different lighting conditions or if lens is flashing On and Off. Adjust helmet sensitivity as follows:
. Adjust helmet sensitivity in lighting con-
ditions helmet will be used in.
S Turn sensitivity control to lowest
setting.
S Press Reset button to turn helmet On.
Helmet lens will darken twice and then
clear.
S Face the helmet in the direction of use,
exposing it to the surrounding light conditions.
S Gradually turn sensitivity setting clock-
wise until the lens darkens, then turn
sensitivity control counterclockwise
until slightly past setting where lens
clears. Helmet is ready for use. Slight
readjustment may be necessary for
certain applications or if lens is flashing
on and off.
Grind Mode
. Do not weld in the Grind mode; the lens
will not darken.
To use the Grind mode, turn the Sensitivity
control clockwise to the far right position
(Grind). To resume welding, return the control to the desired sensitivity setting.
1
Recommended Sensitivity Settings
Stick Electrode Mid-Range
Short Circuiting (MIG) Low/Mid-Range
Pulsed & Spray (MIG) Mid-Range
Gas Tungsten Arc (TIG) Mid/High-Range
Plasma Arc Cutting/Welding Low/Mid-Range
Grind Mode Grind Position − Far Right (Clockwise)
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OM-240 362 Page 7
SECTION 4 − ADJUSTING HEADGEAR
. There are four headgear adjust-
ments: headgear top, tightness,
angle adjustment, and distance
adjustment.
1 Headgear Top
Adjusts headgear for proper depth
on the head to ensure correct balance and stability.
2 Headgear Tightness
To adjust, push in the adjusting knob
located on the back of the headgear
and turn left or right to desired tightness.
. If adjustment is limited, it may be
necessary to remove the comfort cushion.
3 Distance Adjustment
Adjusts the distance between the
face and the lens. To adjust, loosen
both outside tension knobs and
press inward to free from adjustment
slots. Move forward or back to desired position and retighten. (Both
sides must be equally positioned for
proper vision.)
4 Angle Adjustment
Four pins on the right side of the
headband top provide adjustment
for the forward tilt of the helmet. To
adjust, loosen the right outside tension adjustment knob then lift on the
control arm tab and move it to the desired position. Retighten tension adjustment knob.
. When using the back distance
adjustment positions, only the
back three angle adjustment
pins can be used.
804 118
1
2
3
4
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OM-240 362 Page 8
SECTION 5 − REPLACING THE LENS COVERS
5-1. Replacing Outside Lens Cover
! Never use the auto-darkening
lens without the inside and
outside lens covers properly
installed. Welding spatter will
damage the auto-darkening
lens and void the warranty.
1 Front Lens Holder
2 Release Points
3 Lens Cover
4 Gasket
Remove front lens holder by pressing release points and pulling the
holder away from the helmet.
Remove lens cover and gasket from
the holder. Replace lens cover and
reinstall gasket and lens in holder.
Reinstall holder in helmet.
. Be sure the flat side of lens
cover gasket faces the lens cover holder.
8804 814 / 804 816
1
2
Be sure flat side of gasket
faces lens cover holder.
2
4
3
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OM-240 362 Page 9
5-2. Replacing Inside Lens Cover
! Never use the auto-darkening
lens without the inside and outside lens covers properly
installed. Welding spatter will
damage the auto-darkening
lens and void the warranty.
1 Lens Assembly
2 inside Lens Cover
Remove the lens cover holder (see
Section 5-1). Remove lens assembly.
Remove the inside lens cover by prying the cover up at either thumbnail
opening at each side of the cover.
Slide cover it out of either side of
frame. Replace lens cover and reinstall the assembly in the helmet by reversing the above procedure.
. Be sure the cover lens is seated
properly (flat) to prevent fogging.
804 817 / 804 818
1
1
2
SENSITIVITY
DELAY
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OM-240 362 Page 10
SECTION 6 − REPLACING THE BATTERY
To replace the batteries, remove
the auto-darkening lens
assembly (see Section 5).
1 Battery Tray
After removing the lens assembly,
slide the battery holding trays out
and remove the old batteries.
Replace with CR2450 lithium type
batteries (2 required) or equivalent
(Hobart Part No. 770 284).
. Be sure Positive (+) side of the
battery faces up (toward inside
of helmet).
Reinstall the battery trays. To test,
press the Reset button. The lens
should flash dark twice. Reinstall
the lens assembly.
. Left and right battery trays are
not interchangeable. The
auto−darkening helmet will not
work if battery trays are
installed on the wrong sides.
804 847
++
1
Be sure Positive (+) side
of battery faces up.
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OM-240 362 Page 11
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS
1 Optional Magnifying Lens
Starting at the bottom, slide magnifying lens into the helmet retaining
brackets. Align the magnifying lens
with the auto-darkening lens assembly.
D Remove lens holding frame
(with auto-darkening lens)
from helmet shell.
D Remove auto-darkening
lens from lens holder.
D Position lens holder with
magnifying lens holding
tabs facing toward you.
From the bottom up, slide
magnifying lens into position. (Slide magnifying lens
up or down slightly as desired.)
D Reinstall the auto-darkening
lens in the lens holder.
D Reverse procedure to re-
move magnifying lens.
. To prevent lens fogging, install
flat side of magnifying lens toward auto-darkening lens.
804 818
1
SECTION 8 − MAINTENANCE
NOTICE − Never use solvents or abrasive cleaning detergents.
NOTICE − Do not immerse the lens assembly in water.
The helmet requires little maintenance. However, for best performance clean
after each use. Using a soft cloth dampened with a mild soap and water solution,
wipe the cover lenses clean. Allow to air dry. Occasionally, the filter lens and
sensors should be cleaned by gently wiping with a soft, dry cloth.
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OM-240 362 Page 12
SECTION 9 − TROUBLESHOOTING
Trouble Remedy
Auto lens not ON – autolens will not darken momentarily when the Reset
button is pressed.
Check batteries and verify they are in good condition and installed
properly. Also, check battery surfaces and contacts and clean if
necessary. Check battery for proper contact and gently adjust
contact points if necessary. This is particularly important if the
helmet has been dropped. Verify left and right battery trays are
installed on the correct sides.
Not switching – auto-lens
stays light and will not
darken when welding.
Stop welding immediately: Press the Reset button if lens is AutoOn type. If lens if Manual-On type, make sure the lens is turned
On. If power is on, review the sensitivity recommendations and
adjust sensitivity. Clean lens cover and sensors of any obstructions. Make sure the sensors are facing the arc; angles of 45_ or
more may not allow the arc light to reach the sensors.
Not Switching – auto-lens
stays dark after the weld
arc is extinguished, or the
auto-lens stays dark when
no arc is present.
Fine-tune the sensitivity setting by making small adjustments to
the control by turning it toward the “min” setting. In extreme light
conditions, it may be necessary to reduce the surrounding light
levels.
Sections of the auto-lens
are not going dark, distinct
lines separate the light and
dark areas.
Stop welding immediately: The auto-lens may be cracked which
can be caused by the impact of dropping the helmet. Weld spatter
on the auto lens may also cause cracking. (The lens may need to
be replaced; most cracked lenses are not covered by warranty).
Switching or Flickering –
the auto-lens darkens then
lightens while the welding
arc is present.
Review the sensitivity setting recommendations and increase the
sensitivity if possible. Be sure the arc sensors are not being
blocked from direct access to the arc light. Check the lens cover
for dirt and spatter that may be blocking the arc sensors. Increasing Lens Delay 0.1 − 0.3 second may also reduce switching.
Inconsistent or lighter
auto-lens shading in the
dark-state, noticeable on
the outside edges and corners.
Referred to as an angle of view effect, auto-darkening lenses
have an optimum viewing angle. The optimum viewing angle is
perpendicular or 90_ to the surface of the auto-lens. When that
angle of view varies in the dark-state, welders may notice slightly
lighter areas at the outside edges and the corners of the lens. This
is normal and does not represent any health or safety hazard.
This effect may also be more noticeable in applications where
magnifying lenses are used.
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OM-240 362 Page 13
SECTION 10 − PARTS LIST
2
804 814
4
6
3
1
5
Figure 10-1. Prowler Auto-Darkening Welding Helmet
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OM-240 362 Page 14
Description
Part
No.
Item
No. Quantity
Figure 10-1. Prowler Auto-Darkening Welding Helmet
1 770613 Ratchet Headgear Assembly (Does Not Include Item 2) 1. . . . . . . . . . . . . . . . . . .
2 770616 Comfort Cushion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 770274 Diopter Lens 150X 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
770275 Diopter Lens 175X 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
770276 Diopter Lens 200X 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
770277 Diopter Lens 250X 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 770612 Cover Lens (Includes Front Lens Cover Gasket, 1. . . . . . . . . . . . . . . . . . . . . . . . .
Front Lens Covers, 2 Inside Lens Covers)
5 770614 Auto-Darkening Lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
770284 Battery, CR2450 Lithium (Not Shown) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 770615 Front Lens Holder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-240 362 Page 15
SECTION 11 − LIMITED WARRANTY
Effective January 1, 2008
LIMITED WARRANTY – Subject to the terms and conditions below. Hobart Welding
Retail, Appleton, Wisconsin, warrants to its original retail purchaser that the new Hobart equipment sold after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is purchased at the retailer. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OR MERCHANTABILITY AND FITNESS.
Hobart auto-darkening lens helmets are warranted for two (2) years from the date
of purchase. Proof of purchase is required for warranty transactions so it is
imperative that a copy of the original invoice or sales receipt be retained.
For warranty transactions, contact your original Hobart retailer.
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PRINTED IN USA © 2008 Hobart Welders
Hobart Welders
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 800-332-3281
Visit our website at
www.HobartWelders.com
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