Page 2 - From Hobart to You
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Hobart distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-877-Ho...
Page 3 - TABLE OF CONTENTS
The following terms areused interchangeablythroughout this manual:MIG=GMAW TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-210 088 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T...
Page 6 - WELDING can cause fire or explosion.
OM-210 088 Page 2 Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld. ARC RAYS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-210 088 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 nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly siz...
Page 8 - EMF Information
OM-210 088 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-210 088 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un mes...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-210 088 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer ...
Page 13 - SECTION 2 – SPECIFICATIONS; Specifications
OM-210 088 Page 9 SECTION 2 – SPECIFICATIONS 2-1. Specifications A. 120 VAC Model Rated Welding Output Amperage Range Maximum Open- Circuit Voltage DC Amperes Input at Rated Load Output 120 V, 60 Hz, Single-Phase KVA KW Weight W/ Gun Overall Dimensions 90 A @ 19 Volts DC, 30% Duty Cycle 75 A @ 19 Vo...
Page 14 - Duty Cycle And Overheating; A or V
OM-210 088 Page 10 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding....
Page 16 - SECTION 3 – INSTALLATION; Installing Welding Gun; Changing Polarity
OM-210 088 Page 12 SECTION 3 – INSTALLATION 3-1. Installing Welding Gun Ref. ST-802 024 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew. Insert gunend through opening until it bottomsagainst drive assembly. Tightenthumbscrew. 4 Gun Trigger Leads Insert leads, one at a time, th...
Page 17 - Installing Gas Supply
OM-210 088 Page 13 3-4. Installing Gas Supply Obtain gas cylinder and chain torunning gear, wall, or other station-ary support so cylinder cannot falland break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close v...
Page 18 - Selecting A Location And Connecting Input Power For 120 VAC Model
OM-210 088 Page 14 3-5. Selecting A Location And Connecting Input Power For 120 VAC Model 1 Rating Label 2 Grounded Receptacle A 120 volt, 20 ampere individualbranch circuit protected by time-de-lay fuses or circuit breaker is re-quired. 3 Plug From Unit Select extension cord of 14 AWGfor up to 50 f...
Page 19 - Selecting A Location And Connecting Input Power For 230 VAC Model
OM-210 088 Page 15 3-6. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle. 4 Line Disconnect Device See Section 3-7. Y Special installation may berequired where gasoline orvolatile liquids are p...
Page 20 - Electrical Service Guide For 230 VAC Model; Installing Wire Spool And Adjusting Hub Tension
OM-210 088 Page 16 3-7. Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 19.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30 Min Input Conductor Size In AWG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min G...
Page 21 - Threading Welding Wire
OM-210 088 Page 17 3-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 7 6 1 3 4 5 6 in (150 mm) Pull and hold wire; cut off end. 4 in (102 mm) Tighten Rem...
Page 22 - SECTION 4 – OPERATION; Controls; THICKNESS; WIRE; OFF; PURGE
OM-210 088 Page 18 SECTION 4 – OPERATION 4-1. Controls 1 Voltage Switch The higher the selected number,the thicker the material that can bewelded (see weld setting label inwelding power source or Sections4-2 and 4-3, as applicable). Do notswitch under load. 2 Voltage Switch - Purge “0”Position In pu...
Page 23 - Weld Parameters For 120 VAC Model
OM-210 088 Page 19 4-2. Weld Parameters For 120 VAC Model 205 406-A Brackets and Rims Basketball Farm Equipment Frames, Frames, ”A” Axles, Brackets, 5356 (.035) 1/4 1/2 5/16 3/4 1/2 1/2 1/2 1/2 3/4 1/4 1/2 1/2 5/16 1/2 1/4 5/16 5/16 5/16 5/16 1/4 1/4 1/4 3–4 3–42–3 2–3 3–42–33–4 2–32 4–53–4 3–43–43 ...
Page 24 - Weld Parameters For 230 VAC Model
OM-210 088 Page 20 4-3. Weld Parameters For 230 VAC Model 205 424-A Welding Guide Settings are approximate. Adjust as required. WIRE TYPE\SIZE TO WELD: (Inches/ Gauge) GAS FLOW POLARITY WELDING VOLTAGE WIRE SPEED WIRE STICKOUT (Inches) (Cubic Ft/Hr) THICKNESS Auto Body Lawnmower Handles,Wagons, Tric...
Page 25 - SECTION 5 – MAINTENANCE &TROUBLESHOOTING; Routine Maintenance; Months; Overload Protection
OM-210 088 Page 21 SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replaceunreadablelabels. Repair orreplacecrackedweld cable. Clean andtighten weldterminals. 6 Months Blow out orvacuum inside.During heavyservice, cleanmonthly. Or...
Page 26 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
OM-210 088 Page 22 5-3. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide SecuringScrew 2 Inlet Wire Guide Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw. 3 Drive Roll The drive roll consists of two differ-ent sized grooves. The stampedmarkings on ...
Page 27 - Cleaning Or Replacing Piecemaker 14-A Gun Liner
OM-210 088 Page 23 5-5. Cleaning Or Replacing Piecemaker 14-A Gun Liner Ref. ST-801 995 1/16 in To Reassemble Gun: Insert new liner. Push liner against quick-connectplug, and tighten set screw. Cut liner off so that 3/4 in (19.05mm) sticks out of head tube. Install adapter, contact tip, andnozzle. L...
Page 28 - Troubleshooting Table
OM-210 088 Page 24 5-6. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Check circuit b...
Page 29 - Notes
Page 30 - SECTION 6 – ELECTRICAL DIAGRAM; Figure 6-1. Circuit Diagram For 120 VAC Model
OM-187 926 Page 26 SECTION 6 – ELECTRICAL DIAGRAM ST-205 400 53 Figure 6-1. Circuit Diagram For 120 VAC Model
Page 31 - Figure 6-2. Circuit Diagram For 120 VAC CSA Model
OM-210 088 Page 27 ST-210 011-C 53 Overload Feed Motor Figure 6-2. Circuit Diagram For 120 VAC CSA Model
Page 32 - Figure 6-3. Circuit Diagram For 230 VAC Model
OM-187 926 Page 28 ST-205 423-B 53 53 Figure 6-3. Circuit Diagram For 230 VAC Model
Page 33 - SECTION 7 – MIG WELDING (GMAW) GUIDELINES; Typical MIG Process Connections
OM-210 088 Page 29 SECTION 7 – MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. Wire Feeder/ Power Source Workpiece Gun ...
Page 34 - Typical MIG Process Control Settings; NOTE
OM-210 088 Page 30 7-2. 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 tospecifications. NOTE 1/8 or .125 in Material thickness determines weldparame...
Page 35 - Holding And Positioning Welding Gun
OM-210 088 Page 31 7-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing 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 G...
Page 36 - Conditions That Affect Weld Bead Shape
OM-210 088 Page 32 7-4. 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 Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AN...
Page 37 - Gun Movement During Welding; Poor Weld Bead Characteristics
OM-210 088 Page 33 7-5. 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 ormultiple stringer beads works better. NOTE 1 Stringer Bead – SteadyMovement Along Seam ...
Page 40 - -14. Troubleshooting – Waviness Of Bead
OM-210 088 Page 36 7-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not coverjoint 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)...
Page 42 - SECTION 8 – PARTS LIST
OM-210 088 Page 38 SECTION 8 – PARTS LIST . Hardware is common andnot available unless listed. ST-802 066 Figure 8-1. Main Assembly
Page 47 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-877-HOBART1for your localHobart distributor. hobart standard 7/00 ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contact your distributor orcall 1-800-33...
Page 48 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA 2000 Hobart Welding Products. 1/00 Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equ...
