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Handler 125 And H-9B Gun

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1. ERR MEE EA AC AE RE EUN AUR Ae 28 SECTION 6 ELECTRICAL DIAGRAM S ied Sid e D Ketone a 29 TABLE CONTENTS SECTIONS WIRE WELDING GUIDELINES Rex E d RR n e 9 1 Typical FCAW Process Connections mn 9 2 Typical MIG Process Connections 9 3 Typical Control Settings saxa t EROR a RU iR M 9 4 Holding And Positioning Welding Gun 9 5 Conditions That Affect Weld Bead Shape 9 6 Gun Movement During Welding 2 hn 9 7 Poor Weld Bead Characteristics hn 9 8 Good Weld Bead Characteristics 9 9 Troubleshooting Excessive Spatter 9 10 Troubleshooting Porosity epus ER ERREUR ERR od Peds SERE EE SS EE 9 11 Troubleshooting Excessive Penetration 9 12 Troubleshooting Lack Of Penetration 9 13 Troubleshooting Incomplete Fusion ccc eee eee eee eee 9 14 Troubleshooting Burns Through iae pe eR RE RR EORR rm EE qeu xd eene 9 15 Troubleshooting Wav
2. 9 JO SSOUHOIU 10 pue 19H91UL pouinboa se 5 9JIM HOA SLL 10 Spiny Weld Parameter Chart 6 3 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance before maintaining Lx Maintain more often during severe condi tions Check Change Clean Replace Reference To be done by Factory Authorized Service Agent 3 Months x Damaged Or Unreadable Labels x Repair Or Replace Clean And Tighten Weld Cracked Weld Cable Terminals JE 6 Months Inside Unit 7 2 Overload Protection 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 803 379 A 7 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 947 Page 22 7 4 Changing Drive Roll Or Wire Inlet Guide a 1 Pressure Adjustment Knob Pivot pressure adjustment knob down and lift pressure a
3. 947 212 149 2010 07 Processes B HOBART Flux Cored FCAW Welding W ELDER S MIG GMAW Welding Optional Description Arc Welding Power Source And Wire Feeder Handler 125 And H 9B Gun Online Forum www HobartWelders com OWNER S MANUAL File Flux Cored FCAW Fe 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 15 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 90 0001 of reliable service with proper maintenance And if for some reason the unit needs repair REGISTERED there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you every power source Hobart is registered to the you may need to fix the problem Warranty and from Hobart is backed by Quality System service information for your particular model the best warranty in the business are also provided Protect Your Investment Hobart Welders manufactures a full line of welders and welding
4. dE Rel o e RO ER i e 1 MEC QURE 212 979 ROLL drive 024 030 085 oi sie b d HERO er ar apes 1 NE Er MM 212 389 RETAINER feedroll 1 TIC Be 212 368 GUIDE s d oes Rau RE ol OR Ua 1 WE a 212 3842 COVER 5d s Enos ia a 1 212 369 KNOB TENSION 5 228225 abdo 1 212 387 SPRING compression 1 Aon 212 9080 52x CUP SDEDG ei eth ooo ike Ro A Rud Ade da on 1 NOCERE 212 389 SCREW torch COVER REDE RO Een Be 1 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 Table 10 2 Options PART NO DESCRIPTION REMARKS 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg 195 158 MIG Conversion Kit For Gas Metal Arc Welding GMAW 195 216 Hub Kit For 8 in Wire Spool 195 186 Protective Cover Weatherproof Nylon gt If individual parts are required see Parts List chapter of this manual for part number to order OM 947 Page 41 Notes Work like a
5. 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 16 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move 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 9 17 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 tip adapter 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
6. e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal 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 e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette man uvre est ex cuter dans un endroit 50 lorsque l on porte l quipement homologu protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute sub stance inflammable 79 5 Q S e LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 947 Page 7 Les PI CES MOBILES peuvent causer des ble
7. 9 5 Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage The Drag or Pull technique is generally recommended when welding with flux cored tubular wire Push Perpendicular Drag or Pull p d 10 10 1 lt lt lt Electrode directed Electrode pointed ahead of bead back into bead Direction Of Welding ee E GUN ANGLES WELD BEAD PROFILES uU U v Short Normal Long ELECTRODE EXTENSIONS STICKOUT FILLET WELD ELECTODE EXTENSIONS STICKOUT Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 947 Page 33 9 6 Gun Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better Stringer Bead Steady Movement Along Seam Weave Bead Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 9 7 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 9 8 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new
8. Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Cable Lay gun cable out straight WN Tools Needed Hold wire tightly to keep it from unraveling gt Y Gin 150 1 cd 7 f 4 Pull and hold wire cut off end Push wire thru guides into gun liner continue to hold wire Loosen knob completely then rotate pressure adjustment knob in a clockwise direction until drive roll is tight against the welding wire ON Adjust drive roll pressure just tightly enough to prevent wire from slipping against drive roll LS during operation INPUT POWER Be sure that wire is positioned Remove gun nozzle and contact tip Turn power on in proper feed roll groove Close and tighten pressure d s fen dis assembly and let go of wire COE TO TECO OUV GAC OLGUN Tighten Q Press gun trigger until wire comes Be sure that contact tip matches wire diameter Feed wire to check drive roll pressure out of gun Reinstall tip adapter if applicable contact tip Tighten knob enough to prevent slipping and nozzle Cut off wire Close door Ref 803 444 A Ref 205 837 OM 947 Page 19 SECTION 6 OPERATION 6 1 Controls 1 Voltage Switch Use control to select the weld voltage range As the thickness of material increases a higher voltage range must be selected see weld setting label in welding power source or Section 6 3 a
9. be sure they comply to specifications Material thickness determines weld parameters 1 8 or 0 125 in p f 0 023 in 30 90A 0 030 in 40 145A 0 035 in 50 180A Wire Speed 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 2 125 250 ipm 1 6 x 125 200 ipm 0 030 in 2 in per ampere 0 035 in 1 6 in per ampere Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage EP Sy Wire speed amperage controls weld 22 penetration wire speed burn off rate O Voltage controls height and width o weld bead Convert Material Thickness to Amperage A 0 001 in 1 ampere 0 125in 125A Select Wire Size Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Select Voltage Ref 803 441 C OM 947 Page 31 9 4 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 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm Cradle Gun and Rest Hand on Workpiece End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS OM 947 Page 32
10. 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 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 casque 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 e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e 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 pa
11. o If unit overheats thermostat s opens output stops and cooling NN fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty Output Amperes 5 EX 60 80100 Duty Cycle 2096 duty cycle at 85 amps 8 Minutes Resting Overheating OR Reduce Duty Cycle m Minutes duty1 4 95 210 517 B The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown HHA f 1 f T f A f y d S A S 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Amperage ssb1 1 10 91 210 518 B OM 947 Page 12 SECTION 5 INSTALLATION 5 1 Installing Work Clamp Connection hardware must be tightened with proper tools Do not just Nut hand tighten hardware A loose electrical connection will cause poor Work Cable From Unit weld performance and excessive heating of the work clamp Work Clamp Screw Work Clamp Tabs Bend tabs around work cable 6 Insulator Grip Slide one insulating grip over work cable before connecting to clamp Slide insulating grips over handles Tools Needed 7 16 in 5 7h Gin Ref 802 456 OM 947 Page
12. 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 4 1 voir les nor mes de s curit e 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 Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile 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
13. tube Separate gun handle halves Remove black sleeving from end of replacement liner Loosen and remove retaining nut from liner Pull liner out of gun cable If necessary twist gt cable to ease removal Install retaining nut on one end of liner Lay gun cable straight on a flat surface Insert bare end of liner end without retaining nut into wire drive end of cable Push liner toward gun If necessary twist cable to ease installation Ref 804 241 A 803 497 A 803 837 A 803 899 A OM 947 Page 26 7 7 Replacing Gun Liner Continued D Ex Lk 13 46 in 21 mm When liner exits cable at gun handle guide liner into head tube Continue to push liner until it exits end of head tube Insert retaining nut into adapter and adjust liner stickout as shown Tighten retaining nut Reinstall cable end into drive housing with retaining grooves inserted into the two retaining ribs Be sure to position gas hose up Position liner in groove so that end is flush with back of groove adjust if necessary 3 8 in 10 mm Be sure that cable is straight Tighten liner setscrew Cut liner so that 3 8 in 10 mm sticks out of head tube File down any sharp points on liner after cutting to length Reinstall cover onto wire drive assembly and secure m with screws 3 Reassemble gun by placing head tube and cable into one half of handle Be 5 ET sure trigger is properly
14. 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 287 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 implants 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 or drape cables around your body OM 947 Page 4 For Gasoline Engines Eng
15. 13 5 2 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work Clamp FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal GMAW Solid wire with DCEP Reverse polarity Connect to positive out Connect to negative output shielding gas put terminal terminal Unit must have MIG conversion kit 195 158 installed 5 3 Changing Polarity 1 Lead Connections For Direct Current Electrode Negative CHANGING DCEN POLARITY Lead Connections For Direct Current Electrode Positive DCEP DCEP Electrode Negative Electrode Positive Always read and follow wire manufacturers recommended po For Flux Core Wire For Solid Wire larity and see Section 5 2 Close door HOLDER Ref 210 428 OM 947 Page 14 5 4 Installing Gas Supply Tools Needed 3 11 16 1 1 8 in 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 This Section only applies to MIG units or units equipped with MIG kit Instal
16. 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 C 2010 Hobart Welding Products 2010 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 1 877 Hobart1 HOBART WELDERS
17. Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Warranty Questions Call 1 800 332 3281 7 5 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 331 WARRANTY Effective January 1 2010 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and 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
18. assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans 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 ru SALETES peuvent provoquer des blessures dans les yeux Le soudage l caillement le passage de la pi ce la brosse en fil de fer 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 e 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 cas de non utilisation e Veiller toujours bien a rer les espaces 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 d
19. at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before 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 11 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 947 Page 35 9 12 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration 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 0 to 15 degrees to achieve maximum penetra
20. 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 e 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 e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e 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 wel
21. 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 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 947 Page 37 SECTION 10 PARTS LIST Hardware is common and not available unless listed 803 446 B Figure 10 1 Main Assembly OM 947 Page 38 Item Dia Par NO Mkgs Description Quantity Figure 10 1 Main Assembly le ROREM 210 432 CASE SECTION front bottom rear 1 MC PER Beh 210 530 5 BLANK e
22. 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 Miller s 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 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 WARRANTY 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 th
23. cause fire on the hidden side e 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 e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e 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 e Do not use welder to thaw frozen pipes OM 947 Page 2 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 butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free 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 BUILDUP OF GAS can injure or kill Shu
24. eed LE e e wats ged 1 io PEUT 196575 SWITCH fOGKER SDS auus o dot EU Erg eo s eed ord 1 o 209879 POTENTIOMETETR 2 4 reprenda ran Re ic Xu 1 220432 TON o ia drerit ra dere Dra heated 1 ET D endo ana 211 338 KNOB DOING dr do wean mien mere te esta 1 Soin Do 207 079 KNOG DOME qa mi n 1 uo 210 398 BUSHING snap in 1 EOM Im 209 412 BUSHING snap in 500 dia 2 OPERE CPP ERE 209 532 DRIVE assy Wire m RR RR eee eee eee 1 NS at are LO ER 193 144 INSULATOR output stud 1 Uo HET 202 720 JAADAFTEB SOOO AUDE de s oes tot 1 eoo eR Barge 202 998 SPRING CDS i ada vids 1 uci EM 204 608 xc NUT si Men Rule que TRE CU ER a 1 CTETUR 209 022 WASHER ERE EE aud es ue a et Qi ot acd ied 1 RS 195 157R H 9B GUN 8 ft 023 035 1 NI 210428 baw Dot uo 1 Wo PER LET 204 036 LABEL w
25. installed into 4 ur er P D anale over trigger slot ead tube and cable Slide locking rings over top and bottom of handle and secure by twisting rings clockwise 1 4 turn Thread welding wire through gun see Section 5 9 Reinstall adapter contact tip and nozzle OM 947 Page 27 7 8 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 5 7 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 if open 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 2 Be sure that Voltage switch is not set between ranges see Section 6 1 Disassemble torch handle and check trigger switch lead connections tighten or reconnect any loose connections No weld output wire feeds Connect work clamp to get good metal to metal contact Check cable connection at work clamp and tighten hardware if necessary see Section 5 1 Replace contact tip see Section 7 5 Check for proper polarity connections see Section 5 3 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switc
26. r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle 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 Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service AY 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
27. related equipment For information on other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 AS Hob Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 USAC Cie cocer oC EUR AUS RO NC ele EUR RODA REX RUN 1 152 Are Welding Hazardo 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1595 P ncipal Safety Standards eu condit dees biked pede wage dL lt 4 156 EDP TORI OM su arsed aio d Da rr d dL eti e De dah ho dn d i Rc e i 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 ac Belo e cras d ir ta diee d ei rt 5 2 2 Dangers relatifs au soudage larc eene 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance
28. 5 410 25 erem ba 1 Rave 210 970 LINER monocoil 023 035 wire 8ft 1 s WT 087 299 contact scr 023 wire x 1 125 D M REPE 000 067 TIP contact scr 2030 wire x 1 125 1 TE NCC NE 000 068 contact scr 035 wire x 1 125 CR NP 226 010 NUT liner retainer 1 P 226 080 MANDLE ASSY im ue ede E sete MISERE PEARL re a 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Table 10 1 Contact Tip Options HOBART PART NO DESCRIPTION REMARKS 196 134 Tip contact scr 023 wire Pkg of 5 196 131 Tip contact scr 030 wire Pkg of 5 196 132 Tip contact scr 035 wire Pkg of 5 196 137 Nozzle slip type 500 orf flush Qty 1 196 135 Adapter contact tip Qty 1 WELD IT PART NO DESCRIPTION REMARKS 770 174 Tip contact scr 023 wire Pkg of 5 770 177 Tip contact scr 030 wire Pkg of 5 770 180 Tip contact scr 035 wire Pkg of 5 OM 947 Page 40 5 9 803 442 Figure 10 3 Wire Drive Assembly Item Part Description Quantity 209 532 Figure 10 3 Wire Drive Assembly TE Pu EET 212 S T x BEARING
29. 7 2 4 Proposition californienne 65 5 8 2 5 Principales normes de S curit suos sauce dee Rea et mes Ace Re Roa eel 9 2 6 Informations relatives aux hs 9 SECTION 3 DEFINITIONS eee dew neers VE ICE E P EE Ie RET CES 11 351 Symbols And t 11 SECTION SPECIFICATIONS xx P aa hears qur sri ess 11 4 MS loa edu Ordo Lis a em Cut fe 11 4 2 Duty Cycle And Overheating sel eee hia des EE oes tia dad outs Dead 12 4 3 QUIVOS sn RO od OR Ac AGREE d oat AO EGRE OR es 12 SECTIONS INSTALEATION earth atr gees shake RU n ie e x en m b c ees 13 5 1 Installing Work Clamp xe RH ERREUR ERE RUE v ERE 2 13 5 2 Process Polarity Table xe ERE ERR REIR inde name 14 5 3 Changing Olay OU ORE RC ERA Oe RR TERR RE REED 14 54 Installing GaS SUPPI ELLE e de adele E wee 15 5 5 Installing Wire Spool And Adjusting Hub Tension 16 5 6 Serial Number And Rating
30. CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes Pr voir une p riode de refroidissement avant 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 consommables 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
31. FR QUENCE H F risque de provoquer des interf rences Le rayonnement haute fr quence 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 Sile 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 de provoquer des interf rences e 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 cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Vei
32. 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 Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but 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
33. LIMS S310N3Q 310N 39VL1OA LLOId 1 LOY L971d L9 Q4VO8 lOMNINOO 2777 O w399hL NNS 2777 SNVAL 27 AIG 22 77 lt SVO TWNOILdO HOLIMS LS gz 9 YO NYP a NIV 1d x 192 HIG TINAA T YO LAM 230 950 A ircuit Diagram Figure 7 1 C OM 947 Page 29 SECTION 9 WIRE WELDING GUIDELINES 9 1 Typical FCAW Process Connections Wire Feeder Power Source Y BH TS 42 3 oe NA Self Shielding Flux Core Wire 9 2 Typical MIG Process Connections Regulator Flowmeter Wire Feeder Power Source Shielding Gas Gas Hose Solid Wire OM 947 Page 30 Gun B RE Work Clamp 4 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 o Q Workpiece fcaw 1 2003 Ref 803 444 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 Gun EIR Work Clamp o Q Workpiece light mig 5 967 Ref 803 444 A 9 3 Typical Control Settings These settings are guidelines only Material and wire type joint design position shielding gas etc affect settings Test welds
34. Label Location 17 5 7 Selecting A Location And Connecting Input Power For 115 Model 17 5 8 Installing Contact Tip And Nozzle 22 18 5 9 Threading Welding Wire its kr eR e RUE REOR anes aay eke Re RC A e ek 19 SECTION 6 OPERATION anse ann sn baer eee SR ive RENE me Civ RU 20 61 CONTOS ae RO RO aU ae ee ROLE nus en dun een 20 6 2 Operating The Gio eraras does ce RC Een o c ROO RC De aie oe ee Eden dr SUR 20 6 3 Weld Parameter Chart su oe oce o n OR a RERO ROO x Oe CHR ORO OR OR d De t 21 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 22 7 15 ROWING MaMIenanCe exce oe Saee ek UE ur aloes Rx a Ges xir nals 22 7 2 ONVerload azote Ead cer EE ad CUPS ME tease 22 1 9 Drive Motor PIDIeCIIONE pirs esu usant rame Hare CE E OE KE eR Gp tri a 22 7 4 Changing Drive Roll Or Wire Inlet Guide 23 7 5 Replacing Gun Contact 24 T6 CICAMING REI Ra a eee ae 25 1 1 Replacing GUM LIBE Ra MAT 26 7 8
35. SOJUIEIS 9JIM POS 104 ___ __ 62 7 0c Sc i eoueJeeddy Sn Son DOLS Ee econ 50 v 08 Y 09 amp 0572 GY vzo 92 9 S0 u3 SEn E TS SPD 529 SAM PHOS 1991109 au 1461 uo suornonajsul ou ees jou OU ui eq plousjos seb y p nb si 5 seb soiim oui pifczremsl eer cee EE 0 V 0 0 7 gi z 60 RER Gee Se RE 06 0 02 1 uwgo 0co P 1nbeu seo bups on 9109 uu 9 peso 06 0 YOU 9L YOU 8 1 zz pz OJIN ses SIM 9109 104 ed L M 9poJ199 3 ES i Pee 5 USEIS uo SI use s Jo uo JequinN sessed ejdninui pue uoneiedeid enbiuyos ONIONVH2
36. arning eee eens 1 ve OD dus quo 208 820 c CEAMP WOK s aera n Its eu b e bue xo Wird 1 cr T 196 61 98 gt WOK cisnienia mod dad weed bd Em c co itia 1 zh Dodd adde du 209905 ADAPTER das ROSE aedem abu tpe det qu 1 sco METRUM 209907 TUBING PVG cds SEM o tit eee dees ee 1 216 397 VALVE 115vac 2way custom port 1 8 orf w frict 1 197 198 CABLE TIE 2 ERE 2 Sibel eee 137 761 NUT 750 npt 1 31hex 27h nyl blk 1 Too xcv LABEL nameplate order by model and serial no 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 947 Page 39 5 See Table 10 1 804 243 A Figure 10 2 H 9B Gun Item Part NO No Description Quantity 195 157R Figure 10 2 H 9B Gun A UPPER 169 715 NOZZLE slip type 500 orfflush 1 TE ME 226 190 NOZZLE flux cored slip type 1 I 169 16 o ADAP VER esie tor ERE ERR ba td Het 1 22
37. bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal 5 0052 8 947 34 9 9 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that neo cool to solid form near weld bead 7 5 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before 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 9 10 Troubleshooting Porosity ENS Porosity small cavities or holes resulting from gas pockets in weld metal LL 5 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding 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
38. 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 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 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
39. 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 947 Page 9 947 10 SECTION 3 DEFINITIONS 3 1 Symbols And Definitions A Amperage V Voltage H Z Hertz Negative Positive dico un 1 single Phase Input Output 6 Voltage Input Q Off Do Not Switch G Gas Metal Arc Flux Cored Arc E While Welding ok Welding GMAW WI gt Welding FCAW SECTION 4 SPECIFICATIONS 4 1 Specifications Amperes Input at Rated Welding Amperage esti Rated Load Output KVA KW Weight Overall Output Range DC g 115 V 60 Hz Single W Gun Dimensions Phase Length 16 7 8 in 85 A 17 5 Volts 429 mm DC 2096 Duty Cycle 20 2 90 2 50 50 Ib 30 125 26 po ee 60 A 20 Volts DC 15 2 202 177 251 2096 Duty Cycle Height 12 1 8 in 808 mm Flux Cored Solid Wire Type Stainless Wire Feed Speed Range And Dia 030 035 in 024 030 in 0 500 IPM 0 13 m min At No Load 0 8 0 9 mm 0 6 0 8 mm 0 415 IPM 0 11 m min Feeding Wire CSA Rating When shielding gas is required MIG conversion kit 195 158 must be installed OM 947 Page 11 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating
40. d e 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 e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection FRA WELDING can cause fire or explosion 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 doing any welding e 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 e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can
41. de 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 Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE 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 la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur 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 la terre de mani re incorrecte ou impropre constitue un danger 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 de
42. e 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 WELDERS warranted separately by the manufacturer hobart_warr 2010 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 otate Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Contact your Distributor for 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
43. e 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 gerles 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 Tenir les bouteilles loign 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 D tourner votre visage du d tendeur
44. e 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 Indicates special instructions e a gt 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 Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord 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 po
45. ectrum Way Suite 100 Ontario Canada LAW 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 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 A
46. ee ieee ees 1 EE 210133 BAFFLE COC nescit eri mma aedi UTERE Ea 1 urea eta ceed trs 1210434 WRAPPER COVER nc be ice ence e td be c ted b oe ne 1 e Ree LT 210485 DOOR ACCESS dti ute o Med e RE esr e 1 SO jor Rs 219 643 BEZEL TONG o seri uei A MR eee 1 vm 196 006 HINGE door access 2 Er 207 587 CIRCUIT CARD ASSY 1 DE RN PUNCTUM 134 2015 oo STANDOFF i errare UR ae beta a 6 ETE 2 09 35 BEOTIEIBE d oes OI eda dal ete 1 NL ERE NE 209 392 BUS BAR output positive 1 193 194 BUS output negative 1 On MP 210 109 SUPPLEMENTARY PROTECTOR man reset 1P 25A 250VAC 1 54 rito uod 3 BUSHING strainTellefaoi e an PERLE REP bee 1 T ERR 147 545 Eres rate pu pq eue 1 TEL Iw 208 HANDLE o e deco ha 1 n usce stre Mee EE 209 467 MOTOR fan 115VAC 1 Er 210413 enceinte 1 ERES 209 213 TRANSFORMER E e 1 LE ods berated Jaleo tee senten 209 86825 TABIBEIZER nei ter aco
47. f this manual 5 7 Selecting A Location And Connecting Input Power For 115 VAC Model 1 Grounded Receptacle A 115 volt 20 ampere individual branch circuit protected by time de lay fuses or circuit breaker is re quired 2 Plug From Unit Select extension cord of 12 AWG for up to 50 ft 15 m or 10 AWG for 50 up to 100 ft 30 m Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Do not move or operate unit where it could tip 803 443 C OM 947 Page 17 Installing Contact Tip And Nozzle a PSP ETE Flux Nozzle Use with flux cored wire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Push nozzle over contact tip and adapter until it is seated onto adapter Contact tip will be exposed approximately 7 16 in 11 3 mm when installed properly Tools Needed OM 947 Page 18 MIG Nozzle Use with solid or flux cored wire Push nozzle over contact tip and adapter until it is seated onto adapter End of contact tip will be flush with end of nozzle when installed properly A Turn off welding power source 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Thread welding wire through gun see Section 5 9 Slide contact tip over wire and tighten tip into tip adapter Install nozzle Ref 804 241 A 5 9 Threading Welding Wire Wire Spool Welding Wire
48. h in desired position see Section 6 1 If using an extension cord check that wire size and length is the proper size for power rating of welding power source see Section 4 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 5 9 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 5 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 Replace drive roll or pressure bearing if worn or slipping see Section 7 4 Check and clear any restrictions at drive assembly and liner see Section 7 6 Release gun trigger and allow gun and motor protection circuitry to reset Have nearest Factory Authorized Service Agent check drive motor OM 947 Page 28 SECTION 8 ELECTRICAL DIAGRAM engine before servicing e Do not operate with covers removed Have only qualified persons install e o X o 2 o o c ea Disconnect input power or stop WARNING Lal Co 3ALLISOd use or service this unit ELECTRIC SHOCK HAZARD 12 L 57 2 7 SAM N ec 11 LAM HOLON JAXA nal LAHM 62 SONIMAVN HO
49. ine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines 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 43rd 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 Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 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 wor
50. iness Of Bead 916 Trodbleshooling DISIONION SEE d esu atn Rte med edu E E wae Ree Reet 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment SECTION 10 PARTS LIST WARRANTY 30 30 30 31 32 33 34 34 34 35 35 35 36 36 36 37 37 37 38 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2010 03 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 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 DANGER Indicates hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related 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 Only qualified persons should install operate maintain and re
51. k 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 Donot 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 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s 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 DANGER Indique une situation dangereuse qui si on 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 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 gar
52. l regulator flowmeter to cylinder valve Be sure that gauge face is vertical for viewing and adjusting 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source Shielding Gas 802 028 Ref 803 379 A 7 Flow Adjust Turn flow adjust screw to increase or decrease gas flow Flow rate should be set when gas is flowing through welding power source and welding gun Turn Range switch to Purge or Fan Only position Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate OM 947 Page 15 5 5 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set Installing 8 in 203 mm Wire Spool optional hub kit E When a slight force is needed to turn spool tension is set Y Retaining ring used with 8 in 203 mm spool only Tools Needed Que ain Ref 802 971 C 803 012 803 013 947 16 5 6 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 o
53. ller 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 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 Les quipements de soudage et coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait 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 accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat 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 947 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisatio
54. n Pour les moteurs essence Les gaz d chappement des moteurs contiennent des duits chimiques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel 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 4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 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 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 Sp
55. ntact tip Remove contact tip from tip adapter and install new contact tip Reinstall nozzle Tools Needed Ref 804 241 A OM 947 Page 24 7 6 Cleaning Gun Liner Remove nozzle Cut off wire at contact tip and remove contact tip and tip adapter Tools Needed Lay gun cable out straight and blow out liner A Turn Off welding power source 1 Nozzle 2 Contact Tip 3 Adapter UD Hold wire tightly to keep it from unraveling Secure end of wire at spool Open pressure assembly Retract wire from liner onto spool Remove screws 3 from cover and remove cover from wire drive assembly Reassemble drive cover Thread wire according to and gun in reverse order Section 5 9 from taking it apart 804 241 A 803 838 A OM 947 Page 25 7 7 Replacing Gun Liner 1 apr A Turn Off welding power source 7 Tools Needed E x7 B IE 8mm 10mm mun Remove nozzle Cut off wire Open pressure assembly Retract Hold wire tightly to keep it at contact tip and remove wire from liner onto spool from unraveling Secure contact tip and tip adapter end of wire at spool Head Tube on PIA Nu Remove screws 3 from d Loosen liner setscrew Twist top and bottom handle locking rings cover and remove cover 25 counterclockwise 1 4 turn Slide bottom ring from wire drive assembly down cable and top ring forward over head
56. orly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable 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 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 Keep all panels and covers securely in place 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 terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower 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 947 1 FUMES AND GASES can
57. pair this unit 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 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 falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit 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 us
58. 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 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 appropri et contre v rifier les connexions Les c bles 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 entrainer 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
59. 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 e Ne pas toucher des porte lectrodes connect s a deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser 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 facon 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 mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 947 Page 5 Il reste une TENSION DC 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
60. s applicable Do not switch under load Switch must click into detent position for weld output 2 Wire Feed Control Use control to select a wire feed speed As Voltage switch setting in creases wire speed range also in creases see weld setting label in welding power source or Section 6 3 as applicable 3 Power Switch DO SWITCH WHILE WELDING Ref 229 999 C 6 2 Operating The Gun 1 Trigger Switch When pressed energized wire feeds and shielding gas flows if unit is equipped with optional gas solenoid Ref 804 240 A OM 947 Page 20 210 428 D OM 947 Page 21 Jew paads se ons y ui Jed qoux snfpy 1 uo spuedep os e pee qouy pesn M Jo 1 YNEN ued AM Humes si pas poo AIM yams jou pesn Jo dn 1261009 LON 340119 ee 4320 98V 0 V Wt 90 0 xs 2 1 se 06 eeiS 9915 ns PR a nu ee nt Fe XIN HL S
61. s 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 947 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 D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec 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 Le soudage effectu sur un plafond plancher
62. s tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber 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 a 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 conditions utiliser les quipements suivants gt Indique des instructions sp cifiques 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
63. s welding machine is installed and grounded according to this manual e lf 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 947 Page 3 1 4 California Proposition 65 Warnings 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 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 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 Standards 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
64. ssembly up 3 Pivot Tube Plate E 4 Securing Screws 5 Pressure Arm Pivot Tube 6 Inlet Wire Guide Remove screws and pivot tube plate Lift out pressure arm pivot tube and slide inlet wire guide out of tube Slide replacement wire guide into tube and place tube back into drive assembly Be sure tip of wire guide is as close to drive roll as possible without touching A m CS NA Wh Reinstall plate and tighten screws 7 Retaining Knob Rotate counterclockwise and remove knob 8 Drive The drive roll consists of two different sized grooves Each side is stamped with the proper size Select the groove that matches the wire size on the wire spool Install drive roll onto motor shaft so that correct groove size stamp faces out away from drive housing 9 Retaining Knob Opening Install retaining knob by placing opening over drive roll opening faces rear of unit Rotate retaining knob clockwise to secure drive roll Position wire into outer groove of drive roll see Section 5 9 030 035 VK DN 024 Groove Groove Stamped 030 035 4 Stamped 024 Tools Needed t 5 16 in Ref 802 444 B 803 442 A OM 947 Page 23 7 5 Replacing Gun Contact Tip A Turn Off power before replacing contact tip 1 Nozzle Hemove nozzle 2 Contact Tip 3 Tip Adapter Cut off welding wire at co
65. ssociation 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 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 le 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 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
66. ssures 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 Ne pas appuyer sur la g chette avant d en avoir recu 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 a 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 LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les 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 LE RAYONNEMENT HAUTE
67. t Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference 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 e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f 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 shielding 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 electromagneticallycompatible e 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 e Be sure thi
68. t off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical 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 Shielding 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 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 shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain
69. 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 oylinder 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 FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system 15 properly sized rated and protected to handle this unit NEZ FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or 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 OVERUSE can cause OVERHEATING e Allow cooling period follow rated d
70. tion Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed 9 13 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 14 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 947 Page 36 9 15 Troubleshooting Waviness Of Bead D ae Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal
71. uty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face 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 J 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 2 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 50 Do not point gun toward any part of the body other people or any metal when threading welding wire 2 5 MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place d D Have only qualified persons remove doors panels covers 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 uni

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