HobartWelders HR-200 MIG GUN Owner's manual

Brand: HobartWelders

Model: HR-200 MIG GUN

Category: Welding System

Type: Owner's manual

OWNER’S MANUAL

OM-286182C 2023-04

Processes

Flux Cored (FCAW) Welding

MIG (GMAW) Welding

Description

Semi-Automatic, Air-Cooled Flux Cored

(FCAW) And MIG (GMAW) Welding Gun

www.HobartWelders.com

HR200 Gun

From Miller to You

Mil_Thank1

2019 01

Hobart is registered to the ISO

9001 Quality System

Standard.

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

This Owner’s Manual is designed to help you get the most out of your

Hobart products. Please take time to read the Safety Precautions.

They will help you protect yourself against potential hazards on the

worksite. We’ve made installation and operation quick and easy. With

Hobart, you can count on years of reliable service with proper

maintenance. And if for some reason the unit needs repair, there’s a

Troubleshooting section that will help you figure out what the problem

is. The parts list will then help you to decide the exact part you may

need to fix the problem. Warranty and service information for your

particular model are also provided.

Hobart Welders 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

specification sheets. To locate your nearest

distributor or service agency call

1-800-332-3281, or visit us at

www.HobartWelders.com on the web.

For Technical Help call 1-800-332-3281.

TABLE OF CONTENTS

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

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

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

1-3 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-4 Principal Safety Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-5 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2-2 Dangers relatifs au soudage à l'arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2-3 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2-4 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2-5 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 3 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3-2 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3-3 Installing Gun With Four Pin Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4-1 Operating The Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5-1 Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5-2 Replacing Switch And/Or Neck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5-3 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5-4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OM-286182 Page 1

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

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.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible haz-

ards are shown in the adjoining symbols or explained in

the text.

NOTICE – Indicates statements not related to personal injury.

Indicates special instructions.

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 these hazards.

1-2. Arc Welding Hazards

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 instruc-

tions to avoid the hazard. The safety information given be-

low is only a summary of the more complete safety

information found in the Principal Safety Standards, and in

welding power source Owner’s Manual. Read and follow all

Safety Standards.

Only qualified persons should install, operate, maintain,

and repair this equipment. A qualified person is defined as

one who, by possession of a recognized degree, certificate,

or professional standing, or who by extensive knowledge,

training and experience, has successfully demonstrated the

ability to solve or resolve problems relating to the subject

matter, the work, or the project and has received safety

training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children,

away.

ELECTRIC SHOCK can kill.

lAlways wear dry insulating gloves.

lInsulate yourself from work and ground.

lDo not touch live electrode or electrical parts.

lReplace worn, damaged, or cracked guns or

cables.

lTurn off welding power source before changing contact tip or gun

parts.

lKeep all covers and handle securely in place.

FUMES AND GASES can be

hazardous.

lKeep your head out of the fumes.

lVentilate area, or use breathing device. The rec-

ommended way to determine adequate ventilation

is to sample for the composition and quantity of fumes and gases

to which personnel are exposed.

lRead and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con-

sumables, coolants, degreasers, fluxes, and metals.

MOVING PARTS can injure.

lKeep away from moving parts.

lKeep away from pinch points such as drive rolls.

WELDING can cause fire or

explosion.

lDo not weld near flammable material.

lDo not weld on containers that have held combus-

tibles, or on closed containers such as tanks,

drums, or pipes unless they are properly prepared according to

AWS F4.1 (see Safety Standards).

lWatch for fire; keep extinguisher nearby.

lRead and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con-

sumables, coolants, degreasers, fluxes, and metals.

BUILDUP OF GAS can injure or kill.

lShut off compressed gas supply when not in use.

lAlways ventilate confined spaces or use approved

air-supplied respirator.

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.

lWear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes from arc rays and sparks

when welding or watching (see ANSI Z49.1 and Z87.1 listed in

Safety Standards).

lWear approved safety glasses with side shields under your

helmet.

lUse protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

lWear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath-

er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

HOT PARTS can burn.

lAllow gun to cool before touching.

lDo not touch hot metal.

lProtect hot metal from contact by others.

OM-286182 Page 2

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

lCheck for noise level limits exceeding those speci-

fied by OSHA.

lUse approved ear plugs or ear muffs if noise level is high.

lWarn others nearby about noise hazard.

WELDING WIRE can injure.

lKeep hands and body away from gun tip when trig-

ger is pressed.

READ INSTRUCTIONS.

lRead and follow all labels and the Owner’s Manual

carefully before installing, operating, or servicing

unit. Read the safety information at the beginning

of the manual and in each section.

lUse only genuine replacement parts from the manufacturer.

lPerform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo-

cal codes.

1-3. California Proposition 65 Warnings

WARNING – This product can expose you to chemicals in-

cluding lead, which are known to the state of California to

cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65Warnings.ca.gov.

1-4. Principal Safety Sections

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro-

tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Weld-

ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro-

tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-

part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

SR7 2022–01

1-5. EMF Information

Electric current flowing through any conductor causes localized elec-

tric and magnetic fields (EMF). The current from arc welding (and al-

lied processes including spot welding, gouging, plasma arc cutting,

and induction heating operations) creates an EMF field around the

welding circuit. EMF fields can interfere with some medical implants,

e.g. pacemakers. Protective measures for persons wearing medical

implants have to be taken. For example, restrict access for passers

−by or conduct individual risk assessment for welders. All welders

should use the following procedures in order to minimize exposure to

EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the weld-

ing circuit as possible.

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

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding,

spot welding, gouging, plasma arc cutting, or induction heating opera-

tions. If cleared by your doctor, then following the above procedures

is recommended.

OM-286182 Page 3

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives

aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! – Indique une situation dangereuse qui si on l’é-

vite pas peut donner la mort ou des blessures graves. Les

dangers possibles sont montrés par les symboles joints

ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut

donner la mort ou des blessures graves. Les dangers pos-

sibles sont montrés par les symboles joints ou sont expli-

qués dans le texte.

AVIS – Indique des déclarations pas en relation avec des blessures

personnelles.

Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DAN-

GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE-

CES CHAUDES. Reportez-vous aux symboles et aux directives ci-

dessous afin de connaître les mesures à prendre pour éviter tout

danger.

2-2. Dangers relatifs au soudage à l'arc

Les symboles donnés ci-après sont utilisés dans tout le ma-

nuel pour attirer l’attention sur les dangers possibles et

pour indiquer le type de danger dont il s’agit. Quand on voit

le symbole, prendre garde et suivre les directives corres-

pondantes pour éviter le danger. Les consignes de sécurité

présentées ci-après ne font que résumer l’information

contenue dans les Normes de sécurité principales, et dans

le Guide d’utilisation de la source de courant de soudage.

Lire et suivre toutes les Normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées. Une per-

sonne qualifiée est définie comme celle qui, par la posses-

sion d’un diplôme reconnu, d’un certificat ou d’un statut

professionnel, ou qui, par une connaissance, une formation

et une expérience approfondies, a démontré avec succès sa

capacité à résoudre les problèmes liés à la tâche, le travail

ou le projet et a reçu une formation en sécurité afin de re-

connaître et d’éviter les risques inhérents.

Au cours de l’utilisation, tenir toute personne à l’écart et

plus particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

lPorter toujours des gants secs et isolants.

lS’isoler de la pièce et de la terre.

lNe jamais toucher une électrode ou des pièces

électriques sous tension.

lRemplacer les pistolets ou câbles de soudage qui sont endomma-

gés, usés ou craquelés.

lMettre la soudeuse hors tension avant de remplacer un bec

contact ou des pièces de pistolet.

lS’assurer que tous les couvercles et poignées sont fermement

assujettis.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

lGarder la tête hors des fumées.

lAérer la zone de travail ou porter un appareil respi-

ratoire. Pour déterminer la bonne ventilation, il est

recommandé de procéder à un prélèvement pour la composition

et la quantité de fumées et de gaz auxquelles est exposé le

personnel.

lLire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,

les nettoyants, les consommables, les produits de refroidisse-

ment, les dégraisseurs, les flux et les métaux.

Les PIÈCES MOBILES peuvent

causer des blessures.

lNe pas s’approcher des organes mobiles.

lNe pas s’approcher des points de coincement tels

que des rouleaux de commande.

Le SOUDAGE peut provoquer un

incendie ou une explosion.

lNe pas souder à proximité de matériaux

inflammables

lNe pas effectuer le soudage sur des conteneurs

fermés tels que des réservoirs, tambours, ou conduites, à moins

qu’ils n’aient été préparés correctement conformément à AWS

F4.1 (voir les Normes de Sécurité).

lPrendre garde aux incendies et toujours avoir un extincteur à

proximité.

lLire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,

les nettoyants, les consommables, les produits de refroidisse-

ment, les dégraisseurs, les flux et les métaux.

LES ACCUMULATIONS DE GAZ

risquent de provoquer des blessures

ou même la mort.

lFermer l’alimentation du gaz comprimé en cas de

non utilisation.

lVeiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent

provoquer des brûlures dans les

yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage

génère 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.

lPorter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

lPorter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

OM-286182 Page 4

lAvoir recours à des écrans protecteurs ou à des rideaux pour pro-

téger les autres contre les rayonnements les éblouissements et

les étincelles ; prévenir toute personne sur les lieux de ne pas re-

garder l’arc.

lPorter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans

huile, comme des gants de cuir, une chemise solide, des panta-

lons sans revers, des chaussures hautes et une casquette.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

lLaisser refroidir le pistolet avant de le toucher.

lNe pas toucher d’objets métalliques chauds.

lAbriter les objets métalliques contre tout contact

par les personnes à proximité.

Le BRUIT peut endommager l’ouie.

Le bruit des processus et des équipements peut

affecter l’ouïe.

lVérifier si les niveaux de bruit excèdent les limites

spécifiées par l’OSHA.

lUtiliser des bouche-oreilles ou des serre-tête antibruit approuvés

si le niveau de bruit est élevé.

lAvertir les personnes à proximité au sujet du danger inhérent au

bruit.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

lÉloigner les mains et le corps de la buse du pisto-

let après avoir appuyé sur la gâchette.

LIRE LES INSTRUCTIONS.

lLire et appliquer les instructions sur les étiquettes

et le Mode d’emploi avant l’installation, l’utilisation

ou l’entretien de l’appareil. Lire les informations de

sécurité au début du manuel et dans chaque

section.

lN’utiliser que des pièces de remplacement provenant du fabricant.

lEffectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de

l’industrie, ainsi que les codes municipaux.

2-3. Proposition californienne 65 Avertissements

AVERTISSEMENT – Ce produit peut vous exposer à des pro-

duits chimiques tels que le plomb, reconnus par l’État de

Californie comme cancérigènes et sources de malforma-

tions ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro-

tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Weld-

ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro-

tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-

part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

SR7_fre 2022–01

2-5. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des

champs électromagnétiques (CEM) à certains endroits. Le courant is-

su d’un soudage à l’arc (et de procédés connexes, y compris le sou-

dage par points, le gougeage, le découpage plasma et les opérations

de chauffage par induction) crée un champ électromagnétique (CEM)

autour du circuit de soudage. Les champs électromagnétiques pro-

duits peuvent causer interférence à certains implants médicaux,

p. ex. les stimulateurs cardiaques. Des mesures de protection pour

les porteurs d’implants médicaux doivent être prises: par exemple,

des restrictions d’accès pour les passants ou une évaluation indivi-

duelle des risques pour les soudeurs. Tous les soudeurs doivent ap-

pliquer les procédures suivantes pour minimiser l’exposition aux CEM

provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câ-

bles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir

ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le

dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les procé-

dures précédentes.

OM-286182 Page 5

SECTION 3 – INSTALLATION

3-1. Specifications

Wire Diameter Range Cooling Method Duty Cycle Rating Weight

Flux Cored Wire: .023–.045 in.

(0.6–1.1 mm)

Solid Wire: .023–.045 in. (0.6–

1.1 mm)

Air Cooled Welding Gun For

GMAW And FCAW Welding

60%: 200 A With Flux Cored Wire

60%: 200 A With CO2Shielding

Gas

60%: 200 A With Mixed Gases

With 15 ft (4.6 m) Power Cable:

6.9 lb (3.1 kg)

3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated

load without overheating.

NOTICE – Exceeding duty cycle can damage unit and void warranty.

60% Duty Cycle At 200A Using Mixed Gases

6 Minutes Welding 4 Minutes Resting

Overheating

A or V

Reduce Duty Cycle

Minutes

sduty1 5/95

3-3. Installing Gun With Four Pin Connector

Ref. 284972-A

Turn off and disconnect input

power.

1 Gun Securing Knob

2 Gun End

Loosen knob. Insert gun end until it bottoms

against drive assembly. Tighten knob.

3 Gun Trigger Plug

Insert into receptacle and tighten threaded

collar.

See power source manual for wire threading

procedure.

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-286182 Page 6

SECTION 4 – OPERATION

4-1. Operating The Gun

Ref. 284972-A

1 Trigger Switch

Press and hold switch to feed energized wire

and start flow of shielding gas.

OM-286182 Page 7

SECTION 5 – MAINTENANCE AND TROUBLESHOOTING

5-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun

Casing

5/8 in.

(16 mm)

Liner

Stickout

Ref.284972-A

Turn off welding power source/wire

feeder.

Wire size stamped on tip, check and

match wire size.

1 Nozzle

2 Contact Tip

3 Contact Tip Adapter

4 Head Tube

5 Gun Liner

6 Compressed Air Nozzle

Cut off wire and remove gun from unit.

Lay gun cable out straight.

Step 1. Remove nozzle, contact tip, and

contact tip adapter from gun.

Step 2. Lay gun cable out straight. Loosen

nut on gun liner and remove liner.

Step 3. Insert air nozzle and blow out con-

duit with compressed air.

Step 4. Install original gun liner or new liner

if necessary. Tighten gun liner nut and trim

gun liner to length as shown.

Refer to owner’s manual for unit to thread

welding wire and determine drive roll

pressure.

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

8 mm, 10 mm

OM-286182 Page 8

5-2. Replacing Switch And/Or Neck Assembly

2 3 4

Turn off welding power source/wire

feeder.

Wire size stamped on tip, check and

match wire size.

1 Handle Hardware

Remove screws and nuts from handle.

2 Locking Cap

Rotate Locking Cap counterclockwise 1/4

turn to separate handle halves.

3 Handle Halves

Remove handle halves to expose trigger

switch.

4 Trigger Switch

Remove trigger switch and replace if neces-

sary. The polarity of the trigger leads is not

critical.

If replacing the head tube continue with the

following instructions.

5 Head Tube

6 Jam Nut

7 Vise

Insert head tube in vise if necessary.

Loosen jam nut. Remove head tube from

vise and turn head tube by hand.

8 New Head Tube Assembly

Thread the new neck assembly into the end

fitting. Make sure the neck assembly is par-

allel to the handle halves before tightening

the lock nut. Torque lock nut to 21 ft lbs

(28.5 N m).

9 Strain Relief Ball

Make sure the strain relief ball is positioned

in the socket handle before closing handle

halves.

10 Trigger switch

11 Locking Cap

12 Handle Hardware

Insert trigger switch between handle halves.

Install handle hardware and tighten.

Squeeze handle halves together and rotate

locking cap 1/4 turn clockwise.

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

14 mm

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose steelbrush nutdriver chippinghammer

solderiron stripcrimp

drill

torque wrench socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab) vicegrip

handream

punch

filterwrench

strapwrench airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

OM-286182 Page 9

5-3. Routine Maintenance

Disconnect power before maintaining.

Maintain more often during severe conditions.

ü= Check ◇= Change m= Clean ¶= Replace

Every 3

Months

OM-249336 Page 1

A complete Parts List is available at www.MillerWelds.com

SECTION 6 MAINTENANCE AND TROUBLESHOOTING

Every

Months

 Weld Terminals

 Labels

Every

Months

6-1. Blowing Out Inside of Unit

804746-B

¶Unreadable Labels mWeld Terminals ¶Damaged Gas Hose ü ¶ Weld Cables

OM-283696 Page 11

3-10. Routine Maintenance

!Disconnect power

before maintaining. Maintain more often

during severe conditions.

 = Check  = Change  = Clean  = Replace

* To be done by Factory Authorized Service Agent Reference

Every

Months

 Unreadable Labels  Weld Terminals  Weld Cables  Gun Cables

 Cords  Cracked Parts  Weld Connections  Tighten Weld Cable

Connections

Every

Months OR

 Inside Unit

3-11. Overload Protection

283237-B

Supplementary

Protector CB1

CB1 protects feeder interface from

overload. If CB1 opens, unit shuts

down.

Reset supplementary protector.

Notes

ü ¶ Cords ü ¶ Gun Cables

Every 6

Months

Complete Parts List is available at www.MillerWelds.com

OM-278215 Page 33

1/2 in.

(13 mm)

SLUDGE

FUEL

mDrive Rolls mInside Unit

*To be done by factory authorized service agent.

5-4. Troubleshooting

Trouble Remedy

Wire does not feed; wire is not ener-

gized; wire feeds unevenly. Check contact tip. Check for kinks in gun cable and liner.

Check gun trigger plug connection at welding power source/wire feeder.

Check, and if necessary, replace gun trigger switch (see section 5-2).

Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing. (see Section 5-1).

Weld Porosity Remove weld spatter buildup in nozzle.

Check O-rings on gun connector and replace if damaged.

Make sure inner head tube is tight in cable connector

Check gun connector to be sure it is fully inserted into drive assembly.

Check shielding gas flow/supply.

.Wire feeding stops or does not feed

properly during welding. Straighten gun cable and/or replace damaged parts (see Section 5-2).

Adjust drive roll pressure (see wire feeder manual).

Change to proper drive roll groove (see wire feeder manual).

Readjust hub tension (see wire feeder manual).

Clean or replace liner if dirty or plugged (see Section 5-1).

Replace drive roll or pressure bearing if worn or slipping (see wire feeder manual)

OM-286182 Page 10

SECTION 6 – PARTS LIST

2345

23 24

Figure 6-1. Complete Assembly For HR–200 MIG Gun

OM-286182 Page 11

Item No. Dia. Mkgs. Part No. Description Quantity

1 770404 Nozzle, Slip Type .500 Orf Flush 1

1 ♦169724 Nozzle, Slip Type .500 Orf .125 Recess 1

1 ♦169725 Nozzle, Slip Type .625 Orf .125 Recess 1

1 ♦169726 Nozzle, Slip Type .625 Orf .Flush 1

1 ♦169726 Nozzle, Slip Type .625 Orf ..125 Stick Out 1

2 ♦770174 Tip, Contact Scr .023 Wire x 1.125 1

2 ♦770117 Tip, Contact Scr .030 Wire x 1.125 1

2 ♦770180 Tip, Contact Scr .035 Wire x 1.125 1

2 ♦770183 Tip, Contact Scr .045 Wire x 1.125 1

3 770402 Adapter, Contact Tip 1

4 169729 Adapter, Nozzle w/Retaining Ring 1

5 170468 O-Ring 1

6 169730 Washer, Shock 1

771002 Kit, Neck Assy Replacement HR200 Includes 1

7 .... Assembly, Neck 1

8 .... Nut, Jam 1

771003 Kit,Handle Assy Replacement HR200 Includes 1

9 .... Handle, Right 1

10 .... Handle, Left 1

11 .... Screw, Socket Head Cap 4

12 .... Handle Cap, 1

13 771005 Switch, Trigger Standard 1

14 2520102 Handle, Spring Assy 1

15 285698 Cable, HR 200 1

16 285701 Strain Relief, Rear Cap 1

17 285700 Strain Relief, Cable 1

18 GN2021 Electrical Connection Assy 1

19 1960012 Nut, Jam 1

20 285702 Strain Relief, Rear 1

21 209080 Screw, M4 1

771006 Assembly, Power Pin HR200 Includes 1

22 .... Power Pin, 1

23 .... O-Ring 1

24 ♦194010 Liner, Monocoil .023/.025 Wire x 15 Ft 1

24 194011 Liner, Monocoil .030/.035 Wire x 15 Ft 1

24 ♦194012 Liner, Monocoil .035/.045 Wire x 15 Ft 1

24 ♦194014 Liner, Monocoil 3/64 AL Wire x 15 Ft 1

25 079975 —O-Ring, .187 ID x .103 CS Rbr 1

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and

serial number required when ordering parts from your local distributor.

Notes

Effective January 1, 2023

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num-

ber preface of ND or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or

warranties expressed or implied.

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

LIMITED WARRANTY - Subject to the terms and

conditions below, Miller Electric Mfg. LLC, dba Ho-

bart Welding Products, Appleton, Wisconsin, war-

rants to its original retail purchaser that 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 shipped. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL

OTHER WARRANTIES, EXPRESS OR IMPLIED,

INCLUDING THE WARRANTIES OF MER-

CHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart/

Miller will repair or replace any warranted parts or

components that fail due to such defects in materi-

al or workmanship. Hobart/Miller must be notified

in writing within thirty (30) days of such defect or

failure, at which time Hobart/Miller will provide in-

structions on the warranty claim procedures to be

followed. Notifications submitted as online war-

ranty claims must provide detailed descriptions of

the fault and troubleshooting steps taken to diag-

nose failed parts. Warranty claims that lack the re-

quired information as defined in the Miller Service

Operation Guide (SOG) may be denied by Miller.

Hobart/Miller shall honor warranty claims on war-

ranted equipment listed below in the event of a de-

fect within the warranty coverage time periods

listed below. Warranty time periods start on the de-

livery date of the equipment to the original retail

purchaser, or 12 months after the equipment is

shipped to a US or Canada distributor, or 18

months after the equipment is shipped to an inter-

national distributor, whichever occurs first.

1 5 Years — Parts and Labor

lOriginal Main Power Rectifiers only to include

SCRs, diodes, and discrete rectifier modules

in non-inverter products

lReactors

lStabilizers

lTransformers

2 3 Years — Parts and Labor Unless Specified

lDrive Systems

lIdle Module

lPC Boards

lRotors, Stators and Brushes

lSolenoid Valves

lSwitches and Controls

3 1 Year — Parts and Labor Unless Specified(90

days for industrial use)

lAccessories (Kits)

lField Options (NOTE: Field options are cov-

ered for the remaining warranty period of the

product they are installed in, or for a minimum

of one year — whichever is greater.)

lHF Units

lMIG Flowgauge Regulators (No Labor)

lMIG Guns/TIG Torches

lPlasma Cutting Torches

lRemote Controls

lReplacement Parts (No labor) - 90 days

lRunning Gear/Trailers

lSpoolguns

4 6 Months — Parts

l12 Volt Automotive-Style Batteries

5 Engines and tires are warranted separately by

the manufacturer.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components; such as contact

tips, cutting nozzles, contactors, brushes,

relays, work station table tops and welding

curtains, or parts that fail due to normal

wear. (Exception: brushes and relays are

covered on all engine-driven products.)

2. Items furnished by Hobart/Miller, but manufac-

tured by others, such as engines or trade ac-

cessories. These items are covered by the

manufacturer’s warranty, if any.

3. Equipment that has been modified by any party

other than Hobart/Miller, or equipment that has

been improperly installed, improperly operated

or misused based upon industry standards, or

equipment which has not had reasonable and

necessary maintenance, or equipment which

has been used for operation outside of the

specifications for the equipment.

4. Defects caused by accident, unauthorized re-

pair, or improper testing.

HOBART PRODUCTS ARE INTENDED FOR

COMMERCIAL AND INDUSTRIAL USERS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at

Hobart’s/Miller’s option, either: (1) repair; or (2) re-

placement; or, if approved in writing by Hobart/Mill-

er, (3) the pre-approved cost of repair or

replacement at an authorized Hobart/Miller service

station; or (4) payment of or credit for the purchase

price (less reasonable depreciation based upon

use). Products may not be returned without

Hobart’s/Miller’s written approval. Return shipment

shall be at customer’s risk and expense.

The above remedies are F. O. B. Appleton, WI, or

Hobart’s/Miller’s authorized service facility. Trans-

portation and freight are the customer’s responsi-

bility. TO THE EXTENT PERMITTED BY LAW,

THE REMEDIES HEREIN ARE THE SOLE AND

EXCLUSIVE REMEDIES REGARDLESS OF THE

LEGAL THEORY. IN NO EVENT SHALL HO-

BART/MILLER BE LIABLE FOR DIRECT, INDI-

RECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING

LOSS OF PROFIT) REGARDLESS OF THE LE-

GAL THEORY. ANY WARRANTY NOT PRO-

VIDED HEREIN AND ANY IMPLIED WARRANTY,

GUARANTY, OR REPRESENTATION, INCLUD-

ING ANY IMPLIED WARRANTY OF MERCHANT-

ABILITY OR FITNESS FOR PARTICULAR

PURPOSE, ARE EXCLUDED AND DISCLAIMED

BY HOBART/MILLER.

Some US states do not allow limiting the duration

of an implied warranty or the exclusion of certain

damages, so the above limitations may not apply

to you. This warranty provides specific legal rights,

and other rights may be available depending on

your state. In Canada, some provinces provide ad-

ditional warranties or remedies, and to the extent

the law prohibits their waiver, the limitations set out

above may not apply. This Limited Warranty pro-

vides specific legal rights, and other rights may be

available, but may vary by province.

Warranty Questions?

Call 1-800-332-3281

8 AM – 5 PM EST

Service

You 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 ques-

tions? Contact your distributor or call 1-800-

332-3281. The expertise of the distributor and

Hobart is there to help you, every step of the

way.

Assistance

Visit the Hobart website:

www.HobartWelders.com

Miller Electric Mfg. LLC

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

For Assistance:

Call 1-800-332-3281

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Thank you for purchasing Hobart. Our trained technical support team is dedicated to your

satisfaction. For questions regarding performance, operation, or service, contact us!

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Service Center:

Call 1-800-332-3281

or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:

Call 1-800-332-3281

8 AM to 5 PM EST – Monday through Friday

HobartWelders HR-200 MIG GUN Owner's manual

Brand: HobartWelders

Model: HR-200 MIG GUN

Category: Welding System

Type: Owner's manual

Download PDF

report

in other languages

français: HobartWelders HR-200 MIG GUN Le manuel du propriétaire

HobartWelders HR-200 MIG GUN Owner's manual

HobartWelders HR-200 MIG GUN Owner's manual

in other languages

Related papers

Other documents