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Hobart OM-186 165C manual

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Table of contents for the manual

  • Page 1

    Processes OM-186 165C October 2000 Olympic VS Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Wire Feeder[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-186 165 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch 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 W arning! Wat[...]

  • Page 6

    OM-186 165 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 RA YS 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[...]

  • Page 7

    OM-186 165 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.[...]

  • Page 8

    OM-186 165 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 yea[...]

  • Page 9

    OM-186 165 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-186 165 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-186 165 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-186 165 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for[...]

  • Page 13

    OM-186 165 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range Input W elding Circuit Rating IP Rating Max. Wire Spool Capacity Overall Dimensions W eight Open-Circuit/ Arc V oltage, 15 T o 100 V olts DC Constant V oltage (CV) Or Constant Current (CC) DC [...]

  • Page 14

    OM-186 165 Page 10 2-2. Installing And Aligning Wire Guide And Drive Roll ST-132 809-B / Ref. ST -132 808-F / Ref. ST -162 079-A / Ref. S-180 967 When changing wire size or type, check drive roll and wire guide size (see Parts List). Installing Wire Guide And Drive Rolls: 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut l[...]

  • Page 15

    OM-186 165 Page 1 1 2-3. T ypical Connections 1 CC Or CV Welding Power Source If using a CC welding power source without a weld output contactor , use optional secondary contactor . 2 Weld Cable 3 W ork Fo r GMAW , use optional gas valve. 1 2 3 2-4. Gun Recommendation T able Process Gun GMA W – Hard or Corded Wires Piecemaker 25A, or 40A Gun FCA [...]

  • Page 16

    OM-186 165 Page 12 2-6. Connecting Shielding Gas (Optional) ST-801 155-A 1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) 2 Shielding Gas Cylinder 3 V alve 4 Flowmeter Close valve on cylinder when fin- ished welding. T ools Needed: 5/8 in 1 Rear View 2 3 4 2-7. Connecting Weld Cable Ref. ST-132 808-F / Ref. ST -157 658-D 1 Weld[...]

  • Page 17

    OM-186 165 Page 13 2-8. Installing And Threading Welding Wire ST-800 586-B / Ref. ST -159 048-A / S-0627-A 1 Retaining Ring 2 Hub T ension Adjustment Nut Installing Wire And Adjusting Hub T ension: Remove retaining ring, and install spool s o hub pin fits spool hole. Re- install retaining ring. Adjust tension nut so only a slight force i s needed t[...]

  • Page 18

    OM-186 165 Page 14 SECTION 3 – OPERA TION 3-1. Controls Ref. ST-139 026-B / Ref. ST -132 808-F 1 Wire Speed Meter (Optional) 2 V oltage Meter (Optional) Us e meter to set and display rate of wire speed in inches per minute (ipm). 3 Power Control Switch 4 Wire Speed Range Switch 5 Wire Speed Control U s e switch to select high or low wire speed ra[...]

  • Page 19

    OM-186 165 Page 15 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 Clean And T ighten W eld T erminals Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Clean Drive [...]

  • Page 20

    OM-186 165 Page 16 4-3. Calibrating Optional IPM Meter Ref. ST-800 586-B / Ref. ST -176 180 Meter is factory calibrated, but may need recalibration after motor brushes are fully seated. T o recali- brate, proceed as follows: 1 CV/CC Switch Set switch to CV . 2 Meter Board PC4 3 Resistor R53 Adjustment Screw (High Range) 4 Resistor R54 Adjustment Sc[...]

  • Page 21

    OM-186 165 Page 17 4-4. T roubleshooting T rouble Remedy Wire does not feed; open-circuit voltage available. Check circuit breaker CB1 and fuse F1. Reset CB1 or replace F1 if necessary (see Section 4-2). Check sensing lead connection. Check gun trigger plug connection. Check gun trigger . See gun Owner ’ s Manual. Have Factory Authorized Service [...]

  • Page 22

    OM-186 165 Page 18 SECTION 5 – ELECTRICAL DIAGRAM SC-176 218 Figure 5-1. Circuit Diagram For Wire Feeder[...]

  • Page 23

    OM-186 165 Page 19 Notes[...]

  • Page 24

    OM-186 165 Page 20 SECTION 6 – P ARTS LIST Figure 6-1. Complete Assembly . Hardware is common and not available unless listed. See T able 6-1 For Drive Roll & Wire Guide Kits *Includes Items 27 Thru 29 **Includes Item 36 8 9 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 32 23* 27 28 29 25 34 35 33** 38 39 40 41 42 43 37 44 45 [...]

  • Page 25

    OM-186 165 Page 21 Figure 6-1. Complete Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 601 965 SCREW , cap stl hexhd .375-16 x 1.000 1 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 26

    OM-186 165 Page 22 Figure 6-1. Complete Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 36 S4 1 18 681 SWITCH, tgl DPDT 15A 125V AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG60 131 056 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 27

    OM-186 165 Page 23 Figure 6-1. Complete Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 79 604 538 W ASHER, flat stl SAE .312 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 124 778 KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar 1 . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-186 165 Page 24 T able 6-1. Drive Roll & Wire Guide Kits (2 Drive Roll) Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for ha[...]

  • Page 29

    OM-186 165 Page 25 Notes[...]

  • Page 30

    OM-186 165 Page 26 Notes[...]

  • Page 31

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distrib[...]

  • Page 32

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding Produc ts An I l li noi s T ool W orks Company 600 West Main St reet Troy , OH 45373 USA For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to or[...]