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Handler 140 And H100S2-10 Gun

1. WOOD c Be sure that tip matches wire diameter Feed wire to check drive roll pressure Reinstall contact tip and nozzle Tighten knob enough to prevent slipping Cut off wire Close door Ref 804 623 A OM 925 Page 21 SECTION 6 OPERATION 6 1 Controls 3 T 100 e 4 DO NOT SWITCH WHILE WELDING NE PAS CHANGER DE PROC D Ref 251 222 A 1 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting increases wire speed range also increases see weld setting label in welding power source or Section 6 2 2 Power Switch 3 Voltage Switch The higher the selected number the thicker the material that can be welded see weld setting label in welding power source or Section 6 2 Do not switch under load Switch must click into detent position for weld output OM 925 Page 22 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 925 Page 23 6 2 Weld Parameter Chart NS
2. 1 Dun OO iude Pag er 216830 Label Warning 2 1 TED 134 20 st Stand Off cic de Savana Xe A ae EEG eO AA 4 ELM S2 id 229432 Switch Rotary 1 Dig du uud R2 209 873 Potentiomet r ceri ves necem eR SR PERCIPIT ea 1 QU hen A NIU 231528 Panel Front W Nameplate 1 Nox SUPR 208 820 lt Clamp Work ix eva tr a ee aa RA EE Dex 1 A dux 196 619 Gable Wo pere a TAA SA e RA AR 1 40 St 196 575 Switch Rocker SPST 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 925 Page 43 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly Continued sud to eod RR 207 079 Knob Pointer Voltage 1 AO acsi as 211338 Knob Pointer Wfs 1 43 DM 217 778 x Motor Gear saut dre a bL PE d E eu 1 P M 193189 Connector Gun 1 E ear is a RH inte 196 654
3. 22222222 9 SECTION S DEFINITIONS 7 eoo re ea ee 11 351 Symbols And Definitions rtr CER A Pr PEE TENET 11 SECTION 4 SPECIFICATIONS reor ek E ne mn ee E ER a NNN ee Ee Rn d 11 4 1 SPECIES 11 4 2 Duty Cycle And Overhealing oreet emm eae ee Ee RU E E s Yd 12 4 3 Volt Ampere Curves 2 ss sede Rt gine seals ERN EU en detente es 13 SECTION 5 INSTALLATION coed 22 2 a DAN SEET SE 14 5 1 Installing Welding Gun 14 5 2 Installing Work Camp 14 5 3 Process Polarity Table 2 eo er a hia eed ER KEE nn ne a MEET EN REN NER 15 5 4 Changing Polarity as men pa BEP REEF EU 15 5 5 Installing Gas Supply is a A ee b P ER en ee 16 5 6 Serial Number And Rating Label Location 22 17 5 7 Selecting A Location And Connecting Input Power 2 17 5 8 Installing Wire Spool And Adjusting Hub Tension 18 5 9 Installing Contact Tip And Nozzle 222 19 5 10 Threading Welding Wire ssussesesessseese eR IIIA IM hM 20 SECTION 6 OPERATION ix wu urines e ENN diese 22 EEN Ee ee ue EE 22 6 2 Weld Parameter Chart est sms een 24 SECTION 7 MAINTENANCE amp TROUBLESHOOTING cc cece cece eee eee n n nnn 26 1 Routine Maintenance sa tette ici ete a Her ora Ronin ee re Ra BR cce we bu Tec it 26 7 2 O
4. ME aed TEES 226 190 NOZZLE flux cored slip type rar 087 299 TIP contact scr 023 wire x 1 125 SHOT RS Res 000 067 TIP contact scr 030 wire x 1 125 Me ne ne 000 068 TIP contact scr 035 wire x 1 125 212 reves 000 069 TIP contact scr 045 wire x 1 125 WE A 170470 RING retaining 442 EE 169 716 ADAPTER contact tip den ran er egen AE Seet ms 246 378 2 TUBE head ii Ada I BEE dus 243 865 702 NUTREN d art dee ud press 242 832 2 HANDLE eut nn sr kb D rennes 225410 SWITCH trigger Orson 246 380 HOUSING power pin WW La WEE 245 927 CONNECTOR feeder Sh 197 123 O RING 312 ID X 062 70 duro buna n T2 LR 194 010 LINER monocoil 023 025 wire x 15ft consisting of 12 mx 194 011 LINER monocoil 030 035 wire x 15ft consisting of KEE EE 194 012 LINER monocoil 035 045 wire x 15ft consisting of CRE 079975 O RING 187 ID x 103CS rbr OPTI
5. SECTION 11 ACCESSORIES CONSUMABLES WARRANTY 32 32 33 34 35 36 36 36 37 37 37 38 38 38 39 39 40 40 42 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 the 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 whene
6. 41 BK BK mE b FA se 77 SWITCH RS AA J NINO o Mr NOTE DENOTES SWITCH NEGATIVE d TERMINAL MARKINGS 24 vac ER Jd RC4 PLG4 HT lt 3 lt gt gt RC2 9 RC2 4 24 MAT lt 4 lt 210 gt gt RC2 10 27 RC2 11 RC2 5 lt k 25 CR CONTROL BOARD i m RC2 12 pc Ride RED f RC6 PLG6 fo 3 ar lt 1 lt 21 RC2 1 MRE DRIVE S9 oE BLK 2 ao o ar z 14 RC1 2 4 89 959 PLGS__ RCS 25029 8 59 8t RC2 PLG2 RC2 6 28 35 23 Evo d 21 RC2 7 lt gt gt CONTROL 0 S25 GUN 28 S 28 FE TRIGGER o gt RC2 8 de gt gt See Se gt 2 gt gt gt RC2 2 52072 a gt 2285079 3 S259 y 3 29558 a sar ee ee 4 WARNING gt D ELECTRIC SHOCK HAZARD OM 925 Page 31 it Diagram Ircul Figure 8 1 C SECTION 9 MIG WELDING GMAW GUIDELINES 9 1 Typical MIG Process Connections 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 ech gt t Workpiece d LA Work Clamp Shielding Gas Ref 801 909 A OM 925 Page 32 9 2 Typical MIG Process Control Settings CS These
7. 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 utilisation 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 pe
8. Screw Thumb 4 oe urn van aaa an ATE can RR TE HD DATED RC REC 1 Dead ede aeter 230012 Fitting Gas Barbed 1 EE ERR 202 925 Roll Feed 024 in 030 035 in Depending On Serial No 1 A rs 246565 Roll Feed 030 035 V And VK Grooves Depending On Serial No 1 er AO ee 194 508 Head Feed Assy 1 A en an 203 025 Guide Wire Inlet 1 Fst bise ta c SER 217 618 Label Weld Chart 1 iUd DO agree eese 221079 Label Weld Chart French 1 E xil LA 204 7011 LG a el Dr A En A 1 a D2 eco CRS 37217 584 Gontactor u ee ee 1 EE tint 203 572 Label Warn Gen Precaution En Fr Models Only 1 Okres Label Nameplate Order By Model And Serial Number 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 925 Page 44 246 670 A Quantity Figure 10 2 H100S2 10 Gun Item Dia Part No Mkgs No Description 245 924 Figure 10 2 H100S2 10 Gun npe in 169 715 NOZZLE slip type 500 orf flush
9. 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 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 tilly VA 20151 telephone 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 co
10. 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 246 565 030 035 8 and 9 V and VK Groove 11 4 Regulator Flowmeter PART NO REMARKS 221 037 For Argon and Argon mixed shielding gas Use with 770 198 replacement hose 222 874 For CO shielding gas Use with replacement gas hose d 212 492 144 108 Available at farm and tool supply retailers Available at Hobart Miller welding distributors 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 925 Page 46 Warranty Questions Call 1 800 332 3281 7AM 5PMEST 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 applies 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 Ho
11. 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 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 not coil or drape cables around your body OM 925 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 r
12. 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 925 Page 36 9 8 Troubleshooting Excessive Spatter ann Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead AD 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 Poro
13. 2 RH LER timer tee 147545 Cord Set 125v 5 15P 14ga 3 C 7ft SPT 3 JKT 1 xe lO esee d vs 111 443 Bushing Strain Relief 1 DE N RE RR cd ufi 137 761 Nut Gas Valve 1 x Os FM 196 063 Motor Fan us oe reve Y epe ati 1 Iu ic FREIER EE 409 953 001 Blade Fan Cooling 1 scu OO era c A ees 217 096 Transformer Power Assy 1 icd sme 208015 Handle Carrying 1 BEN EEE 1960 005 Wrapper issus trete kanal Ra 1 BEER EE 204036 Label Warning 2 1 ee t24 EE 203 491 Clamp Capacitor 1 TP IEEE GH xus 193 039 Capacitor Electit 5S3000uf 1 TED ET ZI es bas 203 868 REACTION ASS Vote an aa aa rase b de 1 CIA ONERE SRI 193191 Rectifier Assy 1 mU ER 193193 Bus Bar Positive eset sd une am a a Ie pn AR ex re Y dna 1 Dn 217 831 Baftle Genter iria a RE Rec CRY dh a REA 1 au cU 405 576 001 Bushing Terminal 1 RC HP AA ms 193 144 Insulator Output Stud 1 Kia Sr een 193 194 Bus Bar Negative
14. CB1 protects unit from overload If nm CB1 opens unit shuts down o Reset supplementary protector e e t J d 802 441 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 925 Page 26 7 4 Changing Drive Roll Or Wire Inlet Guide Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two different 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 10 4 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot m gt X Eu 1 Inlet Wire Guide Securing Tools Needed E Actual drive roll may differ from that shown See Section 11 3 for additional drive roll configurations 030 035 Groove d 023 025 Groove Stamped 024 Stamped 030 035 Ref 803 714 A 7 5 Replacing Gun Contact Tip A Turn Off power before replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Re
15. 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 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 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
16. 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 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 utili
17. 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 RS 1 8 or 0 125 in Convert Material Thickness to P Amperage A A 0 001 in 1 ampere 0 125 in 125 A 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 023in 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 6x 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 925 Page 33 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 Ex
18. slash is Wire Feed Setting is AA 18 ga 16 ga 11 ga 048 in 060 in 1 8 inch 3 16 inch 1 4 inch DCEN 1 2 mm 1 6 mm 3 2 mm 4 8 mm 6 4mm Electrode Negative 1 30 2 00 310 um For Flux Cored Wire A PRES 2 20 3 50 3 30 3 40 3 20 4 30 Electrode Positive For Solid Wire 4 25 2 30 3 40 2 15 3 10 3 90 ao Wire Speed listed is a starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleanliness of metal etc 217618 Make sure that hub tension is not too tight and keep the torch straight as possible A push angle for the torch is recommended 217 618 A OM 925 Page 25 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance A t e ei sch A Disconnect power D ZAS Ex before maintaining So af Maintain more often during severe condi tions y Check Change Clean X Replace Reference To be done by Factory Authorized Service Agent WARNI A ES AU de G d Wa x Damaged Or Unreadable Labels Repair Or Replace Q Clean And Tighten Weld Cracked Weld Cable Terminals 6 Months Q Inside Unit 7 2 Overload Protection N e 1 Supplementary Protector CB1 D DP 1
19. 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 Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open feedhead 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 Ref 804 654 A 802 441 Ref 804 623 A OM 925 Page 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 of this manual 5 7 Selecting A Location And Connecting Input Power ar Q e 9 Do not move or operate unit 460 mm where it could tip 18 in 460 mm 1 Grounded Receptacle 2 Plug From Unit A Special installation may be A 115 volt 20 ampere individual branch Select extension cord of 12 AWG for up to required where gasoline or volatile circuit protected by time delay fuses or 50 ft 15 m or 10 AWG for 50 up to 100 ft liquids are present see NEC circuit breaker is required 30 m Article 511 or CEC Section 20 803 712 C OM 925 Pa
20. ER 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 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 hobart_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 Reso
21. ES A CU Welding Guide for 115 Volt Settings are approximate Adjust as required Thicker materials can be welded using proper technique joint preparation and multiple passes Material Wire Type Suggested Diameter Being and Shielding Gas of Wire Welded Polarity Setting 20 30 cfh Flow Rate Being Used Flux Cored No Shielding Gas Required 030 0 8 mm i ae NEN Steel E71T 11 Good for Windy or DCEN Outdoor Applications Eu 0 9 mm eue Solid Wire C Gas Mixture Stee E 75 Argon 25 CO oem 2m DCEP Produces less Spatter EA A He Better Bead Appearance 035 0 9mm Solid Wire A A E Steel me ES 030 0 8mm DCEP Die A E 035 0 9 mm ES Om 0 6 mm Stainless T a Steel Steel 90 He 7 5 Arl2 5 CO 030 0 8 mm DCEP Aluminum 030 0 8 mm Aluminum ie 100 Argon DCEP EC 0 1 Match feedroll groove to diameter of wire being used CAUTION Do not change Voltage switch position Set Tension Knob Setting to 3 at start while welding See owners manual for Adjust tension per instructions in the manual more information Multiple passes required Aluminum wire is soft so feedability is not as good OM 925 Page 24 Wire Welding Package Recommended Voltage and Wire Speed Settings for thickness of metal being welded Number on left of slash is Voltage Setting Number on right of
22. N Jg B L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT P 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 ei 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 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 gt 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 925 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
23. N OM 925 217 694H NZ an 2011 08 HS ANE WELDERS Description SC Arc Welding Power Source And Wire Feeder Handler 140 And H100S2 10 Gun ED www HobartWelders com 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 150 9001 REGISTERED 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 specification sheets To locate your nearest distributor or service agency call 1 877 Ho
24. ONAL 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 925 Page 45 SECTION 11 ACCESSORIES CONSUMABLES 11 1 Accessories PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 Ib 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg max 195 186 Protective Cover Weatherproof Nylon 11 2 Consumables Item Hobart Package Part No Miller Package Part No Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 770 177 5 per package 000 067 10 per package 035 in 0 9 mm 770 180 5 per package 000 068 10 per package MIG Nozzle Standard 770 404 169 715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716 Wire Inlet Guide 203 025 Replacement Liners 023 025 in 0 6 mm 196 139 194 010 030 035 in 0 8 0 9 mm 196 139 194 011 035 045 in 0 9 1 2 mm 196 140 194 012 Available at farm and tool supply retailers Available at Hobart Miller welding distributors 11 3 Replacement Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PARTNO INCHES mm 237 338 023 025 6 and 030 035 8 and
25. Page 19 5 10 Threading Welding Wire 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 Tools Needed E Hold wire tightly to keep it from unraveling 2 d RE EX I lt gt 6 in Open pressure assembly Make sure 150 mm feed roll is set to correct groove to match wire size see Section 7 4 Pull and hold wire cut off end 4 in TR 102 mm es 4 Straighten approximately 3 or 4 inches 76 or 102 mm of wire before inserting wire into guides Push wire thru guides into gun continue to hold wire OM 925 Page 20 FF Use pressure indicator scale to set a desired drive roll pressure Start 5 Tighten with a setting of 2 or 3 on the scale Pressure I Indicator Scale j Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire F Turn power on Be sure that Voltage range Press gun trigger until wire comes out of gun switch is set to range 1 2 3 or 4 to feed wire Keep gun cable as straight as possible Rotate knob until it clicks into detent Wire will not feed if range switch is set between ranges Tighten
26. 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 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 b
27. age Correct Gun Fully Seated 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew Insert end of gun through opening in front panel until it bottoms against drive assembly Tighten thumbscrew Welding gun must be inserted completely to prevent leakage of shielding gas 4 Gun Trigger Leads Insert leads one at a time through gun opening on front panel Connect female friction terminals to matching male terminals in unit Polarity is not important Close door Ref 804 623 A 5 2 Installing Work Clamp D Tools Needed 7 16 in E 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 TES 22 7 16 in 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 O E ND A Slide both insulating sleeves over handles 802 456 A OM 925 Page 14 5 3 Process Polarity Table Process Polarity Cable Connections Cable To Gun Cable To Work GMAW Solid wire with shield ing gas DCEP Reverse polarity Connect to positive out put terminal Connect to negative output terminal FCAW Self shielding wire no shielding gas DCEN Strai
28. and tighten until nuts are tight 9 Install handle half with secure with screws Remove from vice install switch housing Tools Needed LS XL 19mm Ref 243 840 A OM 925 Page 29 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 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 2 Check Voltage range switch position Rotate knob until it clicks into detent at desired range setting Secure gun trigger leads see Section 5 1 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 4 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during welding Straighte
29. as 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 mis la piece 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 925 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 PIECES 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
30. ative Positive m ae 1 ENS Single Phase Input gt Output y Voltage Input O Off On Do Not Switch G Gas Metal Arc KN SS While Welding ab Welding GMAW olo Wire Feed ix Ene Conector Suitable For Single Phase Welding In An Transformer Environment With O Percent Rated No Load Ee O Voltage Rectifier Increased Risk Of 0 Rated Supply Rated Supply Rated Welding U 1 Voltage U 2 Load Voltage l 1 Current Current X Duty Cycle 4 1 Specifications 3 Amperes Input at Rated Welding Amperage geh Rated Load Output KVA KW Weight Overall Output Range DC g 115 V 60 Hz Single W Gun Dimensions Phase Length 19 1 2 in 90 A 19 Volts DC 495 mm o 20 Duty Cycle 20 2 90 2 30 571b Width 10 5 8 in 25 140 28 26 kg 27 63 A 21 Volts DC 15 2 0 177 20 mm 20 Duty Cycle Height 12 3 8 in 314 mm Solid Flux Cored Aluminum 3 N Wire Feed Speed Range Wire Type Stainless And Diameter 023 035 in 030 035 in 030 in 50 740 IPM 1 3 18 8 m min At No Load 0 6 0 9 mm 0 8 0 9 mm 0 8 mm 40 700 IPM 1 0 17 8 m min Feeding Wire CSA Rating OM 925 Page 11 4 2 Duty Cycle And Overheating 200 140 100 80 60 40 Output Amperes 20 10 4 6 8 10 20 40 60 80100 Duty Cycle 20 duty cycle at 90 amp
31. bart 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 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
32. bartl or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 2009 09 5 3 1 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 RAN THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Us ii oo sede mead DE NUN RERO MERE EX RU EE XR RN ER 1 1 2 Arc Welding Hazards rast ERRARE ECKE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 4 1 6 EMF Information u A DECLA E Orr ERRARE rhe era RU RIDES 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 3 Symboles utilis s Der anna an x ISP I RB see iad 5 2 2 Dangers relatifs au soudage larc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM
33. ctor 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 SECURITE 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 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 to
34. e 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 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 nl OM 925 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 a
35. e 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 PF 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 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 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 electrod
36. eaving 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 925 Page 38 9 14 Troubleshooting Waviness Of 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 925 Page 39 9 16 Common MIG Shielding Gases T
37. een 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 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 OTH
38. eproductive 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 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 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 do
39. erted 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 between 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 925 Page 40 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 connect
40. 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 fumees 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 o
41. ffice Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 telephone 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 amp te et le torse aussi loin que possible du materiel du circuit de soudage 5 Connecter la pince sur la piece 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 925 Page 9 OM 925 Page 10 SECTION 3 DEFINITIONS Electric Shock 3 1 Symbols And Definitions A Amperage V Voltage H Z Hertz Neg
42. ge 17 5 8 Installing Wire Spool And Adjusting Hub Tension ES Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set a 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 Align locking hole in spool with locking pin on spool hub with 8 in 203 mm spool only Tools Needed coc c SE caes 803 012 803 013 B Ref 802 971 C OM 925 Page 18 5 9 Installing Contact Tip And Nozzle 3 Tools Needed MIG Nozzle Standard 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 Flux Nozzle Optional 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 Ze Te A Turn off welding power source 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Thread welding wire through gun see Section 5 10 Slide contact tip over wire and tighten tip into tip adapter Install nozzle Ref 246 669 A OM 925
43. ght Polarity Connect to negative output terminal Connect to positive output terminal 5 4 Changing Polarity 3 T Lu CHANGING POLARITY DCEN Electrode negative for flux cored wire Electrode positive for solid wire 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturers recommended polarity and see Section 5 3 Close door Ref 209 228 Ref 209 229 Ref 804 623 A OM 925 Page 15 5 5 Installing Gas Supply oe DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional CO gas regulator flowmeter 4 P d Argon Gas Or Mixed Gas oc e Tools Needed gt IZ 5 8 1 1 8 in Feedhead Pressure Assembly Open Feedhead 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 Oylinder 4 Regulator Flowmeter Install so face is vertical
44. h 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 925 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 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 Device
45. his 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 ke 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 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 ins
46. ia 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 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 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
47. ide 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 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 suc
48. ien 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 e 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 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 piece la terre ou une lectrode provenant d une autre machine Ne p
49. ion between weld metal and rm 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 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 w
50. ions Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 925 Page 41 SECTION 10 PARTS LIST 22 Hardware is common and not available unless listed 803 716 B Figure 10 1 Main Assembly OM 925 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly BT Rn 199566 Door ACCESS ii gl RI A A A St 1 u bein eau 196 006 Hinge Door 2 Zac A s e et 211 887 Hub NUE Gd uice bra I br TE a a DER b dua b ids 1 su s ai anie ei goi ACER 204 608 NUL i aa aa 1 Tc EE 202998 Spring CPRSN 1 GNI I MR EE 203 072 lt Washer Flat oia te e Fc Rae e Ac ao an Vo 1 SUE ELEC 211 339 H b SpOOl ues asus Iced TOR er er Rede cC dept da 1 zv I ec pc ups 202 726 Adapter Spool Hub 1 I en PC1 217072 Circuit Card Assy Control 1 sx sut een 195999 Base LoWer u ve serve I eed ba Vaca 1 SUM cages CB1 210109 Supplementary Protector 25 Amp 1 sa Teenie s acid 196 467 Tubing PVC 187 ID x 312 OD x 23 00 1 DEn ic TERME G91 2 216 397 oe Valve Gasse EY hse dd e AE a iege Db Price rea ad 1 iu d eh 197 198 Cable Tie 700 799 Bundle Dia
51. ique 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 conditions 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 entret
52. move nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed Ref 246 669 A OM 925 Page 27 7 6 Cleaning Or Replacing Gun Liner Fr A Disconnect gun from unit Head Tube 10 mm N Remove liner Remove nozzle contact tip and tip adapter gas diffuser Blow out gun casing Lay gun cable out straight before installing new liner To Reassemble Gun Insert new liner Install wire outlet guide so that 1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tighten two full turns more Cut liner off so that 3 4 in 19 mm Sticks out of head tube Install gas diffuser adapter contact tip and nozzle Tools Needed COP Co 3 8mm 10mm Ref 246 669 A OM 925 Page 28 7 7 Replacing Switch And Or Head Tube K gt EI A Turn Off welding power source wire feeder and disconnect gun Remove screws from handle 2 Remove handle half TA es 3 Remove switch housing Install new switch and connect leads polarity is not important Reassemble Secure head tube in vice in reverse order If replacing head tube continue to end of figure 6 Loosen jam nut Remove from vice and turn head tube out by hand 6 Hand tighten head tube into cable connector O Place head tube in vice
53. n gun cable and or replace damaged parts Adjust drive roll pressure see Section 5 10 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 8 Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove Replace contact tip if blocked see Section 7 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 or Section 7 6 Replace drive roll or pressure bearing if worn or slipping see Section 7 4 Secure gun trigger leads or repair leads see Section 5 1 Check and clear any restrictions at drive assembly and liner see Section 5 10 or Section 7 6 Release gun trigger and allow gun and motor protection circuitry to reset see Section 7 3 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 OM 925 Page 30 230 952 A SECTION 8 ELECTRICAL DIAGRAM lt Mi De BLATRIBEED oz BEER 5 eu 1 TU ak CBI 11 F oq p 4 VOLTAGE PLAIN NA NU 2 PRI 2 CAN OR GRN YEL er s2 d 4 9 3 1 J PRI 3 F4 E RC4 PLG4 9 3 POSITIVE lt 1 lt i Or Z PRI 4 2 C1 70 am Ho 1 ES TE Si 1 4 PRI 5
54. ocal 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 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 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 925 Page 3 1 4 Californ
55. 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 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
56. rinder 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 Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards EI 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 43 r MOVING PARTS can injure e Keep away from moving parts such as fans N 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 l
57. s DR D 2 Minutes Welding 8 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling 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 Overheating gt gt I2 x Reduce Duty Cycle Minutes Aor V duty1 4 95 217 623 A OM 925 Page 12 4 3 Volt Ampere Curves 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 30 0 25 0 20 0 Voltage al o 10 0 5 0 0 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 Amperage ssb1 1 10 91 217 624 A OM 925 Page 13 5 1 SECTION 5 INSTALLATION Installing Welding Gun 3 E DA gt Be sure that gun end is tight against drive assembly Z Nc Exposed O rings Incorrect Gun Not Seated will cause shielding gas leak
58. s 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 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 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
59. s 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 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 sufficien
60. sateur 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 accessoires 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 925 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
61. sity small cavities or holes resulting from gas pockets in weld metal LAU m 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 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 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 925 Page 37 9 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fus
62. t 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 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 nn LU 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 g
63. t 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 vapors 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 s
64. tension Stickout PA Solid Wire 3 8 to 1 2 in 9 to 18 mm Flux Cored Wire 1 2 to 5 8 in 5 13 to 16 mm 5 Cradle Gun and Rest Hand on Workpiece 4 M us 0 15 WA A 90 90 T j GE End View of Work Angle Side View of Gun Angle GROOVE WELDS 45 0 1 5 on N X a5 NN End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 925 Page 34 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 l l AS Ss Push P J 10 l Leeeem 2 uua i AA lt lt gt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT k kr Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT er A A Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 925 Page 35 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 gt area in one pass of the electrode 3 EE D S 0054 A 9 6
65. u 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 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 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 925 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel
66. ur 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 dimensionn e et prot g e avant de mettre l appareil en service G LA CHUTE DE L EQUIPEMENT 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 N 94 110 lors du levage manuelle de pi ces ou quipements lourds
67. urant 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 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 O
68. urces 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 Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Na KA HOBART HS
69. utes 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 piece 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 A pu Ne pas toucher aux pieces 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 piece 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 lectr
70. uvent 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 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 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 po
71. ver 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 falling 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 wir
72. verload Protection iere RA ecd ve a ed du e p Co Ye LP Abas 26 4 9 Drive Motor Protectio eaae err c eto i e aee ON ne eC B noto RR Rp Sen 26 7 4 Changing Drive Roll Or Wire Inlet Guide 27 7 5 Replacing Gun Contact Tip 27 7 6 Cleaning Or Replacing Gun Line 28 7 7 Replacing Switch And Or Head Tube 22 29 7 8 Troubleshooting Table 422 rn 30 SECTION 8 ELECTRICAL DIAGRAM sssssee III nnn 31 TABLE OF CONTENTS SECTION 9 MIG WELDING GMAW GUIDELINES s seen 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 9 8 Troubleshooting Excessive Spatter 9 9 Troubleshooting Porosity 9 10 Troubleshooting Excessive Penetration 9 11 Troubleshooting Lack Of Penetration 9 12 Troubleshooting Incomplete Fusion 9 13 Troubleshooting Burn Through 9 14 Troubleshooting Waviness Of Bead 9 15 Troubleshooting Distortion 9 16 Common MIG Shielding Gases 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment SECTION 10 PARTS LIST

Handler 140 And H100S2-10 Gun

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