Page 2 - From Hobart to You; Register your product at:; Protect Your Investment!
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local Hobartdistributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-192 440 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adj...
Page 6 - WELDING can cause fire or explosion.
OM-192 440 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 an approved welding helmet fitted with a proper shade of fil- ter lenses to pro...
Page 7 - ARC WELDING can cause interference.
OM-192 440 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 s...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-192 440 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure com...
Page 11 - LE RAYONNEMENT HAUTE; Proposition californienne 65 Avertissements
OM-192 440 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 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 inflammable...
Page 12 - Principales normes de sécurité; Information EMF
OM-192 440 Page 8 2-5. Principales normes de sécurité Safety in Welding, 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 Welding and Cut- ting of...
Page 13 - -2. Welding Power Source Duty Cycle And Overheating; A or V
OM-192 440 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications Max Open Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. Open Circuit Voltage 200 V 230 V KVA KW 200 A at 24 VDC, 60% Duty Cycle 35 40 1.1* 35 1.3* 8 0.31* 6.8 0.18* Wire Type and Diameter No Load Wire Feed Speed Dimens...
Page 14 - -3. Welding Gun Duty Cycle And Overheating; CAUTION
OM-192 440 Page 10 3-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Duty Cycle is percentage of 10 minut...
Page 16 - -6. Connecting To Weld Output Terminals
OM-192 440 Page 12 3-6. Connecting To Weld Output Terminals 803 778-A Y Turn off power before connecting to weld output terminals. Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3...
Page 17 - -9. Installing Wire Spool And Adjusting Hub Tension
OM-192 440 Page 13 3-8. Setting Gun Polarity For Wire Type Tools Needed: 3/4 in 1 1 Polarity Changeover Label 2 Positive (+/Red) Output Terminal 3 Negative ( − /Black) Output Terminal Always read and follow wire manufacturer’s recommended polarity.Close door. Ref. 802 285-D Ref. ST-192 432 3 2 3-9. ...
Page 21 - -13. Selecting A Location And Connecting Input Power
OM-192 440 Page 17 3-13. Selecting A Location And Connecting Input Power 803 766-B / 802 286-E 4 2 Y Do not move or operate unitwhere it could tip. 18 in (457 mm) of space for airflow 1 Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Sp...
Page 23 - -15. Installing Optional Spool Gun Switch In Welding Power Source
OM-192 440 Page 19 3-15. Installing Optional Spool Gun Switch In Welding Power Source 802 936-A Tools Needed: 1/4 in 9/16 in Y Turn Off unit, and disconnect input power. 1 Welding Power Source Center Baffle 2 Switch Location 3 Switch Mounting Plate Remove 2 screws securing switch mounting plate to c...
Page 24 - -16. Connecting Spool Gun To Welding Power Source
OM-192 440 Page 20 3-16. Connecting Spool Gun To Welding Power Source Ref. 802 582-A Tools Needed: Y Turn Off unit. Disconnect and remove MIG (GMAW) welding gun, if applicable.1 Front Panel Opening 2 Spool Gun Weld Cable Route weld cable through front panel open- ing.3 Positive (+) Output Terminal C...
Page 26 - Selecting Wire, Gas and Control Settings; CAUTION! Do not change
OM-192 440 Page 22 4-2. Weld Parameters Input Line Voltage Parameter Chart Settings Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC Weld Will Be Hotter Lower Settings Use Parameter Chart Inside Door Weld Will Be Colder Raise Settings Steel Steel − for outdoor, windy applications or whe...
Page 27 - DriveRolls; Changing Polarity
OM-192 440 Page 23 200 785-C 3/8” (9.5 mm) — — — 5/66 7/70 7/60 7/100 7/82 7/60 7/75 6/50 5/46 — — — — — — 1/4” (6.4 mm) 4/58 5/56 5/40 5/100 5/76 4/60 4/50 5/58 4/38 4/30 6/90 5/70 6/50 6/45 6/18 6/64 6/60 5/36 5/42 5/16 5/56 5/54 1/8” (3.2 mm) 4/75 3/45 4/44 3/75 3/60 3/48 2/30 2/20 2/0 2/0 4/60 4...
Page 28 - Months
OM-192 440 Page 24 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean m...
Page 29 - -3. Replacing Drive Roll And Wire Inlet Guide
OM-192 440 Page 25 5-3. Replacing Drive Roll And Wire Inlet Guide Ref. 802 285-C 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.3 Drive Roll Install correct drive roll for wire size and type.4 Drive Rol...
Page 31 - Casing
OM-192 440 Page 27 5-6. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 804 466-A Y Turn off welding power source/wire feeder. 1 Nozzle 2 Contact Tip 3 Tip Adapter 4 Nozzle Adapter . Wire size stamped on tip − check and match wire size. Head Tube Tools Needed: 5/8,...
Page 33 - Troubleshooting Table
OM-192 440 Page 29 5-8. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-13). Check and replace power switch if necessary. Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 5-...
Page 34 - SECTION 6
OM-192 440 Page 30 SECTION 6 − MIG WELDING (GMAW) GUIDELINES 6-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Wire Feeder/ Power Source Workpiece...
Page 35 - Typical MIG Process Control Settings; NOTE
OM-192 440 Page 31 6-2. 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 to specifications. NOTE 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A...
Page 36 - Holding And Positioning Welding Gun; and tip of wire is positioned correctly on seam.
OM-192 440 Page 32 6-3. 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...
Page 37 - Conditions That Affect Weld Bead Shape
OM-192 440 Page 33 6-4. 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 ELECTODE EXTENSIONS (STICKOUT) ELECTRODE...
Page 38 - Gun Movement During Welding; multiple stringer beads works better.; Poor Weld Bead Characteristics
OM-192 440 Page 34 6-5. 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 Se...
Page 41 - Waviness Of Bead; Distortion
OM-192 440 Page 37 6-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint 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 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment; Problem
OM-192 440 Page 38 6-16. 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 Ga...
Page 44 - Notes
Page 45 - Figure 7-1. Circuit Diagram For Welding Power Source
OM-192 440 Page 41 SECTION 7 − ELECTRICAL DIAGRAM 206 590-A Figure 7-1. Circuit Diagram For Welding Power Source
Page 53 - Optional Spool Gun Switch; DESCRIPTION
OM-192 440 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-5. M-25 Gun (Continued) Quantity 8 169 738 NUT, locking handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 169 732 NUT, jam 1 . . . . . . . . ....
Page 56 - Hobart Welding Products; Please complete and retain with your personal records.; To locate a Distributor,; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA © 2005 Hobart Welding Products. 6/05 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date whic...
