Handler 140 and H100S2-10 Gun Owner's Manual

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    Processes

    OM-925 217 694G2010 05

    Handler 140

    And H100S2-10 Gun

    Arc Welding Power Source AndWire Feeder

    Description

    MIG (GMAW) WeldingFlux Cored (FCAW) Welding

    R

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    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 1-877-Hobart1 orvisit our website at www.HobartWelders.com.

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

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

    job done and get it done right. We know you dont have time to do it anyother way.

    This Owners Manual is designed to help you get the most out of yourHobart products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

    Weve made installation and operation quickand easy. With Hobart you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that will helpyou figure out what the problem is. The partslist will then help you to decide the exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

    Hobart is registered to theISO 9001 Quality SystemStandard.

    Working as hard as youdo every power sourcefrom Hobart is backed bthe best warranty in thebusiness.

    From Hobart to You

    Hob_Thank 2009

    09

    Register your product at:HobartWelders.com

    Protect Your Investmen

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    OM-925 Page 1

    SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINsom _2010 03

    7

    Protect yourself and others from injury read and follow these precautions.

    1-1. Symbol Usage

    DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

    Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

    NOTICE Indicates statements not related to personal injury.

    . Indicates special instructions.

    This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid thehazards.

    1-2. Arc Welding Hazards

    The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

    Only qualified persons should install, operate, maintain, andrepair this unit.

    During operation, keep everybody, especially children, away.

    ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit is

    electrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.D Do not touch live electrical parts.

    D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating mats

    or covers big enough to prevent any physical contact with the workor ground.

    D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

    D Use AC output ONLY if required for the welding process.

    D If AC output is required, use remote output control if present onunit.D Additional safety precautions are required when any of the follow-

    ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

    D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

    D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

    D Always verify the supply ground check and be sure that input

    power cord ground wire is properly connected to ground terminal idisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

    D When making input connections, attach proper grounding conductor first double-check connections.

    D Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

    D Frequently inspect input power cord for damage or bare wiringreplace cord immediately if damaged bare wiring can kill.

    D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it direct

    with a separate cable.D Do not touch electrode if you are in contact with the work, groun

    or another electrode from a different machine.D Do not touch electrode holders connected to two welding ma-

    chines at the same time since double open-circuit voltage will bepresent.

    D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

    D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiec

    or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to preven

    contact with any metal object.D Do not connect more than one electrode or work cable to any

    single weld output terminal.

    SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of inputpower.D Turn Off inverter, disconnect input power, and discharge inpu

    capacitors according to instructions in Maintenance Sectionbefore touching any parts.

    HOT PARTS can burn.D Do not touch hot parts bare handed.D Allow cooling period before working on equip-

    ment.D To handle hot parts, use proper tools and/or

    wear heavy, insulated welding gloves andclothing to prevent burns.

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    OM-925 Page 2

    Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

    FUMES AND GASES can be hazardous.

    D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at the

    arc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Material Safety Data Sheets (MSDSs)

    and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.D Work in a confined space only if it is well ventilated, or while

    wearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

    D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

    D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

    Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

    D Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

    D Wear approved safety glasses with side shields under yourhelmet.

    D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

    D Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

    ARC RAYS can burn eyes and skin.

    Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

    burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

    WELDING can cause fire or explosion.

    D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

    D Do not weld where flying sparks can strike flammable material.D Protect yourself and others from flying sparks and hot metal.D Be alert that welding sparks and hot materials from welding can

    easily go through small cracks and openings to adjacent areas.D Watch for fire, and keep a fire extinguisher nearby.D Be aware that welding on a ceiling, floor, bulkhead, or partition can

    cause fire on the hidden side.D Do not weld on closed containers such as tanks, drums, or pipes,

    unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

    D Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

    D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

    D Do not use welder to thaw frozen pipes.

    D Remove stick electrode from holder or cut off welding wire acontact tip when not in use.

    D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

    D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

    D After completion of work, inspect area to ensure it is free of sparksglowing embers, and flames.

    D Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

    D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51for hot work and have a fire watcher and extinguisher nearby.

    FLYING METAL or DIRT can injure eyes.

    D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

    D Wear approved safety glasses with sideshields even under your welding helmet.

    BUILDUP OF GAS can injure or kill.D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

    approved air-supplied respirator.

    ELECTRIC AND MAGNETIC FIELDS (EMcan affect ImplantedMedical Devices.

    D Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

    D Implanted Medical Device wearers should consult their doctoand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

    NOISE can damage hearing.

    Noise from some processes or equipment candamage hearing.D Wear approved ear protection if noise level is

    high.

    Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

    CYLINDERS can explode if damaged.

    D Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

    D Install cylinders in an upright position by securing to a stationarsupport or cylinder rack to prevent falling or tipping.

    D Keep cylinders away from any welding or other electrical circuitD Never drape a welding torch over a gas cylinder.D Never allow a welding electrode to touch any cylinder.D Never weld on a pressurized cylinder explosion will result.D Use only correct shielding gas cylinders, regulators, hoses, and fit-

    tings designed for the specific application; maintain them andassociated parts in good condition.

    D Turn face away from valve outlet when opening cylinder valve.D Keep protective cap in place over valve except when cylinder is i

    use or connected for use.D Use the right equipment, correct procedures, and sufficient num-

    ber of persons to lift and move cylinders.D Read and follow instructions on compressed gas cylinders,

    associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

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    OM-925 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 isproperly sized, rated, and protected to handle this unit.

    FALLING EQUIPMENT can injure.D Use lifting eye to lift unit only, NOT running

    gear, gas cylinders, or any other accessories.D Use equipment of adequate capacity to lift and

    support unit.

    D If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

    D Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

    D Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94 110) when manu-ally lifting heavy parts or equipment.

    OVERUSE can cause OVERHEATINGD Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle before

    starting to weld again.D Do not block or filter airflow to unit.

    FLYING SPARKS can injure.D Wear a face shield to protect eyes and face.D Shape tungsten electrode only on grinder with

    proper guards in a safe location wearing properface, hand, and body protection.

    D Sparks can cause fires keep flammables away.

    STATIC (ESD) can damage PC boards.

    D Put on grounded wrist strap BEFORE handlingboards or parts.

    D Use proper static-proof bags and boxes tostore, move, or ship PC boards.

    MOVING PARTS can injure.D Keep away from moving parts.D Keep away from pinch points such as drive

    rolls.

    WELDING WIRE can injure.D Do not press gun trigger until instructed to do

    so.D Do not point gun toward any part of the body,

    other people, or any metal when threadingwelding wire.

    MOVING PARTS can injure.D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guards

    closed and securely in place.D Have only qualified persons remove doors, panels, covers, or

    guards for maintenance and troubleshooting as necessary.D

    Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

    READ INSTRUCTIONS.D Read and follow all labels and the Owners

    Manual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

    D Use only genuine replacement parts from the manufacturer.D Perform maintenance and service according to the Owners

    Manuals, industry standards, and national, state, and localcodes.

    H.F. RADIATION can cause interference.

    D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

    D Have only qualified persons familiar withelectronic equipment perform this installation.

    D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

    D If notified by the FCC about interference, stop using theequipment at once.

    D Have the installation regularly checked and maintained.D Keep high-frequency source doors and panels tightly shut, keep

    spark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

    ARC WELDING can cause interference.

    D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

    D Be sure all equipment in the welding area iselectromagnetically compatible.

    D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

    D Locate welding operation 100 meters from any sensitive elec-

    tronic equipment.D Be sure this welding machine is installed and groundedaccording to this manual.

    D If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

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    OM-925 Page 4

    1-4. California Proposition 65 Warnings

    Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

    Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

    This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

    For Gasoline Engines:

    Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

    For Diesel Engines:

    Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.

    1-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, from Glob-al Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:www.nfpa.org and www. sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 4221 Walney Road, 5th Floor,Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:800-463-6727, website: www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,

    25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, wesite: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection AssociatioQuincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.orgOSHA, Occupational Safety and Health Standards for General Indutry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart and Part 1926, Subpart J, from U.S. Government Printing Office, Supe

    intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-795(phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, websitewww.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WesHighway, Bethesda, MD 20814 (phone: 301-504-7923, websitewww.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation , The Na-tional Institute for Occupational Safety and Health (NIOSH), 16Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, websiwww.cdc.gov/NIOSH).

    1-6. EMF InformationElectric current flowing through any conductor causes localized electric

    and magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, access restrictions for passers by or individual risk assess-ment for welders. All welders should use the following procedures inorder to minimize exposure to EMF fields from the welding circuit:

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

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

    welding 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 wirefeeder.

    About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thdevice manufacturer before performing or going near arc welding, spwelding, gouging, plasma arc cutting, or induction heating operationIf cleared by your doctor, then following the above procedures is recommended.

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    OM-925 Page 5

    SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONfre_som_2010 03

    7

    Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

    2-1. Symboles utiliss

    DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

    NOTE Indique des dclarations pas en relation avec des blessurespersonnelles.

    . Indique des instructions spcifiques.

    Ce groupe de symboles veut dire Avertissement! Attention! DANGEDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

    2-2. Dangers relatifs au soudage larc

    Les symboles reprsents ci-dessous sont utiliss dans ce ma-nuel pour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructionsen matire de scurit indiques ci-dessous ne constituentquun sommaire des instructions de scurit plus compltesfournies dans les normes de scurit numres dans la Sec-tion 2-5. Lire et observer toutes les normes de scurit.

    Seul un personnel qualifi est autoris installer, faire fonc-tionner, entretenir et rparer cet appareil.

    Pendant le fonctionnement, maintenir distance toutes lespersonnes, notamment les enfants de lappareil.

    UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr lasortie. Le circuit dalimentation et les circuits inter-nes de la machine sont galement sous tensionlorsque lalimentation est sur Marche. Dans le modede soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalli-ques en contact avec le fil sont sous tensionlectrique. Un quipement install ou mis la terrede manire incorrecte ou impropre constitue undanger.

    D Ne pas toucher aux pices lectriques sous tension.D Porter des gants isolants et des vtements de protection secs et

    sans trous.D Sisoler de la pice couper et du sol en utilisant des housses ou

    des tapis assez grands afin dviter tout contact physique avec la

    pice couper ou le sol.D Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

    D Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

    D Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

    D Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,

    dans lordre indiqu : 1) un poste souder DC tension constante( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations,lutilisation dun poste souder DC fil tension constante est re-commande. En outre, ne pas travailler seul !

    D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouilllalimentation selon la norme OSHA 29 CFR 1910.147 (voir nomes de scurit).

    D Installer le poste correctement et le mettre la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.

    D Toujours vrifier la terre du cordon dalimentation. Vrifier sassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

    D En effectuant les raccordements dentre, fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions.

    D Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgez les contre les tincelles et les pices mtalliqueschaudes.

    D Vrifier frquemment le cordon dalimentation afin de sassurequil nest pas altr ou nu, le remplacer immdiatement sil lesUn fil nu peut entraner la mort.

    D Lquipement doit tre hors tension lorsquil nest pas utilis.D Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

    sante ou mal pisss.D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement

    avec un cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice,

    la terre ou une lectrode provenant dune autre machine.D Ne pas toucher des porte lectrodes connects deux machines

    en mme temps cause de la prsence dune tension vide dou-ble.D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le

    champ les pices endommages. Entretenir lappareil conform-ment ce manuel.

    D Porter un harnais de scurit si lon doit travailler au-dessus du solD Sassurer que tous les panneaux et couvercles sont correctement

    en place.D Fixer le cble de retour de faon obtenir un bon contact mtal-

    mtal avec la pice souder ou la table de travail, le plus prs pos-sible de la soudure.

    D Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

    D Ne pas raccorder plus dune lectrode ou plus dun cble demasse une mme borne de sortie de soudage.

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    Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur UNE FOISlalimentation coupe.D Arrter les convertisseurs, dbrancher le courant lectrique et

    dcharger les condensateurs dalimentation selon les instructionsindiques dans la partie Entretien avant de toucher les pices.

    LES PICES CHAUDES peuventprovoquer des brlures.D Ne pas toucher mains nues les parties

    chaudes.D Prvoir une priode de refroidissement avant de

    travailler lquipement.D Ne pas toucher aux pices chaudes, utiliser les outils recomman-

    ds et porter des gants de soudage et des vtements pais pourviter les brlures.

    LES FUMES ET LES GAZ peuventtre dangereux.Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

    D Eloigner votre tte des fumes. Ne pas respirer les fumes.D lintrieur, ventiler la zone et/ou utiliser une ventilation force au

    niveau de larc pour lvacuation des fumes et des gaz desoudage.

    D Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

    D Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

    D Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

    D Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

    D Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

    LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudaggnre des rayons visibles et invisibles intense

    (ultraviolets et infrarouges) susceptibles de provoquer des brlure

    dans les yeux et sur la peau. Des tincelles sont projetes pendant lsoudage.D Porter un casque de soudage approuv muni de verres filtrants

    appropri pour protger visage et yeux pour protger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 numr dans les normes de scurit).

    D Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

    D Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

    D Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

    LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

    tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosionun surchauffement ou un incendie. Avant de commencer le soudagevrifier et sassurer que lendroit ne prsente pas de danger.

    D Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrisoigneusement avec des protections homologus.

    D Ne pas souder dans un endroit l o des tincelles peuvent tombersur des substances inflammables.

    D Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

    D Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

    D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

    D Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

    D Ne pas effectuer le soudage sur des conteneurs ferms tels quedes rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

    D Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

    D Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

    D Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

    D En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

    D Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sansrevers, des chaussures hautes et un couvre chef.

    D Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

    D Une fois le travail achev, assurez vous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

    D Utiliser exclusivement des fusibles ou coupe circuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

    D Une fois le travail achev, assurez vous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

    D Utiliser exclusivement des fusibles ou coupe circuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

    D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

    DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

    D Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtalliques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

    D Porter des lunettes de scurit avec crans latraux ou un cranfacial.

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    LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort.D Fermer lalimentation du gaz protecteur en cas

    de non-utilisation.D Veiller toujours bien arer les espaces confi-

    ns ou se servir dun respirateur dadductiondair homologu.

    Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

    D Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

    D Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

    LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.D Porter des protections approuves pour les

    oreilles si le niveau sonore est trop lev.

    Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endom-mage, elle peut exploser. Du fait que les bouteillesde gaz font normalement partie du procd de

    soudage, les manipuler avec prcaution.

    LES BOUTEILLES peuvent explosersi elles sont endommages.

    D Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

    DPlacer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

    D Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

    D Ne jamais placer une torche de soudage sur une bouteille gaz.D Une lectrode de soudage ne doit jamais entrer en contact avec

    une bouteille.D Ne jamais souder une bouteille pressurise risque dexplosion.D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

    tuyaux et raccords convenables pour cette application spcifique ;les maintenir ainsi que les lments associs en bon tat.

    D Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

    D Le couvercle du dtendeur doit toujours tre en place, sauf lorsquela bouteille est utilise ou quelle est relie pour usage ultrieur.

    D Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

    D Lire et suivre les instructions sur les bouteilles de gaz comprimlquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

    2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

    Risque DINCENDIE OUDEXPLOSION.D Ne pas placer lappareil sur, au-dessus ou

    proximit de surfaces inflammables.D Ne pas installer lappareil proximit de pro-

    duits inflammables.D Ne pas surcharger linstallation lectrique sassurer que

    lalimentation est correctement dimensionne et protge avantde mettre lappareil en service.

    LA CHUTE DE LQUIPEMENT peutprovoquer des blessures.D Utiliser lanneau de levage uniquement pour

    soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

    D Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

    D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

    D Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

    D Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

    LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.D Prvoir une priode de refroidissement ; res-

    pecter le cycle opratoire nominal.D Rduire le courant ou le facteur de marche

    avant de poursuivre le soudage.D Ne pas obstruer les passages dair du poste.

    LES TINCELLES PROJETESpeuvent provoquer des blessures.D Porter un cran facial pour protger le visage et

    les yeux.D Affter llectrode au tungstne uniquement l

    meuleuse dote de protecteurs. Cette

    manuvre est excuter dans un endroit srlorsque lon porte lquipement homologu deprotection du visage, des mains et du corps.

    D Les tincelles risquent de causer un incendie loigner toute sub-stance inflammable.

    LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.D tablir la connexion avec la barrette de terre

    avant de manipuler des cartes ou des pices.D Utiliser des pochettes et des botes antista-

    tiques pour stocker, dplacer ou expdier descartes de circuits imprimes.

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    Les PICES MOBILES peuventcauser des blessures.D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

    tels que des rouleaux de commande.

    LES FILS DE SOUDAGE peuventprovoquer des blessures.D Ne pas appuyer sur la gchette avant den

    avoir reu linstruction.D Ne pas diriger le pistolet vers soi, dautres

    personnes ou toute pice mcanique enengageant le fil de soudage.

    Les PICES MOBILES peuventcauser des blessures.D Sabstenir de toucher des organes mobiles tels

    que des ventilateurs.D Maintenir ferms et verrouills les portes,

    panneaux, recouvrements et dispositifs deprotection.

    D Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrementsou dispositifs de protection uniquement par du personnel qua-lifi.

    D Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

    LIRE LES INSTRUCTIONS.D Lire et appliquer les instructions sur les

    tiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

    D Nutiliser que les pices de rechange recommandes par leconstructeur.

    D Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

    LE RAYONNEMENT HAUTEFRQUENCE (H.F.) risque deprovoquer des interfrences.D Le rayonnement haute frquence (H.F.) peut

    provoquer des interfrences avec les qui-pements de radio navigation et de com-munication, les services de scurit et les ordi-nateurs.

    D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstallation.

    D Lutilisateur est tenu de faire corriger rapidement par un lectriciequalifi les interfrences rsultant de linstallation.

    D Si le FCC signale des interfrences, arrter immdiatement lap-pareil.

    D Effectuer rgulirement le contrle et lentretien de linstallationD Maintenir soigneusement ferms les portes et les panneaux des

    sources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

    LE SOUDAGE LARC risque deprovoquer des interfrences.D Lnergie lectromagntique risque de

    provoquer des interfrences pour lquipementlectronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

    D Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

    D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

    D Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

    D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

    D En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-

    bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

    2-4. Proposition californienne 65 Avertissements

    Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

    Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent descancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

    Ce produit contient des produits chimiques, notamment duplomb, dont ltat de Californie reconnat quils provoquent

    des cancers, des malformations congnitales ou dautresproblmes de procration. Se laver les mains aprsutilisation.

    Pour les moteurs essence :

    Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

    Pour les moteurs diesel :Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.

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    2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, de GlobalEngineering Documents (tlphone : 1-877-413-5184, site internet :www.global.ihs.com).National Electrical Code , NFPA Standard 70, de National Fire Protec-tion Association, Quincy, MA 02269 (tlphone : 800-344-3555, site

    Internet : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders , CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :800-463-6727, site internet : www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, de American National Standards Institute,

    25 West 43rd Street, New York, NY 10036 (tlphone : 212-642-490site Internet : www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other Hot Work , NFPA Standard 51B, de National Fire Protection AssociatioP.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-300site Internet : www.nfpa.org).OSHA, Occupational Safety and Health Standards for GeneraIndustry, Title 29, Code of Federal Regulations (CFR), Part 1910Subpart Q, and Part 1926, Subpart J, de U.S. Government PrintingOffice, Superintendent of Documents, P.O. Box 371954, Pittsburgh, P15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureauxrgionaux le tlphone de la rgion 5, Chicago, est 312-353-2220, siteInternet : www.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WesHighway, Bethesda, MD 20814 (tlphone : 301-504-7923, site intenet : www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation , TheNational Institute for Occupational Safety and Health (NIOSH), 16Clifton Rd, Atlanta, GA 30333 (tl[hone : 1-800-232-4636, site interwww.cdc.gov/NIOSH).

    2-6. Informations relatives aux CEMLe courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudagecre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:1. Rassembler les cbles en les torsadant ou en les attachant avec

    du ruban adhsif ou avec une housse.2. Ne pas se tenir au milieu des cbles de soudage. Disposer les

    cbles dun ct et distance de loprateur.3. Ne pas courber et ne pas entourer les cbles autour de votre

    corps.

    4. Maintenir la tte et le torse aussi loin que possible du matriel dcircuit de soudage.

    5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

    6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

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

    En ce qui concerne les implants mdicaux :Les porteurs dimplants doivent dabord consulter leur mdecin avade sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre leprocdures prcdentes.

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    SECTION 3 DEFINITIONS3-1. Symbols And Definitions

    A Amperage V Voltage Hz Hertz NegativePositive Direct Current(DC) Single Phase Input

    Output Voltage Input Off On

    Do Not SwitchWhile Welding

    Gas Metal ArcWelding (GMAW) Wire Feed

    SECTION 4 SPECIFICATIONS4-1. Specifications

    Rated WeldingOutput AmperageRangeMaximum Open-Circuit Voltage

    DC

    Amperes Input atRated Load Output115 V, 60 Hz, Single-

    PhaseKVA KW WeightW/ Gun OverallDimensions

    90 A @ 19 Volts DC,20% Duty Cycle

    63 A @ 21 Volts DC,20% Duty Cycle*

    25 140 2820

    15*

    2.90

    2.20*

    2.50

    1.77*

    57 lb(26 kg)

    Length: 19-1/2 in.(495 mm)

    Width: 10-5/8 in.(270 mm)

    Height: 12-3/8 in.(314 mm)

    Wire TypeAnd Diameter

    Solid/ Stainless

    Flux Cored Aluminum Wire Feed Speed Range

    .023 .035 in.(0.6 0.9 mm)

    .030 .035 in.(0.8 0.9 mm)

    .030 in.(0.8 mm)

    50 740 IPM (1.3 18.8 m/min) At No Load40 700 IPM (1.0 17.8 m/min) Feeding Wire

    * CSA Rating

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    4-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.NOTICE Exceeding duty cycle

    can damage unit or gun and void warranty.

    Overheating

    0

    15

    A or V

    ORReduce Duty Cycle

    Minutesduty1 4/95 217 623-A

    20% duty cycle at 90 amps

    1 4 10 20 40 60 1002 6 80810

    20

    40

    60

    80100

    200

    140

    Duty Cycle %

    Output Amperes

    2 Minutes Welding 8 Minutes Resting

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    4-3. Volt-Ampere CurvesThe volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

    ssb1.1 10/91

    217 624-A

    RANGE4

    RANGE3RANGE2

    RANGE1

    0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 1600.0

    5.0

    10.0

    15.0

    20.0

    25.0

    30.0

    Amperage

    Voltage

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    SECTION 5 INSTALLATION5-1. Installing Welding Gun

    Ref. 804 623-A

    1 Drive Assembly2 Gun Securing Thumbscrew3 Gun EndLoosen thumbscrew.Insert end ofgun through opening in frontpanel until it bottoms againstdrive assembly. Tightenthumbscrew.Welding gun must be insertedcompletely to prevent leakage ofshielding gas.4 Gun Trigger LeadsInsert leads, one at a time, throughgun opening on front panel.Connect female friction terminals tomatching male terminals in unit.Polarity is not important.Close door.

    CorrectIncorrect

    . Be sure that gun end is tight against drive assembly.

    3

    Gun Fully Seated

    3

    Gun Not Seated

    Exposed O-ringswill cause shielding

    gas leakage.

    4

    1 2

    3

    5-2. Installing Work Clamp1 Nut2 Work Cable From Unit3 Work Clamp4 Screw5 Work Clamp TabsBend tabs around work cable.6 Insulating SleevesSlide one insulating sleeve overwork cable before connecting toclamp.Slide both insulating sleeves overhandles.

    802 456-A

    . Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp.

    Tools Needed:

    7/16 in.

    7/16 in.

    1

    2

    3

    45

    6

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    5-3. Process/Polarity Table

    Process PolarityCable Connections

    Cable To Gun Cable To Work

    GMAW Solid wire with shield-ing gas

    DCEP Reverse polarity Connect to positive (+) out-put terminal

    Connect to negative ( ) outputterminal

    FCAW Self-shielding wireno shielding gas

    DCEN Straight Polarity Connect to negative ( )output terminal

    Connect to positive (+) outputterminal

    CHANGINGPOLARITY

    5-4. Changing Polarity1 Lead Connections For Direct

    Current Electrode Negative(DCEN)

    2 Lead Connections For DirectCurrent Electrode Positive(DCEP)

    Always read and follow wiremanufacturers recommendedpolarity, and see Section5-3.Close door.

    Ref. 209 228 / Ref. 209 229 / Ref. 804 623-A

    1

    2

    DCENElectrode negative for

    flux cored wire

    DCEPElectrode positive for

    solid wire

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    5-5. Installing Gas SupplyObtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve.1 Cap2 Cylinder ValveRemove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.3 Cylinder4 Regulator/FlowmeterInstall so face is vertical.5 Regulator/Flowmeter Gas

    Hose Connection6 Welding Power Source Gas

    Hose ConnectionConnect supplied gas hosebetween regulator/flowmeter gashose connection, and fitting on rearof welding power source.7 Flow Adjust

    Flow rate should be set when gas isflowing through welding powersource and welding gun. Openfeedhead pressure assembly sothat wire will not feed. Press guntrigger to start gas flow.Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturers recommendedflow rate.After flow is set, close feedheadpressure assembly.

    Tools Needed:

    Ref. 804 654-A / 802 441 / Ref. 804 623-A

    5/8, 1-1/8 in.

    6

    Argon Gas OrMixed Gas

    . DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter.

    Feedhead Pressure Assembly Open

    Feedhead Pressure Assembly Closed

    1

    2

    3

    4

    5

    7

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    5-8. Installing Wire Spool And Adjusting Hub Tension

    When a slight force is neededto turn spool, tension is set.

    1/2 in.

    Tools Needed:

    Installing 8 in. (203 mm) Wire Spool

    Installing 4 in. (102 mm) Wire Spool

    When a slight force is neededto turn spool, tension is set.

    Retaining ring used with 8 in. (203 mm)

    spool only.

    Adapter used with 8 in.(203 mm) spool only.

    803 012 / 803 013 -B / Ref. 802 971-C

    Align locking hole inspool with locking pinon spool hub.

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    5-9. Installing Contact Tip And Nozzle

    Tools Needed:

    Ref. 246 669-A

    ! Turn off welding power source.1 NozzleRemove nozzle.2 Contact Tip3 Tip AdapterThread welding wire through gun (seeSection5-10).

    Slide contact tip over wire and tightentip into tip adapter.Install nozzle.

    Flux Nozzle (Optional)

    MIG Nozzle (Standard)

    Use with flux cored wire only.Narrow design allows access intight spaces and provides bettervisibility of puddle during welding.

    Use with solid or flux cored wire.

    Push nozzle over contact tip andadapter until it is seated ontoadapter. Contact tip will beexposed approximately 7/16 in.(11.3 mm) when installed properly.

    Push nozzle over contact tip andadapter until it is seated ontoadapter. End of contact tip will beflush with end of nozzle wheninstalled properly.

    1

    2 3

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    5-10. Threading Welding Wire

    1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Gun Conduit CableLay gun cable out straight.

    Tools Needed:

    Pull and hold wire; cut off end.

    Open pressure assembly. Make surefeed roll is set to correct groove tomatch wire size (see Section7-4).

    . Hold wire tightly to keep it from unraveling.

    6 in.(150 mm)

    1 2

    4 in.(102 mm)

    Straighten approximately 3 or 4 inches (76 or 102 mm) of wire before insertingwire into guides. Push wire thru guides into gun; continue to hold wire.

    3

    6

    1 3

    4

    52

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    Remove gun nozzle and contact tip.

    Ref. 804 623-A

    Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

    Cut off wire. Close door.

    Press gun trigger until wire comes out of gun.(Keep gun cable as straight as possible.)

    Turn power on. Be sure that Voltage rangeswitch is set to range 1, 2, 3, or 4 to feed wire.Rotate knob until it clicks into detent. Wirewill not feed if range switch is set betweenranges.

    . Use pressure indicator scale to set a desired drive roll pressure. (Start with a setting of 2 or 3 on the scale.)

    PressureIndicatorScale

    Be sure that wire is positioned in proper feed roll groove.Close and tighten pressure assembly, and let go of wire.

    Be sure that tip matches wire diameter.Reinstall contact tip and nozzle.

    4 5

    6 7

    8 9

    4

    23

    1

    Tighten

    WOOD4

    23

    1

    Tighten

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    SECTION 6 OPERATION

    6-1. Controls

    1 Wire Speed ControlUse control to select a wire feed speed. AsVoltage switch setting increases, wirespeed range also increases (see weldsetting label in welding power source orSection6-2).

    2 Power Switch3 Voltage SwitchThe higher the selected number, the

    thicker the material that can be welded(see weld setting label in welding power

    source or Section6-2). Do not switch underload.

    . Switch must click into detent position for weld output.

    Ref. 230 002-A

    2

    3

    1

    NE PAS CHANGERDE PROCD

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    Notes

    16 Gauge (.063 in.)

    22 Gauge (.031 in.)

    24 Gauge (.025 in.)

    20 Gauge (.037 in.)18 Gauge (.050 in.)

    14 Gauge (.078 in.)1/8 in. (.125 in.)

    3/16 in. (.188 in.)

    1/4 in. (.25 in.)

    5/16 in. (.313 in.)

    3/8 in (.375 in.)

    1/2 in (.5 in)

    MATERIAL THICKNESS REFERENCE CHART

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    6-2. Weld Parameter Chart

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    217 618-A

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    SECTION 7 MAINTENANCE & TROUBLESHOOTING7-1. Routine Maintenance

    ! Disconnect powerbefore maintaining.

    . Maintain more oftenduring severe condi-tions.

    n = Check Z = Change ~ = Clean l = Replace* To be done by Factory Authorized Service Agent

    Reference

    3 Months

    l Damaged Or Unreadable Labels l Repair Or ReplaceCracked Weld Cable

    ~ Clean And Tighten WeldTerminals

    6 Months

    OR

    ~ Inside Unit

    7-2. Overload Protection

    802 441

    1 Supplementary Protector CB1CB1 protects unit from overload. IfCB1 opens, unit shuts down.

    Reset supplementary protector.

    1

    7-3. Drive Motor Protection

    Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, releatrigger and wait until protection circuit resets allowing drive motor to feed wire again.

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    7-4. Changing Drive Roll Or Wire Inlet Guide

    1 Inlet Wire Guide SecuringScrew

    2 Inlet Wire GuideLoosen 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 the end surface of thedrive roll refers to the groove on theopposite side of the drive roll. Thegroove closest to the motor shaft isthe proper groove to thread (seeSection5-10).4 Retaining PinTo secure drive roll, locate open slotand push drive roll completely overretaining pin, then rotate drive roll(1/4 turn) to closed slot.

    Tools Needed:

    Ref. 803 714-A

    .023/.025 Groove.030/.035 Groove

    Stamped .024 Stamped .030/.035

    4

    1

    2

    3

    7-5. Replacing Gun Contact Tip

    Ref. 246 669-A

    ! Turn Off power beforereplacing contact tip.

    1 Nozzle2 Contact TipCut off welding wire at contact tip.Remove nozzle.Remove contact tip and install newcontact tip. Reinstall nozzle.

    Tools Needed:

    12

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    7-6. Cleaning Or Replacing Gun Liner

    Ref. 246 669-A8 mm / 10mm

    ! Disconnect gun from unit.

    Tools Needed:

    To Reassemble Gun:Insert new liner.Install wire outlet guide so that 1/8in. (3 mm) of liner sticks out. Handtighten outlet guide, and then

    tighten two full turns more.Cut liner off so that 3/4 in. (19 mm)sticks out of head tube.Install gas diffuser, adapter, contacttip, and nozzle.

    Lay gun cable out straightbefore installing new liner.

    Head Tube

    8 mm

    Remove liner.

    Remove nozzle, contact tip andtip adapter/gas diffuser.

    Blow out gun casing.

    10 mm

    1 2

    3

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    7-7. Replacing Switch And/Or Head Tube

    Ref. 243 840-A

    Tools Needed:

    19 mm

    Remove screws from handle. Remove handle half.

    Secure head tube in vice.

    Loosen jam nut. Remove from viceand turn head tube out by hand.

    Hand-tighten head tube into cable connector.

    Place head tube in vice and tighten until nuts are tight.

    ! Turn Off welding power source/wire feeder and disconnect gun.

    Remove switch housing. Install new switch andconnect leads (polarity is not important). Reassemblein reverse order. If replacing head tube, continue toend of figure.

    1 2

    3

    4

    5

    6

    7

    Remove from vice. install switch housing.8

    Install handle half with secure with screws.9

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    7-8. Troubleshooting Table

    Trouble Remedy

    No weld output; wire does not feed; fandoes not run.

    Secure power cord plug in receptacle (see Section5-7).

    Replace building line fuse or reset circuit breaker if open.

    Place Power switch in On position (see Section6-1).

    Reset welding power source supplementary protector (see Section7-2).

    No weld output; wire does not feed; fanmotor continues to run.

    Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes wunit has cooled (see Section4-2).

    Check Voltage range switch position. Rotate knob until it clicks into detent at desired range settin

    Secure gun trigger leads (see Section5-1).

    No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

    Replace contact tip (see Section7-5).

    Check for proper polarity connections (see Section5-4).

    Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

    Low weld output. Connect unit to proper input voltage or check for low line voltage.

    Place voltage switch in desired position (see Section6-1).

    Electrode wire feeding stops duringwelding.

    Straighten gun cable and/or replace damaged parts.Adjust drive roll pressure (see Section5-10).Change to proper drive roll groove (see Section7-4).Readjust hub tension (see Section5-8).Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.Replace contact tip if blocked (see Section7-5).

    Clean or replace wire inlet guide or liner if dirty or plugged (see Section7-4or Section7-6).Replace drive roll or pressure bearing if worn or slipping (see Section7-4).Secure gun trigger leads or repair leads (see Section5-1).Check and clear any restrictions at drive assembly and liner (see Section5-10or Section7-6).Release gun trigger and allow gun and motor protection circuitry to reset (see Section7-3).Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighteif necessary.

    Have nearest Factory Authorized Service Agent check drive motor.

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    OM-925 Page 31

    SECTION 8 ELECTRICAL DIAGRAM

    230 952-A

    Figure 8-1. Circuit Diagram

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    OM-925 Page 32

    SECTION 9 MIG WELDING (GMAW) GUIDELINES

    mig1 2009 12

    Wire Feeder/ Power Source

    Workpiece

    Gun

    Regulator/ Flowmeter

    Gas

    Shielding Gas

    Work Clamp

    9-1. Typical MIG Process Connections

    ! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

    Ref. 801 909-A

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    OM-925 Page 33

    9-2. 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.

    3.5 x 125 A = 437 ipm2 x 125 A = 250 ipm

    1.6 x 125 A = 200 ipm

    30 90 A40 145 A50 180 A

    Convert MaterialThickness toAmperage (A)

    Material thickness determines weld parameters.

    .035 in

    Recommendation Wire Speed(Approx.)

    1/8 or 0.125 in.

    (0.001 in. = 1 ampere)0.125 in. = 125 A

    Wire Size Amperage Range

    0.023 in.0.030 in.0.035 in.

    Select Wire Size

    WireSize

    0.023 in.0.030 in.0.035 in.

    3.5 in. per ampere2 in. per ampere

    1.6 in. per ampere

    Select Wire Speed(Amperage)

    125 A based on 1/8 in.material thickness

    ipm = inches per minute

    Low voltage: wire stubs into workHigh voltage: arc is unstable (spatter)

    Set voltage midway between high/low voltage

    Select Voltage

    Voltage controls height and width of weld bead.

    Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)

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    OM-925 Page 34

    9-3. 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.

    1 Hold Gun and Control GunTrigger

    2 Workpiece3 Work Clamp4 Electrode Extension (Stickout)

    1/4 to 1/2 in. (6 To 13 mm)5 Cradle Gun and Rest Hand onWorkpiece

    2 3

    5

    4

    90 90

    0 -15

    45

    45

    1

    0 -15

    S-0421-A

    End View of Work Angle Side View of Gun Angle

    GROOVE WELDS

    End View of Work Angle Side View of Gun AngleFILLET WELDS

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    OM-925 Page 35

    9-4. 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.

    Slow

    FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

    ELECTRODE EXTENSIONS (STICKOUT)

    GUN ANGLES AND WELD BEAD PROFILES

    10

    10

    GUN TRAVEL SPEED S-0634

    Push

    Perpendicular Drag

    Short Normal Long

    Short Normal Long

    Normal Fast

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    OM-925 Page 36

    9-5. 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.

    1 Stringer Bead SteadyMovement Along Seam

    2 Weave Bead Side To SideMovement Along Seam

    3 Weave PatternsUse weave patterns to cover a widearea in one pass of the electrode.

    S-0054-A

    3

    1 2

    9-6. Poor Weld Bead Characteristics

    1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During Welding4 Bad Overlap5 Poor Penetration

    5

    42 3

    1

    S-0053-A

    9-7. Good Weld Bead Characteristics1 Fine Spatter2 Uniform Bead3 Moderate Crater During

    WeldingWeld a new bead or layer for each1/8 in. (3.2 mm) thickness in metalsbeing welded.4 No Overlap5 Good Penetration into Base

    Metal

    S-0052-B

    2 3

    1

    4

    5

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    OM-925 Page 37

    9-8. Troubleshooting Excessive Spatter

    Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

    S-0636

    Possible Causes Corrective Actions

    Wire feed speed too high. Select lower wire feed speed.Voltage too high. Select lower voltage range.

    Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

    Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before we

    Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding ar

    Dirty welding wire. Use clean, dry welding wire.

    Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

    Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power so

    9-9. Troubleshooting

    Porosity

    Porosity small cavities or holes resulting from gas pocketsin weld metal.

    S-0635

    Possible Causes Corrective Actions

    Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding ar

    Remove spatter from gun nozzle.

    Check gas hoses for leaks.

    Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

    Hold gun near bead at end of weld until molten metal solidifies.

    Wrong gas. Use welding grade shielding gas; change to different gas.

    Dirty welding wire. Use clean, dry welding wire.

    Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

    Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before wel

    Use a more highly deoxidizing welding wire (contact supplier).

    Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

    9-10. Troubleshooting Excessive Penetration

    Good Penetration

    Excessive Penetration weld metal melting through base metaland hanging underneath weld.

    Excessive PenetrationS-0639

    Possible Causes Corrective Actions

    Excessive heat input. Select lower voltage range and reduce wire feed speed.

    Increase travel speed.

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    9-11. Troubleshooting Lack Of Penetration

    Lack Of Penetration shallowfusion between weld metal andbase metal.

    Lack of Penetration Good PenetrationS-0638

    Possible Causes Corrective Actions

    Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove whmaintaining proper welding wire extension and arc characteristics.

    Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

    Keep arc on leading edge of weld puddle.

    Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

    Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

    Reduce travel speed.

    Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power so

    9-12. Troubleshooting Incomplete Fusion

    Incomplete Fusion failure of weld metal to fuse completely withbase metal or a preceeding weld bead.

    S-0637

    Possible Causes Corrective Actions

    Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.

    Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

    Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

    Adjust work angle or widen groove to access bottom during welding.

    Momentarily hold arc on groove side walls when using weaving technique.

    Keep arc on leading edge of weld puddle.

    Use correct gun angle of 0 to 15 degrees.

    9-13. Troubleshooting

    Burn-Through

    Burn-Through weld metal melting completely through base metalresulting in holes where no metal remains.

    S-0640

    Possible Causes Corrective Actions

    Excessive heat input. Select lower voltage range and reduce wire feed speed.

    Increase and/or maintain steady travel speed.

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    9-14. 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) beyond nozzle.

    Unsteady hand. Support hand on solid surface or use two hands.

    9-15. Troubleshooting Distortion

    Distortion contraction of weld metal during welding that forcesbase metal to move.

    Base metal movesin the direction of

    the weld bead.S-0642

    Possible Causes Corrective Actions

    Excessive heat input. Use restraint (clamp) to hold base metal in position.

    Make tack welds along joint before starting welding operation.

    Select lower voltage range and/or reduce wire feed speed.

    Increase travel speed.

    Weld in small segments and allow cooling between welds.

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    9-16. Common MIG Shielding Gases

    This is a general chart for common gases and where they are used. Many different combinations (mixtureshielding gases have been developed over the years. The most commonly used shielding gases are listed infollowing table.

    Application

    Gas Spray Arc Steel Short Circuiting Steel Short CircuitingStainless Steel Aluminum

    Argon X

    Argon + 25% CO2 X

    80% or greater Argon +balance CO2 or Oxygen

    X X1

    100% CO2 X

    Tri-Mix2 X1 Limited short circuiting use

    2 90% HE + 7-1/2% AR + 2-1/2% CO2

    9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

    Problem Probable Cause RemedyWire feed motor operates, butwire does not feed.

    Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

    Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matcwire size and type if necessary.

    Wire spool brake pressure too high. Decrease brake pressure on wire spool.

    Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip damaged. Check size of contact tip and cable liner,replace if necessary.

    Wire curling up in front of thewire feed rolls (bird nesting).

    Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

    Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner lenand diameter, replace if necessary.

    Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push end into housing just enough so it does not touch wirefeed rolls.

    Dirty or damaged (kinked) liner. Replace liner.

    Wire feeds, but no gas flows.Gas cylinder empty. Replace empty gas cylinder.Gas nozzle plugged. Clean or replace gas nozzle.

    Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

    Restriction in gas line. Check gas hose between flowmeter and wire feeder, angas hose in gun and cable assembly.

    Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wirin

    Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gsolenoid valve.

    Incorrect primary voltage connected to welding powersource.

    Check primary voltage and relink welding power sourcefor correct voltage.

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    Problem RemedyProbable Cause

    Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace wdrive rolls if necessary.

    Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

    Incorrect voltage setting for selected wire feed speed onwelding power source.

    Readjust welding parameters.

    Loose connections at the gun weld cable or work cable. Check and tighten all connections.

    Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

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    SECTION 10 ACCESSORIES/CONSUMABLES10-1. Accessories

    PART NO. DESCRIPTION REMARKS770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) m194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) m195 186 Protective Cover Weatherproof Nylon

    10-2. ConsumablesItem Hobart Package Part No.* Miller Package Part No. **

    Contact Tips.023/.025 in (0.6 mm) 770 174 (5 per package) 087 299 (10 per package)

    .030 in (0.8 mm) 770 177 (5 per package) 000 067 (10 per package)

    .035 in (0.9 mm) 770 180 (5 per package) 000 068 (10 per package)

    MIG Nozzle (Standard) 770 404 169 715Gasless Flux Cored Nozzle 770 487 226 190

    Tip Adapter 770 402 169 716Wire Inlet Guide 203 025

    Replacement Liners.023/.025 in (0.6 mm) 196 139 194 010

    .030/.035 in (0.8/0.9 mm) 196 139 194 011

    .035/.045 in (0.9/1.2 mm) 196 140 194 012*Available at farm and tool supply retailers.** Available at Hobart/Miller welding distributors.

    10-3. Replacement Drive Rolls

    For All Feed Head AssembliesPART NO. WIRE DIAMETERINCHES (mm)237 338 .023/.025 (.6) and .030/.035 (.8 and .9)202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

    10-4. Regulator/FlowmeterPART NO. REMARKS221 037** For Argon and Argon mixed shielding gas. Use with

    replacement hose 222 874.770 198*

    212 492**For CO2 shielding gas. Use with replacement gas hose

    144 108.*Available at farm and tool supply retailers.**Available at Hobart/Miller welding distributors.

    A complete Parts List is available on-line atwww.HobartWelders.comTo maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

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    Warranty Questions?

    Call1-800-332-32817 AM 5 PM EST

    hobart_warr 2010

    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 1-800-332-3281. Theexpertise of the distributorand Hobart is there tohelp you, every step ofthe way.AssistanceVisit the Hobart website:www.HobartWelders.com

    Effective January 1, 20105/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot weld

    serial number preface of MA 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 conditionsbelow, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin,warrants to its original retail purchaser that new Hobartequipment sold after the effective date of this limited warranty isfree of defects in material and workmanship at the time it isshipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEUOF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,INCLUDING THE WARRANTIES OF MERCHANTABILITY ANDFITNESS.Within the warranty periods listed below, Hobart/Miller will repairor replace any warranted parts or components that fail due tosuch defects in material or workmanship. Hobart/Miller must benotified in writing within thirty (30) days of such defect or failure, atwhich time Hobart/Miller will provide instructions on the warrantyclaim procedures to be followed.Hobart/Miller shall honor warranty claims on warrantedequipment listed below in the event of such a failure within thewarranty time periods. All warranty time periods start on thedelivery date of the equipment to the original retail purchaser, andnot to exceed one year after the equipment is shipped to a NorthAmerican distributor or eighteen months after the equipment isshipped to an International distributor.1. 5 Years Parts and Labor

    * Original Main Power Rectifiers only to include SCRs,diodes, and discrete rectifier modules

    * Reactors* Stabilizers* Transformers

    2. 3 Years Parts and Labor* Drive Systems* Idle Module* PC Boards* Rotors, Stators and Brushes* Solenoid Valves* Spot Welder Transformer* Switches and Controls

    3. 1 Year Parts and Labor Unless Specified(90 days for industrial use)* Accessories* Batteries (Trek 180 Only)* Contactors* Field Options

    (NOTE: Field options are covered for the remainingwarranty period of the product they are installed in, orfor a minimum of one year whichever is greater.)

    * Flowgauge and Flowmeter Regulators (No Labor)* HF Units* MIG Guns/TIG Torches* Motor-Driven Guns* Plasma Cutting Torches* Regulators* Relays* Remote Controls* Replacement Parts (No labor) 90 days* Running Gear/Trailers* Water Coolant Systems

    4. Engines, batteries (except Trek 180) and tires arewarranted separately by the manufacturer.

    Hobarts 5/3/1 Limited Warranty shall not apply to:1. Consumable components; such as contact tips

    cutting nozzles, contactors, brushes, relays, workstation table tops and welding curtains, or parts thafail due to normal wear. (Exception: brushes anrelays are covered on all engine-driven products.)

    2. Items furnished by Hobart/Miller, but manufactothers, such as engines or trade accessories. Thitems are covered by the manufacturers warraany.

    3. Equipment that has been modified by any party

    than Hobart/Miller, or equipment that has improperly installed, improperly operated or mbased upon industry standards, or equipment whicnot had reasonable and necessary maintenanceequipment which has been used for operation outthe specifications for the equipment.

    HOBART PRODUCTS ARE INTENDED FOR PURCHUSE BY COMMERCIAL/INDUSTRIAL USERS ANDTRAINED AND EXPERIENCED IN THE UMAINTENANCE OF WELDING EQUIPMENT.In the event of a warranty claim covered by this warraexclusive remedies shall be, at Hobarts/Millers option: (or (2) replacement; or, where authorized in writiHobart/Miller in appropriate cases, (3) the reasonable repair or replacement at an authorized Hobart/Miller station; or (4) payment of or credit for the purchase prireasonable depreciation based upon actual use) upon retthe goods at customers risk and expense. Hobarts/M

    option of repair or replacement will be F.O.B., FacAppleton, Wisconsin, or F.O.B. at a Hobart/Miller auservice facility as determined by Hobart/Miller. Therecompensation or reimbursement for transportation costskind will be allowed.

    TO THE EXTENT PERMITTED BY LAW, THE RPROVIDED HEREIN ARE THE SOLE AND EXREMEDIES. IN NO EVENT SHALL HOBART/MLIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDCONSEQUENTIAL DAMAGES (INCLUDING LPROFIT), WHETHER BASED ON CONTRACT, TOROTHER LEGAL THEORY.ANY EXPRESS WARRANTY NOT PROVIDED HEANY IMPLIED WARRANTY, GUARANTREPRESENTATION AS TO PERFORMANCE, ANREMEDY FOR BREACH OF CONTRACT TORT OTHER LEGAL THEORY WHICH, BUT FOR THIS PMIGHT ARISE BY IMPLICATION, OPERATION

    CUSTOM OF TRADE OR COURSE OF DEALING, INANY IMPLIED WARRANTY OF MERCHANTABFITNESS FOR PARTICULAR PURPOSE, WITH RESANY AND ALL EQUIPMENT FURNISHHOBART/MILLER IS EXCLUDED AND DISCLAHobart/Miller.Some states in the U.S.A. do not allow limitations of howimplied warranty lasts, or the exclusion of incidental, special or consequential damages, so the above limitatexclusion may not apply to you. This warranty provideslegal rights, and other rights may be available, but may vastate to state.In Canada, legislation in some provinces provides for additional warranties or remedies other than as stated hand to the extent that they may not be waived, the limitatiexclusions set out above may not apply. This Limited Wprovides specific legal rights, and other rights may be avbut may vary from province to province.

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