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Handler 125 EZ And H

1. 9 2 6 Information EME 882 honte NN damien den A d oe Rae 9 SECTION 3 SPECIFICATIONS cono eii da 11 3 14 Specifications c s 0 pm rennais aan ae ah 11 3 2 Duty Cycle And Overheating 444422000422 11 3 3 Volt Ampere Curves e core A A AAA wae es 12 SECTION 4 INSTALLATION 2422 624 ENNER A miens AEN ENER 13 4 1 Installing Work Camp 13 4 2 Process Polarity Table ui A A A 13 DEC PAR O A AR US 13 4 4 Installing Wire Spool And Adjusting Hub Tension 14 4 5 Selecting A Location And Connecting Input Power For 115 VAC Model 15 4 6 Installing Contact Tip And Nozzle 2 16 4 7 Threading Welding Wie 17 SECTION 5 OPERATION a une ee 18 O EE 18 5 2 Operating The QU RE Ee ad RE Sy ae arrete 19 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 20 6 1 Routine Maintenance 2 EES us es REENEN ERNEIEREN d seine martin d 20 6 2 Overload ProtectiOn sieis 80 deat NEE M be RUE dt PME n eue eed ees 20 6 3 Drive Motor Protection sss sas ieee ended amine aan aa are e fade A ARENS 20 6 4 Changing Drive Roll Or Wire Inlet Guide 2 21 6 5 Replacing Gun Contact Tp 44444 22 6 6 Cleaning Gun Linet 44444444 uuee teen eens 23 6 7 Replac
2. D D fo SS o e E an Lo ES 5 Esos 2 256 ge one oore Re 20358558 ED02 50 EENEG KEE g ES ce 8 E D o E 35 2 S os agsars ee ee o S E os Sun E 5 z lt gx 941 v9 OL y D wa OL ZL rz 3 a Y9 ZL 94 z LAM HOLON vo 91 81 l 3NYO 38M 1937138 IWIXILYN ZS 39NV8 TAM 87 FE SONNE Tell JALLVOIN HOLIMS SILONGA 3LON BEED E A A a an S l d 1 EI l MO Y o de O v lud Z Az e 17 3ALUISO4 e der Tom cud F 5 er gt ZS STAS Z lud zZ SANIN BOVLIOA Ta 5 LL K z 10Y K L LON K 8 z0Y K Z08 1191 1108 zI1d ZIY 191d 104 K 194 Lod a yog TOYINOO K 604 lt o o E baal N yout AN O vaant o NND fou gt gt WG SNVUL L 7304 gt 1 gt yy J lal E gt z oC cw zum 9 y 11982 AT q l l 21109 Thm TI OWN vz I a I l l Mid i LL L Z LION SE ENER SE 1 720 TF HOLIMS HIMOd 9 734 ae gt des a ZU NID YO NYI Le NWId SoY y E 185 VE HERR ETA YO LM gt ircuit Diagram Figure 7 1 C OM 923 Page 27 SECTION 8 WIRE WELDING GUIDELINES 8 1 Typical FCAW Process Connections A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder
3. e ei ar cg A Disconnect power Maintain more often LS D gt t before maintaining during severe condi H tions Y Check Change Clean Replace Reference To be done by Factory Authorized Service Agent 3 Months gt vit Damaged Or Unreadable Labels Repair Or Replace Q Clean And Tighten Weld Cracked Weld Cable Terminals 6 Months Q Inside Unit 6 2 Overload Protection 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector C C d co om gt gt o 804 127 A 6 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 923 Page 20 6 4 Changing Drive Roll Or Wire Inlet Guide 030 035 VK Groove Stamped 030 035 N Tools Needed EE Bn CE 5 16 in d 024 Groove Stamped 024 0000
4. 1 Pressure Adjustment Knob 2 Pressure Assembly Pivot pressure adjustment knob down and lift pressure assembly up 3 Pivot Tube Plate 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 Reinstall plate and tighten screws 7 Retaining Knob Rotate counterclockwise and remove knob 8 Drive Roll 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 4 7 804 123 A 804 129 A OM 923 Page 21 6 5 Replacing Gun Contact Tip E gt A Turn Off power before replacing us id contact tip 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Cut off welding wire at contact tip Remove contact tip from tip adapter and install new contac
5. Notes Notes Notes Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART AC WELDERS HOBART 5 3 11 WARRANTY Effective January 1 2008 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of LJ or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace an
6. provoquer des blessures gt ei e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 923 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures CA e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien 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 Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur 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 ren
7. MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged 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 them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in plac
8. Power Source D GE Work Clamp Workpiece Self Shielding Flux Core Wire fcaw 1 2003 Ref 803 444 A OM 923 Page 28 8 2 Typical Control Settings CS These settings are guidelines only Material and wire type joint design fitup position shielding gas etc affect settings Test welds to be sure they comply to specifications Material thickness determines weld parameters 1 8 or 0 125 in L 4 Convert Material Thickness to Amperage A 0 001 in 1 ampere 0 125 in 125A y Amperage Range Wire Size A 0 023 in 30 90 A SEN 0 030 in 40 145 A Select Wire Size 0 035 in 50 180 A Wire R Wire Speed Select Wire Speed Size ecommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute y Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage Select Voltage Ref 804 121 C OM 923 Page 29 8 3 Holding And Positioning Welding Gun CS 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
9. keep flammables away e Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards SS e MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire LE 3 STATIC ESD can damage PC boards MOVING PARTS can cause injury a e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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 e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the instal
10. o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le 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 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
11. PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de Vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 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 923 Page 9 OM 923 Page 10 SECTION 3 SPECIFICATIONS 3 1 Specifications F S Amperes Input at Rated Welding Maximum bere Rated Load Output KVA Kw Weight Overall Output Amperage DC g 115 V 60 Hz Single W Gun Dimensions Phase Length 16 7 8 in 90 A 19 Volts DC 429 mm 20 Duty Cycle Ke e 20 2 90 220 SCH Width 9 7 8 in 63 A 21 Volts DC 15 2 20 177 251 mm 20 Duty Cycle Height 12 1 8 in 308 mm Flux Cored Wire Feed Speed Range Wire Type z And Dia 030 035 in 183 295 IPM 4 6
12. The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 923 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Fed
13. 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 Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls wire feed rolls bird nesting Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary 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 Metal Thickness Selector switch setting on Change Metal Thickness Selector switch setting welding power source 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 Feed motor bogging down Too much feed roll pressure Loosen tension knob OM 923 Page 35 SECTION 9 PARTS LIST Hardware is common and not available unless listed 804 124 B Figure 8 1 Main Assembly OM 923 Page 36 Item Dia Par No Mkgs No Description Quantity Figure 8 1 Main Assembly E EE 210432 CASE SECTION front bottom rear 1 a eet Donal ees 210530 BLANK Snap
14. Overtightening hub tension may cause wire feed problems When a slight force is needed to turn spool tension is set ar Installing 8 in 203 mm Wire Spool gt te ith E Only applies to units equipped with Ge Ge optional hub kit spool only When a slight force is needed to turn spool tension is set with 8 in 203 mm spool only Tools Needed EA D E A Ref 802 971 C 803 012 803 013 B OM 923 Page 14 4 5 Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt 20 ampere individual branch circuit protected by time de lay fuses or circuit breaker is re quired 3 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 E Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Do not move or operate unit where it could tip 804 122 C OM 923 Page 15 4 6 Installing Contact Tip And Nozzle CH HI ES A Turn off welding power source 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Thread welding wire through gun see A Section 4 7 Slide contact tip over wire and tighten tip into tip adapter Install nozzle 4 Flux Nozzle MIG Nozzle Use with flux cored wire only Narrow design allo
15. across gaps a weave bead or multiple stringer beads works better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 EE DM S 0054 A 8 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration O E ND A S 0053 A 8 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 N being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 923 Page 32 8 8 Troubleshooting Excessive Spatter o eee Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead S 0636 Possible Causes Corrective Actions Metal Thickness Selector switch set too high Set Metal Thickness Selector switch to a lower selection 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 Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubrican
16. and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection 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 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 cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared ac
17. end of nozzle and tip of wire is positioned correctly on seam 1 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout 7 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 aS 4 aes 0 15 Vd A 90 90 va AOS End View of Work Angle Side View of Gun Angle GROOVE WELDS 45 0 15 N A X 45 7 N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 923 Page 30 8 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 gt The Drag or Pull technique is generally recommended when welding with flux cored tubular wire Push Perpendicular Drag or Pull kd 10 7 l l E AAA ALAN Electrode directed Electrode pointed ahead of bead back into bead Direction Of Welding GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT Le Le 1 Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT SS Ee AS Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 923 Page 31 8 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
18. in 1 EE 210433 BAFFLE Genfer cuco A AE 1 an LES EE 210 434 WRAPPER Cover 1 A A E 210 495 DOOR ACCESS ui a A A A i 1 NEE EE 213643004 BEZEL TEE 1 DN sr sm dust 196 006 HINGE door access 2 LM 9 s inde dr rite ane 222 457 CIRCUIT CARD ASSY control 1 30 BF cee Ata ah Weeden as 134 204 2 STANDOFF ico a owas aA Sade ea Wa AE eee 6 ea EE 209 356 RECTIFIER assy 1 R OR panes 209 392 BUS BAR output positive 1 nh WEE 193 194 BUS BAR output negative 1 H PE ee ee eee 210109 SUPPLEMENTARY PROTECTOR man reset 1P 25A 250VAC 1 Mat EC sated nape oa EE 111 443 BUSHING strain relief 1 a E ote dee ae ets 147 5453 e e TE RT RE 1 e KEE 208 015 HANDLE 2 1 A a Aa 1 ei T d E gS 209 467 MOTOR fan 11BMAC ee 1 AO ad e e a 210413 BLADES EAE a SR a gna O o fe 2 1 O avwiataostdsa aa wea eas 209 213 ws TRANSFORMER usina yeaa eas dana aaa 1 beste CS ET teal nen 203808 STABILIZER ican cord dtd wate adie dde nana ale 1 pie One eae we ei E 196575 SWITCH rocker spst 1 eles a as 229432 SWITCH rotary 1 NDS Aid aaa abe be A 207 079 KNOB Pointer
19. 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 attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit gt Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil gt Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr a la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage ave
20. sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES N 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 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 alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servi
21. 3 12 10 ga Range4 10ga 3 16 ssb1 1 10 91 210 519 A OM 923 Page 12 SECTION 4 INSTALLATION 4 1 Installing Work Clamp Connection hardware must be tightened with proper tools Do not just 1 Nut EE hand tighten hardware A loose electrical connection will cause poor 2 Work Cable From Unit weld performance and excessive heating of the work clamp 3 Work Clamp 4 Screw 5 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 To Zb 76m Ref 802 456 4 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 4 3 Polarity e ar Polarity must be set for DCEN POLARITY flux core wire only 1 Lead Connections For Direct DCEN Current Electrode Negative El N DCEN ectrode egative Always read and follow wire For Flux Core Wire manufacturers recommended polarity and see Section 4 2 Close door Ref 210 428 OM 923 Page 13 4 4 Installing Wire Spool And Adjusting Hub Tension E Installing 4 in 102 mm Wire Spool
22. 3 108 dass an de fi wale bhi deeded ace hide wale 1 E ala fairs eB Beas 210 398 BUSHING Snap in 1 ROA WEE 209 412 BUSHING snap in 500 dia 2 3 25 tn a cde ete Aas 209532 DRIVE assy wire 1 scm COL Oe aren tie tae tes 193 144 INSULATOR output stud 1 eg As hot ei tras Bae ee A eS 202726 ADAPTER spool hub 1 Ne EE 202 998 SPRING cprsn 1 BE TR 204608 aia NU Td ai taa taa Satan 1 OE A 2039072004 WASHER 22 sac aaa r dha diane darts 1 BE LT PE ae 225 397 H 9B GUN 8 ft 023 085 1 AA a A 223 790 LABEL setup guide corrio cat eee ENN ANEN EN EN 1 E EE 204 036 LABEL warning 1 RC A agate bammatal IR DE e OTT e TEE 1 e ee doo a tet 196 619 4 GABLES Work 00d EE 1 PS Lo EEE eas 210 530 BLANK snap in nyl 1 250 mtg hole black 1 E as LABEL nameplate order by model and serial no 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 923 Pa
23. 3 8 in 10 mm Be sure that cable is straight Tighten liner setscrew Cut e 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 with screws 3 A Reassemble gun by placing head tube and cable into one half of handle Be sure trigger is properly installed into trigger slot Place other half of handle over head 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 4 7 Reinstall adapter contact tip and nozzle OM 923 Page 25 6 8 Troubleshooting Table Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 4 7 Change to proper drive roll groove see Section 6 4 Readjust hub tension see Section 4 4 Replace contact tip if blocked see Section 6 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 6 4 Replace drive roll or pressure bearing if worn or slipping see Section 6 4 Check and clear any restrictions at drive assembly and liner see Section 4 7 Release gun trigger and allow gun and motor protection circuitry to reset Have nearest Factory Aut
24. 7 5 m min At No Load 0 8 0 9 mm 112 236 IPM 2 8 6 0 m min Feeding Wire CSA Rating 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating H unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for 135 unit to cool Reduce amperage or 100 duty cycle before welding o NOTICE Exceeding duty cycle 80 e can damage unit or gun and void 2 60 warranty E Ei 40 o 5 O 20 10 1 2 4 6 8 10 20 40 60 100 Duty Cycle 20 duty cycle at 90 amps DR O 2 Minutes Welding 8 Minutes Resting Overheating Das o Aorv nO Y gt O E gt gt Reduce Duty Cycle Minutes duty1 4 95 210 517 A OM 923 Page 11 3 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 33 0 m 28 0 23 0 o o EN gt 18 0 13 0 80 00 100 200 300 400 500 60 700 800 90 1000 1100 1200 1300 Amperage e Range 1 18 16 ga a Range2 16 12 ga a Pange
25. 923 Page 38 5 9 803 442 B Figure 8 3 Wire Drive Assembly Item Part No No Description Quantity 209 532 Figure 8 3 Wire Drive Assembly E E AR EE OIE ts 212 377 BEARING idler 1 E is Seah rare ET nn 212379 ROLL drive 024 030 035 1 NC EEN 212383 RETAINER feedroll 1 A char od Y tra teh aad Ee 212 368 GUIDE wire inlet 1 Ge Me e EE 212384 COVER torch 1 E AO dibs nth ede ange tee ses 212 385 KNOB tension 1 RE Greene AA cto at 212387 SPRING compression 1 EN EE EE 21238800000 CUR SPAN EE ais 1 A a a 212389 SCREW torch cover 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 8 2 Options PART NO DESCRIPTION REMARKS 194 776 Small Running Gear Cylinder Rack To Mount Unit For Maneuverability 195 216 Hub Kit For 8 in Wire Spool 195 186 Protective Cover Weatherproof Nylon NOTE If individual parts are required see Parts List chapter of this manual for part number to order OM 923 Page 39
26. OM 923 223 112D Ne AK EA 2008 10 e H2 Flux Cored FCAW Welding Z FC WELDERS Description e Ki Arc Welding Power Source And Wire Feeder Handler 125 EZ And H 9B Gun ot L ES File Flux Cored FCAW d FC 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 2000 QUALITY SYSTEM Hobart is registered to the ISO 9001 2000 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 ind
27. ance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA O 2008 Hobart Welding Products 2008 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call 1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se KA HOBART tHe
28. c du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques 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 IW e Ne pas toucher aux pi ces lectriques sous tension e Porter des gants isolants et des v tements de protection secs et sans trous e Sisoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l 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 talliques telles 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 sui
29. ces ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique 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
30. 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 Additional safety 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 v
31. cording to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 923 Page 2 CND Do not use welder to thaw frozen pipes 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 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator
32. doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION 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 LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement
33. dous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with 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 fil ter lenses to protect your face
34. e over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard d e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury 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 7 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn nn e as a FLYING SPARKS can cause injury y 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
35. eady travel speed OM 923 Page 34 8 14 Troubleshooting Waviness Of Bead nil Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal La wm 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 8 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 Set Metal Thickness Selector switch to a lower selection Increase travel speed Weld in small segments and allow cooling between welds 8 16 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but Too little pressure on wire feed rolls Increase pressure setting on wire feed rolls wire does not feed 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
36. ed 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 Do nat 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 Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power i Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 923 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazar
37. eral 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 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble 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_2007 04 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 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
38. ge 37 804 243 A Figure 8 2 H 9B Gun Item Part No No Description Quantity 225 397 Figure 8 2 H 9B Gun NEE oe 169715 NOZZLE slip type 500 orf flush 1 e A 226 190 NOZZLE flux cored slip type 1 wD ta a 169 716 ADAPTER contact tip 1 WEE 225 410 SWITCH trigger 1 EE 210 970 LINER monocoil 023 035 wire x ft 0 0 ees 1 E ada 087 299 TIP contact scr 023 wire x 1 125 Sek Te 000 067 TIP contact scr 030 wire x 1 125 1 Ne A 000 068 TIP contact scr 035 wire x 1 125 NO res 226 010 NUT liner retainer 1 KEE 226 080 HANDLE AGGL 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 8 1 Contact Tip Options HOBART PART NO DESCRIPTION REMARKS 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 770174 Tip contact scr 023 wire Pkg of 5 770177 Tip contact scr 030 wire Pkg of 5 770180 Tip contact scr 035 wire Pkg of 5 OM
39. horized Service Agent check drive motor No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 4 5 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 5 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 resets when unit has cooled see Section 3 2 Be sure that Material Thickness Selector switch is not set between ranges see Section 5 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 4 1 Replace contact tip see Section 6 5 Low weld output Connect unit to proper input voltage or check for low line voltage Place Material Thickness Selector switch in correct setting see Section 5 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 3 1 OM 923 Page 26 SECTION 7 ELECTRICAL DIAGRAM
40. ing Gun Liner iii e dd done der 24 6 8 Troubleshooting Table 2 2 26 SECTION 7 ELECTRICAL DIAGRAM 44444 27 TABLE OF CONTENTS SECTION 8 WIRE WELDING GUIDELINES occcccccccccco eee eee eens 8 1 Typical FCAW Process Connections 8 2 Typical Control Settings ici ne en en nr non A A ere ne ue TA CS 8 3 Holding And Positioning Welding Gun 8 4 Conditions That Affect Weld Bead Shape 8 5 Gun Movement During Welding 8 6 Poor Weld Bead Characteristics 8 7 Good Weld Bead Characteristics 8 8 Troubleshooting Excessive Spatter 8 9 Troubleshooting Porosity 4422 8 10 Troubleshooting Excessive Penetration 8 11 Troubleshooting Lack Of Penetration 8 12 Troubleshooting Incomplete Fusion 4222 8 13 Troubleshooting Burn Through 0 0 0 eens 8 14 Troubleshooting Waviness Of Bead 8 15 Tr
41. iter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 923 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation 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 DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e 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 A 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 te
42. ividual specification sheets To locate your nearest distributor or service agency call 1 877 Hobartl or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob_Thank 4 05 5 3 11 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 AC NUI hi D TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 AS E O RN 1 1 27 lt Are Welding Hazards tt AA ae A ae ta es 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 2 4 156 EMF Information w Aug re EE a dE A aie gia elk ba alte le wie Sale pede tik 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 21 Symboles utiles Bees a sit E bad 5 2 2 Dangers relatifs au soudage l arc 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
43. la 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 electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f 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 923 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of Califor
44. ments 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 Pair de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de larc 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 ap
45. mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A 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 a base de plomb produits chimi ques dont l tat de Californie reconna t 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 OM 923 Page 8 Pour les moteurs a essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat 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 A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ati
46. n 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 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 the exclusion of incide
47. nia to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 749 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 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 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that
48. nnexions 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 entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e 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 deux machines en m me temps cause de la pr sence d une tension vide dou bl e e Nutiliser 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 pi ce pour v
49. ntal 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 2008 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assist
50. oltage 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 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions 2 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 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 When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks 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 requir
51. on 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 749 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping 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 P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Resea
52. oosen liner setscrew Twist top and bottom handle locking rings from wire drive assembly counterclockwise 1 4 turn Slide bottom ring down cable and top ring forward over head 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 D ZA KR gt K E D pr SS Z VA Ref 804 241 A 804 123 A 803 837 A 803 899 A OM 923 Page 24 6 7 Replacing Gun Liner Continued EL le 13 16 in 21 mm HE 3 lt 8mm When liner exits cable at gun gt 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
53. oubleshooting Distortion 2 8 16 Troubleshooting Guide For Semiautomatic Welding Equipment SECTION 9 PARTS LIST WARRANTY 28 28 29 30 31 32 32 32 33 33 33 34 34 34 35 35 35 36 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 A Protect yourself and others from injury read and follow these precautions 1 A A 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 A A e 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 repair this unit During operation keep everybody especially
54. 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 UN L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT De e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal River 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 gt LES ETINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement a la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque Pon 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 Ac circuits imprim s SIS So e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent
55. prouv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage 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 pas regarder larc 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 923 Page 6 LE SOUDAGE peut provoquer un in cendie 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 pieces 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 a une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l
56. r d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ou e 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 endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage 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 Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne
57. rch Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que lexposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L4W 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 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 11 West 43rd Street New York NY 10036 8002 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 Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh
58. red for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries 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 slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 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 by Hobart Miller i
59. t on welding wire from feeder or liner 8 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions 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 8 10 Troubleshooting Excessive Penetration m2 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 Set Metal Thickness Selector switch to a lower selection Increase travel speed OM 923 Page 33 8 11 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 Join
60. t 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 Set Metal Thickness Selector switch to a higher selection Reduce travel speed 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead A 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 Set Metal Thickness Selector switch to a higher selection 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 8 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 Set Metal Thickness Selector switch to a lower selection Increase and or maintain st
61. t tip Reinstall nozzle Tools Needed EF Ze Ref 804 241 A OM 923 Page 22 6 6 Cleaning Gun Liner Turn Off welding power source 1 Nozzle 2 Contact Tip 3 Adapter Head Tube 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 end of wire at spool contact tip and tip adapter Remove screws 3 from cover and remove cover from wire drive assembly Tools Needed gt gt IL 8mm Reassemble drive cover and gun in reverse order from taking it apart Lay gun cable out straight and blow out liner Thread wire according to Section 4 7 804 241 A Ref 804 123 A 804 128 A Ref 803 837 A OM 923 Page 23 6 7 Replacing Gun Liner A Turn Off welding power source Tools Needed E Te Ss Head AE 8 mm 10 mm Tube ES ae 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 d contact tip and tip adapter from unraveling Secure end of wire at spool cover and remove cover Remove screws 3 from a L
62. te pressure adjustment knob in a clockwise direction until drive roll is tight against the welding wire Adjust drive roll pressure just tightly enough to prevent wire from slipping against drive roll during operation Remove gun nozzle and contact tip Tip adapter may also require removal to allow wire to feed out end of gun D Push wire thru guides into gun liner continue to hold wire on OF INPUT POWER Turn power on Tighten Q WOOD Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door 804 123 A OM 923 Page 17 SECTION 5 OPERATION 5 1 Controls 1 Material Thickness Selector SH Switch Use switch to select the material thickness range Do not switch under load E Switch must click into detent position for weld output 2 Power Switch DO NOT SWITCH WHILE WELDING 035 WIRE 030 WIRE 18GA 16GA 12GA 1 8 10GA 3 16 050 in 0625 in 109 in 125 in 140 in 1875 in 1 2 mm 1 6 mm 2 5 mm 3 2 mm 3 4 mm 4 8 mm Ref 230 001 A OM 923 Page 18 5 2 Operating The Gun e 1 Trigger Switch AN When pressed energized wire feeds Ref 804 240 A OM 923 Page 19 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance
63. vants dans l ordre indiqu 1 un poste souder DC tension constante F Indique des instructions sp cifiques o PF 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 fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord a 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 co
64. ws 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 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 EF gt Ref 804 241 A OM 923 Page 16 4 7 Threading Welding Wire Tools Needed 0000 LE 1 2 3 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Cable Lay gun cable out straight O O1 PS Co ND Open pressure assembly gt Tighten Z Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Press gun trigger until wire comes out of gun Be sure that contact tip matches wire diameter Reinstall tip adapter if applicable contact tip and nozzle FF Hold wire tightly to keep it from unraveling A gt mu 6 in 150 mm Pull and hold wire cut off end Loosen knob completely then rota
65. y 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 Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are cove

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