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1. Duty Cycle is percentage of 10 230 VAC minutes that unit can weld at rated rue load without overheating 00 If unit overheats thermostat s 350 opens output stops and cooling un 300 fan runs Wait fifteen minutes for 11 250 unit to cool Reduce amperage or Ee 200 duty cycle before welding g 175 NOTICE Exceeding duty cycle lt 150 can damage unit or gun and void O warranty Li 100 50 10 ES 20 30 40 50 60 70 8090100 DUTY CYCLE 30 duty cycle at 150 amps 3 Minutes Welding 7 Minutes Resting 115 VAC 150 135 120 100 HI 90 M 75 o 65 lt Q 50 e Lu 0 25 0 o O O O A 10 15 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE 20 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting Overheating GEN 0 Aor V yua X S OR Reduce Duty Cycle Minutes duty1 4 95 249 620 A OM 249 498 Page 13 4 4 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage
2. 230 VAC and amperage output capabilities of the welding power source Curves 35 of other settings fall between the curves shown 30 7 25 6 5 o 20 o gt 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 Amperage 115 VAC 35 30 25 o 20 o S E 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 Amperage ssb1 1 10 91 249 621 A OM 249 498 Page 14 SECTION 5 INSTALLATION 5 1 Installing Nozzle Contact Tip And Adapter D A Turn off welding power 1 Nozzle 2 Contact Tip 3 Tip Adapter EF Wire size stamped on tip check and match wire size 8 mm Tools Needed C Xe IT 8mm Ref 243 839 A 5 2 Installing Welding Gun D 1 Drive Assembly DAMES 2 MG 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew Spool Gun Welding gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in MIG Gun position Close door
3. O dr D NES o5 Z ER Exposed O rings will cause shielding Incorrect gas leakage Correct Gun Not Seated Gun Fully Seated 804 695 A OM 249 498 Page 15 5 3 Installing Work Clamp ESP 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 To DP 76 Nut Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp OO ND A Slide insulating sleeves over handles 802 456 A OM 249 498 Page 16 5 4 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW Solid wire with shield DCEP Reverse polarity Connect to positive out Connect to negative output ing gas put terminal terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal 5 5 Changing Polarity e A Turn off welding power CHANGING 1 Lead
4. 1 xus sc bsp 211338 Knob Pointer WES 2 1 SUA re rain 217 718 MOTOR Gear ar ur mars PA ENEE aie wa Ph C AT date 1 m 193 189 z Connector GUN ia e ae a C CAR TR De GU CA Td 1 dns nuit een 196 654 Screw Thumb 1 O da a 230012 Fitting Gas Barbed 1 wig EE 246 565 Roll Feed 030 035 in VK Groove And 030 035 in Smooth Groove 1 22 2 AB uu siue 194508 Head Feed Assy 1 sud ha dena vatis 203 025 Guide Wire Inlet 1 sti DO isi ve EPA ES 250015 Label Welding Guide 1 bob dat se ect s 2047 TT m alcance uoo Eden aee LO E un eos 1 E xag ati 217 585 Conltaclor cio a e ENEE a sla teat ae aus 1 TE s e e 203572 Label Warn Gen Precaution En Fr Models Only 1 E ER Label Nameplate Order By Model And Serial Number 1 EE 048 282 Rept W Skts Service Kit 1 OO eebe EE 230 033 LED yelloW 2 e aaa ebe Seene 1 E NEE 219261 Adapter Power Cable 5 15P 115V 15A 1 EE 219258 Adapter Power Cable 6 50P 230V 50A 1 e ENEE 233346 PLATE stiffener base
5. 2 9 8 Troubleshooting Excessive Spatter 9 9 Troubleshooting Porosity eno nada dite ee Here I ae edad E SENI e DEP n P ea din 9 10 Troubleshooting Excessive Penetration 9 11 Troubleshooting Lack Of Penetration 22222 9 12 Troubleshooting Incomplete Fusion 9 13 Troubleshooting Burn Through 44222 9 14 Troubleshooting Waviness Of Dead 9 15 Troubleshooting Distortion remitte ene De e ERR RR LE e x qe 9 16 Common MIG Shiel 9 17 Troubleshooting Gu SECTION 10 PARTS LIST WARRANTY ding GaSe teo xe dote er ttr ei e SO te re m S REPE ide For Semiautomatic Welding Equipment 34 36 36 37 38 39 40 40 40 41 41 41 42 42 42 43 43 44 44 46 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2011 01 A Protect yourself and others from injury read and follow these precautions 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 hazards are shown in the adjoining symbols or ex plained in th
6. r MOVING PARTS can injure e Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read 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 Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shie
7. 1 E CIBETT 229 793 2 leed E RE 1 SECHER 221 037 Regulator Flowmeter 10 50 CFH Argon COs 1 a a eet vs 183581 Hose Assembly Gas A A a Pad ar ne 219259 Adapter Power Cable 5 20P 115V 20A 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 OM 249 498 Page 48 Item Dia Part No Mkgs No Figure 10 2 H100S4 10 Gun Description 243 842 A Quantity 245 926 Figure 10 2 Hi00S4 10 Gun cd estre 169 715 Nozzle Slip Type 500 orf Flush xal w Sech 226 190 Nozzle Flux Cored Slip Type EE 087 299 Tip Contact Scr 023 Wire X 1 125 E EEN 000 067 Tip Contact Scr 030 Wire X 1 125 EE 000 068 Tip Contact Scr 035 Wire X 1 125 Daria 000 069 Tip Contact Scr 045 Wire X 1 125 CUN 170470 Ring Retaining Aaa 169716 Adapter Contact Tip D EE 246373 Tube Head 6 eens ras 243 865 Nut Jam T ea etna ee 242 832 Handle EE esses 8 xau 225 410 Switch Trigger Data 079878 Housing Plug amp Pins 10 ca
8. 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et l
9. LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les E tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque
10. Excessive Spatter un Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead e Se 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 welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc 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 source 9 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal LAU A Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc 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 D
11. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire 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 match wire 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 if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire 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 length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed 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 bet
12. general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements 5 8 Extension Cord Data Use Shortest Cord Possible When calculating max cord length remember to include conductor length from line disconnect device to input power receptacle Input Power Input Voltage Phase Hertz Conductor Size Max Cord Length 115V 1 60 14 ANG 25 ft 8 m 115V 1 60 12 ANG 55 ft 17 m 115V 1 60 10 AWG 100 ft 30 m 230 V 1 60 14 ANG 53 ft 16 m OM 249 498 Page 19 5 9 Multi Voltage Plug MVP Connection lE er a Selecting Plug 4 1 Power Cord Connector From 5 Welding Power Source 6 Select plug for power supply receptacle a available at site Not all plugs shown are provided as standard with unit 2 Plug NEMA Type 5 15P 3 Receptacle NEMA Type 5 15R Customer Supplied Selecting Plug A Do not cut off power cord connector and rewire The power cord connector and plugs will work with standard NEMA receptacles Modifying power cord connector and
13. l l AS Push b 4 10 l Leeeem 2 uua AA lt lt gt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT Recommend that stickout be in mm for solid wire and Y in for flux cored wire Le Le Je Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT See A Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 249 498 Page 39 9 5 Gun Movement During Welding CS 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 Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 EE DM S 0054 A 9 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration O E ND A S 0053 A 9 7 Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals oO m being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 249 498 Page 40 9 8 Troubleshooting
14. physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard d e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders o
15. 2 89 4 0S 2 sv 9 0p 9 0p S 0z Sc 9 0 9 Sc v 0 v Ov v 02 9 Sc 9 SE 9 Sc 0 v DIE Sc 9 0 9 Sv 9 0c s 08 S 0c scit SE 19915 0S 2Z sso urels 02 4 ASLL d390 10 Dugiod 19S Se 0z 0 0 02 9 S2 9 0v 9 023 3 09 00L St 4 0v 4 05 9 se 9 0p 9 02 S 10 Aelod 195 03 S 0 S SL S SIE ASLL eoueJeedde J9nog d390 gt o SH d L M bunjes Deel amp JIM s USe s Jo 4f uo Jaquinn Bulnes eBeiJoA s USEIS jo Ya uo JequinN sessed ejdiy nu pue uoreiedeid wuel enbjuuoe 1edo1d Buisn pepjem Buleq ejeu jo sseuxou 104 sBulyes peeds au pue eBejjoA papusuosey papjem aq ueo slEUeieu 16H91 peinbei se jsn py eyeuiixodde ee sues oDex5ed BUIPISM AIM HOA OEZ SLL 40 SPIND BuipjeM 250 015 A OM 249 498 Page 28 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance Nica NP LA X A Disconnect power before maintaining E Maintain more often during severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent S p Y EN E t Jf 2 RV Every Unreadable Labels Q Weld Terminals Damaged Gas Hose X Weld Cables 3 Months X Cords Gun Cables Every d 6 77 A Months A X e le Q Drive Rolls Q Inside Unit 7 2 O
16. 246 380 Housing Power Pin ex A 245 927 Connector Feeder rm 197123 O ring 312 ID X 062 70 Duro Buna n wd esee 194 010 Liner Monocoil 023 025 Wire X 15ft Consisting Of usd eu 194 011 Liner Monocoil 030 035 Wire X 15ft Consisting Of vdd scent 194 012 Liner Monocoil 035 045 Wire X 15ft Consisting Of Nr TE 079 975 O Ring 187 ID X 103cs Rbr x OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model is required when ordering parts from your local distributor OM 249 498 Page 49 10 3 Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PARTNO INCHES 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 Options PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 lb 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg max 245 926 H100S4 10 Replacement Gun 10 ft length 030 035 wire size 300 796 Spool Runner 100 Spool Gun For push pull wire feeding 195 186 Protective Cover Weatherproof nylon 212 492 Regulator Flowmeter For use with CO shielding gas 10 50 CFH 144 108 Gas hose 5 ft For use with regulator flowmeter 212 492 10 5 Consumables ITEM HOBART PACKA
17. Bead EE Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal LA Ka 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 forces i Base metal moves in 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 OM 249 498 Page 43 9 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel eed Aluminum Argon X Argon 25 CO X 80 or greater Argon X x balance CO or Oxygen 100 CO X Tri Mix X 1 Limited short circuiting use 2 90 HE 7 1 2 AR 2 1 2 CO 9 17
18. Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit A Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr a la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur
19. Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues en contact avec le fil sont sous tension lectrique Un quipement install ou mis a la terre de mani re incorrecte ou impropre constitue un danger A pu Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditi
20. North American distributor or eighteen months after the equipment is shipped 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 remaining warranty period of the product they are installed in or for 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 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 fur
21. Satan tu ante eee E EA OE VES Ml EAS MAA A Me AN nr enr Modeste bad DY Saga eS Sete ia d SECTION 7 MAINTENANCE amp TROUBLESHOOTING s sees I nnne 7 1 7 2 7 3 7 4 7 5 7 6 7 7 Routine Maintenance occcccccocc 44e Overload Protection uere cree qu A A E e a Drive Motor Protection Changing Drive Roll Or Wire Inlet Guide 2 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing Replacing Switch And Or Head Tube Troubleshooting Table 55 vite nets ge eras We re ate hak Gee aid ea ER BUR ARI ERE OO JO O1 ast PS GO A ch ch MM MM bMbMMbMMM MM A ch ch ch ch 4 ch ch cb ch ch ch ch cb zk sch Jr OO BR o NO 2 OD JJ oO O1 O1 P ND ON M gt a TABLE OF CONTENTS SECTION 8 ELECTRICAL DIAGRAM TL I SECTION 9 MIG WELDING GMAW GUIDELINES seeeeeeen IR nne 9 1 Typical MIG Process Connections 9 2 Typical MIG Process Control Settings 9 3 Holding And Positioning Welding Gun 9 4 Conditions That Affect Weld Bead Shape 9 5 Gun Movement During Welding 9 6 Poor Weld Bead Characteristics 9 7 Good Weld Bead Characteristics
22. com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 t l phone 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 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS t l phone 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 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage
23. de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements gt gt OM Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres acce
24. doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes OM 249 498 Page 2 CH Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free
25. of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet a BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Compressed gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks
26. plugs will void product warranty Connecting Plug To Power Cord A C_ E a MVP Plug1 2010 10 Ref 805 390 C Plug NEMA Type 5 20P Optional Connecting Plug To Power Cord Receptacle NEMA Type 5 20R Customer Supplied Plug NEMA Type 6 50P Receptacle NEMA Type 6 50R Customer Supplied Follow electrical service guide for 230 VAC in Section 5 7 Do not use plug rating to size branch circuit protection Align arrow on plug with arrow on power cord connector Push together Tighten threaded collar As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle OM 249 498 Page 20 5 10 Serial Number And Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 5 11 Selecting A Location And Connecting Input Power Y LG de ar p N 18 in 457 mm of space for airflow A Do not move or operate unit where it could tip ne 3 4 M Ca ws A 86 ES Ke 7 8 Align arrows before threading together 250 332 A A Do Not modify or rewire receptacle For 115 VAC input power a 20 ampere 5 Plug NEMA Type 5 20P Optional connec
27. trigger leads see Section 5 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 7 5 Check for proper polarity connections see Section 5 5 Check thumbscrew securing gun end to feed head adapter and tighten if necessary 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 7 6 Check contact tip Check for kinks in gun cable Blow out liner and gun casing see Section 7 5 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 5 16 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 14 Replace contact tip if blocked see Section 7 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 or Section 7 5 Replace drive roll or pressure bearing if worn or slipping see Section 7 4 Secure gun trigger leads or repair leads see Section 5 2 Check and clear any restrictions at drive ass
28. 23 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute y Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate OM 249 498 Page 37 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 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout PA 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 4 M us 09 15 WA A 90 90 GE End View of Work Angle Side View of Gun Angle GROOVE WELDS e 0 15 e 45 7 N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 249 498 Page 38 9 4 Conditions That Affect Weld Bead Shape CS 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 p 10
29. 5 15P gt 2 gt SH RC10 PLG10 gt 1 gt TP1 oe gt 2 gt RC11 PLG11 15 CONTROL CONTACTOR CR7 12 THERMAL OVERLOAD PL1 z GUN 5 21 TRIGGER 2 gt 2 53 SPOOLGUN va 2o MOTOR PLG13 RC13 Figure 8 1 Circuit Diagram WARNING 2 ELECTRIC SHOCK HAZARD e Do not touch live electrical parts Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install Use or service this unit 1 301 praia Ir 106 PRI X7 i 211 P d 314 PRI 2 i POSITIVE 6e 2 312 PRI 3 1 io a x Z1 TE sel K9 310 PRI 4 d ERA TNT COM aq pa 308 PRI 5 x5 NEGATIVE ANDRE E 6 306 PRI 6 SWITCH n 2 304 PRI 7 E e X6 L2 302 PRI 8 NOTE DENOTES SWITCH 301 lt lt N O 102 RC2 gt 212 ERG 103 lt lt COM RC3 X 2j K RC7 1 E 25 C RC7 5 RC1 8 gt gt s 106 CONTROL RC1 16 gt BLK K RCE BOARD ck Rcs PC1 a4 ep RC8 1 gt lt K RC7 8 RC1 PLG1 CS1 24 RC4 PLG4 lt KRO7 4 RC7 PLG7 32 22 A RC7 2 RC8 PLG8 on p MIG 9 KRc1 6 S d ER 14 Ae A4 RC1 7 gt gt 13 SPOOL RC1 13 GUN lt lt RC1 2 5 p lt KRC1 5 RED RC4 1 gt gt 19 KRC1 15 WIRE DRIVE M
30. Connections For Direct POLARITY Current Electrode Negative DCEN DCEN 2 Lead Connections For Direct Electrode negative for Current Electrode Positive flux cored wire DCEP Always read and follow wire manufacturers recommended polarity and see Section 5 4 Close door Electrode positive for solid wire Ref 209 228 Ref 209 229 OM 249 498 Page 17 5 6 Installing Gas Supply DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional CO gas regulator flowmeter 4 4 4 a o Pressure Assembly Open Tools Needed 3 e 5j8 1 1 8 in Argon Gas Or Mixed Gas a cS Pressure Assembly Closed Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adju
31. EFINITIONS EE 3 1 Symbols Ard Definitions la EE NN RR SECTION 4 SPECIFICATIONS 4444 nen nh nnn nnn nnn 4 1 4 2 4 3 4 4 Specifications For 230 MAC Specifications For 115 VAC ninie atea te mta AA qu e re Ya vea Yun Duty Cycle And Overheating Volt Ampere GUIves i v VUE VR E Rh A en A ETAT AX a RE dua SECTION 5 INSTALLATION 4444 444444 nh snnm nnn 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 Installing Nozzle Contact Tip And Adapter Installing Welding Gun sark eene a nh eee Installing Work Clamp sico a la een wend e ire Process Polarity Table 88 ge pe CRY aA da anne Changing Polarity EE Installing Gas Supply Electrical Service Guide 2224 48448 ENEE ee we a a eee ee Extension Cord Data Use Shortest Cord Possible Multi Voltage Plug MVP Connection Serial Number And Rating Label Location Selecting A Location And Connecting Input Power Connecting 1 Phase Input Power For 230 VAC Input Connecting 1 Phase Input Power For 115 VAC Input Installing Wire Spool And Adjusting Hub Tension 000 ccc eee tte teens Connecting Optional Spool Gun Threading Welding Wire RENE ee ee ELE ER RE ER BR ERR SECTION 6 OPERATION 4444 4 4444 eee eee eee eee eee nnn nnn 6 1 6 2 Gontrol 3 cd paca eebe e
32. EN Hp Mens ue Dp Red res 2 Wo WEE 211 887 y HUB Nut zi a a e EDI vu rac Aer eg Tat cT 1 asd Eos pa NS 204608 S NU ane AE ENEE a ARA Ae MAT wes 1 O Meer 202998 Spring Cprsn 1 i2 WEE 209 072 sc Washer Flat ut 20e ent din aan A e e 1 de M EE be a Ea 211339 Hub Spool EE NEE NEE NENNEN Rer ee RR regn 1 vehere erp 202 726 Adapter Spool Hub 1 Pf Qi NN 246 242 Circuit Card Assy Control 1 cg MO didnt a aaron dre s 251 195 Bas LOWER EE 1 A Mans 184946 Blank Snap in Nyl 2 1 DITA WEE A 196 467 Tubing PVC 187 ID X 312 OD X 23 00 1 A ta tana 216607 ae Valve Gas aaa Ange delt Sage AT aces 1 ES ad owt 197 198 Cable Tie 700 799 Bundle Dia 2 br Eo smart 299 588 Cable POWER umi siete E a Ra aaa ace 1 CROPS mrad sus 010 290 Bushing Strain Relief 1 Sih A 137 761 Nut Gas Vale ent aed cic aa degt A Reo 1 Lu TO singe chee 2306 925 MOTOR Fal teo cos reb Ra eS 1 eau co iia 409 953 001 Blade Fan Cooling 1 s Dru E CE EO 248 730 Transformer Power 1 se 21 pe EEN E 208015 Handle Carrying 1 uds haie is 196 005 2 Wrapper x o pv Da VE
33. GE NO MILLER PACKAGE NO Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 035 in 0 9 mm 770 180 5 per package 000 068 10 per package 045 in 1 2 mm 770 177 5 per package 770 183 5 per package 000 067 10 per package 000 069 10 per package MIG Nozzle Standard 770 404 169715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716 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 NOTE If individual parts are required see Parts List chapter of this manual for part number to order OM 249 498 Page 50 Warranty Questions Call 1 800 332 3281 7 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 questions 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 HOBART AC WELDERS HOBART S31 WARRANTY Effective January 1 2011 5 311 WARRANTY applie
34. LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province h
35. OTOR 12 lt K RC 12 RC4 2 gt BLK 9 KRC1 9 18 RC1 18 3 lt 1 RC1 1 10 A i RC1 10 gt 2 lt a zT wes RC1 3 19 amp 4 RC1 19 1 lt RC1 4 PLG9 RC9 17 lt KRC1 17 249 315 A 20 lt K RC1 20 OM 249 498 Page 35 SECTION 9 MIG WELDING GMAW GUIDELINES 9 1 Typical MIG Process Connections A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter i Wire Feeder Power Source Gun qo s vu bsc ele 2 Gas S E gt t Workpiece d LA Work Clamp Shielding Gas Ref 801 909 A OM 249 498 Page 36 9 2 Typical MIG Process Control Settings CS 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 Material thickness determines weld parameters YES 1 8 or 0 125 in Convert Material Thickness to P Amperage A A 0 001 in 1 ampere 0 125 in 125A y Wire Size Amperage Range Y k 0 023 in 30 90A m 0 030 in 40 145 A Select Wire Size 0 035 in 50 180A Wire Wire Speed Select Wire Speed Size Recommendation Approx Amperage 0 0
36. Online Forum www HobartWelders com OM 249 498B 2011 03 Gen Processes a MIG GMAW Welding HOBART tgo Flux Cored FCAW Welding WELDERS Description 2 CS E Arc Welding Power Source And Wire Feeder Handler 210 MVP OWNERS MANUAL File MIG GMAW m 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 BEL REGISTEHED QUALITY SYSTEM Hobart is registered to the ISO 9001 Quality System Standard 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 spec
37. RDE VITIA EIL dike ay 1 SAO era ve EP 204 036 Label Warning 1 ox s onm osito ond 203491 Clamp Capacitor 1 SUD esu d iue he 226 191 Capacitor Electrlt 100000uf 1 A E EE 225 891 qe REACTOR ASSY oo eid aa SARI NEAR ASIDE EP 1 stall c rite ere pda 193316 lt Rectifier Assy EE 1 O tario 227 180 Bus Bar POSITIVO cocaina ria nee LAR Eo eR e mate 1 RIRA WEEN 251 236 Baffle e EE 1 OO aia Ad 196 575 witch Rocket ii a A Eg Ta CRT 1 d r dd doe e erra 193 144 Insulator Output Stud 1 EE En 193 194 Bus Bar Negative 1 SUIS EE 216830 Label Warning 1 o A ET a 194201 Stand hd be EA ia AA ER MEER a 6 UD TO 226813 Switch Rotary 32A 7 Position 1 sent EE 209 873 Potentlometer er ree aa Pa tag ein aca 1 sate AB usd rap ae e 249909 Panel Front csv ondes ara AWO de Maia etl dat 1 ET EE 208 820 Clamp Work ooccoccccccc e 1 E WEE 196 619 Gables e EE 1 OM 249 498 Page 47 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly Continued pa eril 248 732 Supplementary Protector Man Reset 1 Ds on deii a 228 400 Knob Pointer Voltage
38. SL v SE v Sp V SL S DIE wiwig 0 0 0 ASLL 2320 uw6 0 S60 UOBIY 00L Y 9808 BEES wwg o 0 0 Ulnuluiniy jeuondo uuwug 0 0 0 ASLL 4390 yum Iuue0 0 UOBIY 00L IV Etok unuimuniy uwg 0 0 0 Uinuiuniv uuie 0 5 0 wwg 0 080 uiuit Sto wwi6 0 GE0 wiwig 0 080 UG 0 GEO wwug 0 0 0 001 47 001 9 06 9 001 9 SL E AOE 0Z S 02 2 09 06 7 001 42 se Z 82 9 98 9 0 Z SbII 03 v se s Sv S AOE s9 SL Sc S 01 1 0c c Sc 6 09 2 0L v 0oc v suoneoiddy 100p1nO st 10 PUIM 40 poo Ha pounbey noez seg Buipjaius ON 0 9 0S 2 sels Sv 9 09 9 LLLL3 2109 SD SL L 02 1 ASLL d390 104 209 8 Z yAeJod 19S uuw9 0 Fe EE ww6 0 eg GIE 19915 wwig 0 0 0 ADES ssojuieis wiwig 0 F Vue 0 SEO uug 0 0 0 UI9 0 7Z0 wiwig 0 seg 9 S0 H3 wuig 0 0 0 NOEZ 94M PIOS ww9 0 Fe uwu6 0 S 0 uwg 0 080 uwu9 0 pzo Jeyeds sso seonpoid Duuen Seo 09 SZ H 94 9 S0 83 s 02 9 09 9 05 S Op 08 EJE EJE oziz uwg0 0 0 noez Simi Seo 2 al PHOS EA EA EA CO ZU E CZE AE 02 1 uso vg uge uu wwz wwg o uso Bumes ul 9E ul 90 ul 8 0 ul 0 0 ul pzo pesn Buteg ebeyoA Y Mol4 UJO DE 07 Auelod Bol ef pz 94M JO indul set Bulplelus pue buleg Jojoureiq peisobbns eus se Z 0b Z 09 9 09 9 02 9 ST L SEIL 09 Z se s or s S9 S 0 4 0S
39. ants have to be taken For example access restrictions for passers by or individual risk assess ment 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 OM 249 498 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 48rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Reg
40. 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 source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base 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 before welding 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 metal resulting 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 OM 249 498 Page 42 9 14 Troubleshooting Waviness Of
41. connect leads polarity is opposite side d not important Reassemble in reverse order If replacing head tube continue to end of figure 4 Secure head tube in vice Loosen jam nut Remove from vice and turn head tube out by hand 7 Place head tube in vice and tighten until 6 Hand tighten head tube into cable connector nuts are tight H 9 Reinstall screws 8 Remove from vice Reposition handle halves and and nuts install switch housing mA STE Bs Reinstall screw on opposite side SH CRAN N Tools Needed LI SS T 15mm phillips 243 840 A OM 249 498 Page 32 7 7 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 5 11 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 6 1 Reset welding power source supplementary protector see Section 7 2 No weld output wire does not feed fan motor continues to run Thermostat TP1 open overheating Allow fan to run with gun trigger switch off thermostat closes when unit has cooled see Section 4 3 Check Voltage range switch position Rotate knob until it clicks into detent at desired range setting Secure gun
42. du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s SIS 2o e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 249 498 Page 7 RA Les PI CES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PI CES MOBILES peuvent causer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique
43. e text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A 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 instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of fall
44. e torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit 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 d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 249 498 Page 9 OM 249 498 Page 10 3 1 SECTION 3 DEFINITIONS Symbols And Definitions A Amperage V Voltage H Z Hertz Negative i Direct Current Positive l DC 1 ENS Single Phase Input e Output y Voltage Input O Off On Do Not Switch G Gas Metal Arc D Q ES While Welding E of olo Wire Feed O Circuit Protector Welding GMAW U Rated No Load Conventional Load Voltage Average U 1 Primary Voltage U 2 Voltage D i Line Connection Single Phase Rated Maximum Rated Welding X Gd Duty Cycle y Lr Transformer l imax Supply Current 2 Current Rectifier T i O P Protective Earth emperature ncrease O ercen Ground Suitable For Welding In An IS Environment With Rated Supply Maximum Effective Incr
45. eased Risk Of Electric Shock mmm Current La Supply Current OM 249 498 Page 11 SECTION 4 SPECIFICATIONS 4 1 Specifications For 230 VAC Amperes Input at Rated Welding Amperage Memen Opan Rated Load Output KVA KW Weight Overall Output Range DC g 230 V 60 Hz W Gun Dimensions Single Phase Length 19 1 2 in 495 mm 150 A O 23 Volts 79 lb Width 10 5 8 in DC 30 Duty Cycle 25 210 34 24 5 54 4 72 86 kg 273 mm Height 12 3 8 in 314 mm SEU Flux Cored Aluminum Wire Feed Speed Range Wire Type EE And Diameter 023 035 in 030 045 in 030 035 in 70 750 IPM 1 8 19 0 m min At No Load 0 6 0 9 mm 0 8 1 2 mm 0 8 0 9 mm 40 680 IPM 1 0 17 3 m min Feeding Wire 4 2 Specifications For 115 VAC Maximum Amperes MO at seg e Rated Welding prona Rated Load Out eight vera Output Amperage Range opan e put 120 V 60 Hz KVA KW WI Gun Dimensions 9 Single Phase Length 19 1 2 in 495 mm 90 19 su Volts DC 20 25 140 28 20 284 2 41 7916 Widin 1055 81 Duty Cycle 36 kg 273 mm Height 12 3 8 in 314 mm a Flux Cored Aluminum Wire Feed Speed Range Wire Type x And Diameter Ze SC e Ec 030 in 60 740 IPM 1 5 18 8 m min At No Load inn 0 8 e 0 8 mm 40 600 IPM 1 0 15 2 m min Feeding Wire mm OM 249 498 Page 12 4 3 Duty Cycle And Overheating
46. embly and liner see Section 5 16 or Section 7 5 Gun is not secured to feed head Check thumbscrew securing gun end to feed head adapter and tighten if necessary Have nearest Factory Authorized Service Agent check drive motor 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 Check for proper output polarity see Section 5 5 OM 249 498 Page 33 SECTION 8 ELECTRICAL DIAGRAM WARNING 2 ELECTRIC SHOCK HAZARD e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install Use or service this unit OM 249 498 Page 34 BLK lt CB1 12 72 202 SET o To OO e 17 77 RED 201 lt O DUR o _ GRN_ ORN YEL CR7 POWER CORD ADAPTER CONFIGURATIONS WHT RED 230V 50A amp so Y P O GRN RED BLK 115V 20A 5 20P WHT BLK SZ GRN BED 24 VAC FM gt 5 RED BLK WHT BLUE 6 115V 15A gt 1 gt
47. ification sheets To locate your nearest distributor or service agency call 1 877 Hobart1 or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 2009 09 5 31 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com Ga NUI THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 2 1 3 1 4 1 5 1 6 Symbol Usage ita dai AA n e pe e a quet rer pc ec edes Arc Welding Hazards o oococcccccc ehh he mr nns Additional Symbols For Installation Operation And Maintenance California Proposition 65 Warnings 2 Principal Safety Standards eere er erbe eR ere m n Rr E omar pc ee EMF Iriforrriation lt a EEN SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 2 2 2 3 2 4 2 5 2 6 Symboles utillS S snb ba a PLAIN PRG PX CPP Der Dangers relatifs au soudage l arc e Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Proposition californienne 65 Avertissements Principales normes de s curit Informations relatives aux CEM he rn SECTION 3 D
48. igneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d hu
49. ile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES E XU SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non u
50. ing Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic 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 welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes E Indicates special instructions e A T i This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power c
51. ion 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 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 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 operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2010 03 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte
52. irty 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 welding 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 Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 249 498 Page 41 9 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and T m A base metal Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of O 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
53. is la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 249 498 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les c
54. lding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment Such as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 249 498 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety S
55. n es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensio
56. nished by Hobart Miller but manufactured by others such as engines or trade accessories 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 HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable 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 actual use upon return of the goods at customer s risk and expense Hobart s Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY
57. nn e et prot g e avant de mettre l appareil en service G LA CHUTE DE L QUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N294 110 lors du levage manuelle de pi ces ou quipements lourds N Jg B L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Ba e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal MMC e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et
58. obart warr 2011 01 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 Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2011 Hobart Welding Products 2011 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call 1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Na KA HOBART HS
59. ons utiliser les quipements suivants EF Indique des instructions sp cifiques nm cal Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre approp
60. onsommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un ca
61. ord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level e Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output
62. ors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 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 Wear an approved welding helmet fitted with a proper shade of filter 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 Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection CH WELDING can cause fire or explosion A Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before
63. r any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment nn d t OVERUSE can cause OVERHEATING e Allowcooling period follow rated duty cycle Ze e Reduce current or reduce duty cycle before e D starting to weld again e Do not block or filter airflow to unit N FLYING SPARKS can injure e Wear a face shield to protect eyes and face e e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards Les N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire LE 5
64. resent see NEC Ar ticle 511 or CEC Section 20 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding 2 Conductor 3 Input Power Cord 4 Disconnect Device switch shown in y KL the OFF position 5 Disconnect Device Grounding Terminal 3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 5 7 fused disconnect switch shown 8 Receptacle NEMA 6 50R Customer Supplied Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 230 VAC 1 v Tools Needed H Ref 250 332 A OM 249 498 Page 22 5 13 Connecting 1 Phase Input Power For 115 VAC Input A Installation must meet all National and Local Codes have only qualified persons make this installation A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal For 115 volts AC input power a 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 1 Multi Voltage Plug And Po
65. ri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas m
66. rigger until wire comes out of gun EF Hold wire and spool tightly to keep it from unraveling L 6in 150 mm Pull and hold wire cut off end EF Use pressure indicator scale to set a desired drive roll pressure Pressure Indicator Scale Remove gun nozzle and contact tip Be sure that tip matches wire diameter Reinstall contact tip and nozzle 120 mm Push wire thru guides into gun continue to hold wire Turn power on Be sure that Voltage range switch is set to range 1 2 3 4 5 6 or 7 to feed wire Rotate knob until it clicks into detent Wire will not feed if range switch is set between ranges Tighten WOOD Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Ref 804 688 B OM 249 498 Page 26 SECTION 6 OPERATION 6 1 Controls Es DO NOT SWITCH WHILE WELDING 1 Wire Speed Control Control varies the rate of wire being fed through the welding gun 2 Power Switch Supplementary Protector Turns power on and off Also this switch functions as supplementary protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset power protector switch supplementary 3 Vol
67. roll 1 4 turn to closed slot 4 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 16 250 763 A OM 249 498 Page 30 7 5 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing D A Turn off welding power 1 Nozzle 2 2 Contact Tip lt 4 3 Tip Adapter Head y q ON Tube Wire size stamped on tip check 1 V lg AD d and match wire size Cut off wire and disconnect gun from feeder 8 mm Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out gun casing a straight before e installing new liner Reassemble gun in reverse order from taking it apart Install Liner e a Liner uw sun Stickout Thread wire according to welding power source wire feeder manual Tools Needed COP C Xe 3 8 mm 10 mm 243 839 A OM 249 498 Page 31 7 6 Replacing Switch And Or Head Tube e ar A Turn Off welding power source EX wire feeder and disconnect gun 1 Remove screws 5 2 Remove handle halves and nuts 4 SS 2 Bs Remove screw on 3 Remove switch housing Install new ita ei switch and
68. s to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MB 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 Hobart Miller Electric Mfg Co Appleton Wisconsin warrants 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 by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY 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 material 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 instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a
69. sque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 249 498 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir so
70. ssoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent 249 498 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins
71. st Flow rate should be set when gas is flowing through welding power source and welding gun Open pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate After flow is set close pressure assembly Ref 804 654 A 802 441 Ref 804 688 A OM 249 498 Page 18 5 7 Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommendationsare for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 60 Hz Single Phase Input Voltage V 230 Volts AC 115 Volts AC Input Amperes A At Rated Output 24 Max Recommended Standard Fuse Rating In Amperes A 20 ampere Time Delay Fuses 30 individual branch circuit Normal Operating Fuses 35 protected by time delay fuses Min Input Conductor Size In AWG 4 14 or circuit breaker 53 is required Max Recommended Input Conductor Length In Feet Meters 16 See Section 4 2 Min Grounding Conductor Size In AWG 4 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating
72. tage Control Control varies the voltage level of the welding arc The voltage range is 4 minimum to 7 maximum on 115 VAC and 1 minimum to 7 maximum on 230 VAC 250 650 A Switch must click into detent position DO NOT switch under load 4 Over Temperature Light Light illuminates if main transformer overheats 5 Gun Trigger Receptacle 6 Trigger Switch When pressed energizes wire feed motor and gas valve for shielding gas flow OM 249 498 Page 27 Weld Parameter Chart 6 2 V SL00SC Sam P2409 XN 4 104 9AnleboN oponoo 3 Nada 94IM PIIOS 104 SANISOd 9P0 119913 d390 ALI VW 10d ONIONVHI unujunje 10 pspUSWWO991 jewou s 4910 ay 10 a Bue ysnd y el UINUJUIN Y 3jos 34 yM pajeloosse sanss qep ueu sejeurue unf joods y payoeye uno joods eui YIM ae sBunies M WINUJUIN Y yy uBisep jurof pue uoneoridde au uo Bulpusdap p nb ag Aew sessed ejdniniw 919 EIS 10 sseuijueojo ejBue pjam peeds jane no YANS se uons UolyeuJojur 81001 Jenuew ay ui suononusul Jad uoisua snipy Se qeueA Jayjo uo spuedep osje peeds ai Buipiam au peuni eui 10 jenuew siaumo ees Bulpjam eiu Meis ye o Bunjes qouy uoisue 19S aq ueo Bumes paads aum juo enjeA Bulyeys e si paisi peeds AM uonisod yoyms eBeyoA aBueyo jou og juoyned pesn Bulag 91M Jo 1 J WELIP 0 SADOJ Wope UNEN 06 2 08 S 06 8 08 4 09 9 02 S 0c 9 0b Z
73. tandards Safety 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 Welding and 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 Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum 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 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical impl
74. terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns NS OM 249 498 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vap
75. tilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loig
76. tion individual branch circuit protected by 6 Receptacle NEMA Type 5 20R Do Not cut ott power cord IY Soen Sa For sodva Customer Supp connector and rewire The power pis E 7 Plug NEMA Type 6 50P put power see Section 5 12 9 VD cord connector and plugs will work 8 R tacle NEMA Type 6 50R with standard NEMA receptacles 1 Rating Label e ac G e ype o Modifying power cord connector Supply correct input power see Customer Supplied and plugs will void product Section 5 10 Select plug for power supply receptacle warranty available at site Install plug onto power A Special installation may be required E rowel NOI Connector cord adapter AS threaded collar i where gasoline or volatile liquids 3 Plug NEMA Type 5 15P lee poan ae a adapter Uni are present see NEC Article 511 or 4 Receptacle NEMA Type 5 15R H ee PENSE CEC Section 20 Customer Supplied Connect plug to receptacle OM 249 498 Page 21 5 12 Connecting 1 Phase Input Power For 230 VAC Input A Installation must meet all National and Local Codes have only qualified persons make this installation GND PE Earth Ground A Disconnect and lockout tagout input power before connecting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal A Special installation may be required where gasoline or volatile liquids are p
77. tion 5 5 4 2 Close door Be sure that gun end is tight against drive assembly 8 Wire Feed Speed Control Wire feed speed control controls rate at which the is fed through the 3 welding gun to the weld puddle 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see VS Z Section 6 2 or door chart for d IB appropriate setting 10 Trigger Press trigger to energize welding O an D SE Exposed O rings will cause shielding power source contactor start Incorrect gas leakage Correct shielding gas flow and begin wire Gun Not Seated Gun Fully Seated feed 804 695 A 804 696 A OM 249 498 Page 25 5 16 Threading Welding Wire T p Ye Tools Needed ee gt Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight 4 2 3 4 5 6 O ET 0000 O es Open pressure assembly Make sure feed roll is set to correct groove to match wire size see Section 7 4 Tighten Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Press gun t
78. verload Protection 3 PES 40 50 en l o o 3 o 20 LU wo V 10 07 Q d E DO NUT SWITCH le ES WHILE WELDING 15V 230V e OG 1 Supplementary Protector CB1 Power Switch CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector power switch CB1 also turns unit on and off 250 653 A 7T 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again OM 249 498 Page 29 7 4 Changing Drive Roll Or Wire Inlet Guide nx Tools Needed 023 025 V Groove 030 035 V Groove 030 035 080 085 Smooth Knurled Groove Groove Stamped 030 035 Stamped 030 035 Stamped Ge 030 035 VK i A Turn off welding power source 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Retaining Pin To remove drive roll push drive roll in and rotate it 1 4 turn to the open slot and slide it out over the retaining pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive
79. ween flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas solenoid valve not operating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage OM 249 498 Page 44 Problem Probable Cause Remedy Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive 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 on welding 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 OM 249 498 Page 45 SECTION 10 PARTS LIST Hardware is common and not available unless listed 250 327 A Figure 10 1 Main Assembly OM 249 498 Page 46 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly pud xus ese mee 199 566 DOOF ACCESS ci sos Ro dee SEENEN a aig WA aii 1 ds a dao eterno deiode 196 006 Hinge Door 32 enki rp bt E
80. wer Cord Connector NEMA Type 5 15P Plug Shown For multi voltage plug connections see Section 5 11 2 Receptacle NEMA Type 5 15R Customer Supplied Ref 250 332 A OM 249 498 Page 23 5 14 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool SE When a slight force is needed to turn spool tension is set Lar Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only When a slight force is needed to turn spool tension is set with 8 in 203 mm spool only Tools Needed X E J 1 2 in 803 012 803 013 B Ref 802 971 C OM 249 498 Page 24 5 15 Connecting Optional Spool Gun 1 Drive Assembly EX Ge ESCH 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End 7 Loosen thumbscrew Insert end through opening until it bottoms Spool Gun against drive assembly Tighten SP thumbscrew 5 Spool gun must be inserted ors completely to prevent leakage of N E shielding gas o 5 Gun Trigger Plug W Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch P d F Place switch in Spool Gun position 13 7 Polarity Changeover Terminal 6 MIG Gun Block To make proper polarity connection see Sec

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