Mercedes-Benz 2006 S 500 4MATIC Automobile User Manual
Contents
1. eene 1 Ix Da s UO Tx deb 799 se VALVE eA VAG meii ilc ies c il 1 M ME 134 464 LABEL warning general precautionary 1 Too PED 184 660 WRAPPER ASSEMBLY orar RA e 1 Die 1040906 x BASE A D Grades an SR ue 1 E a aio nAn AUS 100 67 su AXLE A etl tet a BS io mange oa 1 T o EP 0906S N ER Re ne nn ce Om die co Cou 2 34 121 614 RING retaining Lie Rae reri id 2 E OPEP 184 664 2 PANEL SOS sxe COEPI Eae ob c DX ena oe OL LN UP NS bee EN 1 36 Z 130999 s STABILIZER Sn ee E CROP ei n do a a 1 PA TP2 x4 1692600 ane THERMOSTAT NG 2i ss Y ON ia 005 999 w CASTER ausuaitaun vide due sertta durs ited diste mun tes hake neonate dare 2 dolo ee cri 146 149 GABLE WOK oii tia tale duc Demandes dise C a 1 EEC rate 1390 250 GLAMP WOK d e aking A be EN 1 ET 192 121 4 REGULATOR FLOWME TER austeridad use pou Mt E 144 109 2 HOSE GAS see bbc dr Cr ENS D OA desinet e ov aeree eund aes op p en ieget vaa Diss rene 048 282 HEGEPTAGLE W SOGNKBETS oubli p c DC RAO at 1 V OPE 204 413 BUSHING snap in nyl 2 1 pude usar ti 169589 MIS GUN FIGO O ne pr ades ha 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 loca2. Check and clear any restrictions at drive assembly and liner see Section 4 3 Have nearest Factory Authorized Service Agent check drive motor OM 929 Page 22 SECTION 5 ELECTRICAL DIAGRAM SC 186 683 dNV IO AJOM 89 LJ e 3ALLV93N JAILISOd 189 L5 ld AVIS Zdl 1934 0a L LS LL caa Le r LEO E ZOM Figure 5 1 Circuit Diagram For Welding Power Source OM 929 Page 23 SECTION 6 PARTS LIST Hardware is common and not available unless listed 801 873 C Figure 6 1 Main Assembly OM 929 Page 24 Item Dia Part No Mkgs No Description Quantity Figure 6 1 Main Assembly O A 196902 LABEL set nameplate amp side decals 1 ATO pai a xs 184670 zx HANDLE s a decade de RE ben deca Nd Zo ra 1 VIN MU 194 557 e PANEL MOD secre a ia ded o tton edibus 1 4 81 124511 SWITCH tgl DPST 40A 600VAC On Off 1 TE PP ISA TOO x GE q i a nd dta ases ars te mn die at 2 6 R1 035897 POTENTIOMETER CP 1 T 2W 1K linear Voltage Control Wire Feed Speed 1 Jd d ipao tia 149 956 x HANDLE SWIC acto duce Lun hea en UR Do GEN DP ROO OLEO eds 1 8 82 153 197 SWITCH selector 6 position 1 9 T1 184669 TRANSFORMER pwr main 200 230 460 1 tie d Rue ERA Fig 6 2 CENTER BA
3. 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 lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from Na
4. eugniticaliorides Symboles 55 cet nex es anew FRED i ep RIDERE wan EN CD EE Dangers relatifs au soudage l arc Dangers suppl mentaires en relation avec l installation le fonctionnement erla mantenant sise rss sr eve Rs E adus es AO ons Deus Principales normes de s curit Information sur les champs lectromagn tiques SECTION 2 INTRODUCTION csse vadrxsru b EE RR ERES TODORE T ea ee 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 SDECITICAIONS ita a NS a di ans Duty Cycle And Overheating 280 Volt Ampere Curves 35 aca ete sun miam dhe a m E ba acd Ai a ra Lat dede d Installing Welding GUA ccv x va eder AAA ESSE IS Setting Gun Polarity For Wire Type socorrista stalling Gas SUPP y sra 2 2 395 ant atii ouch els ord a b ata uoi e sr d Installing Wire Spool And Adjusting Hub Tension Changing Input Voltage From 230 Volts To 200 Volts Electrical Service Guide sorbo Rete v dr eee Das e Tea y SEES 2 10 Selecting A Location And Connecting Input Power 2 TT d BreadingvVeldiig VIG d se Steg oe duc t S ets ee edm oo mo a om ca fem SECTION S OPERATION x inus ex SS tss ov A mA S d sU AE Via EA 3 1 3 2 CONTOS e rae a D Un ds a n
5. 1 re E 134 201 STAND OFF SUPPORT PC card 4 eso ee eee EEE 104965 5 DOME sn me ee 1 96 CB2 180912 CIRCUIT BREAKER man reset 1P 5A 250V 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 929 Page 27 gt Hardware is common and not available unless listed 800 792 B Figure 6 3 M 15 Gun Item Part No No Description Quantity 169 589 Figure 6 3 M 15 Gun Fig 6 1 Item 41 eem 169 715 NOZZLE slip type 500 orf flush 1 2 4087299 TIP contact scr 023 wire x 1 125 2 000 067 TIP contact scr 030 wire x 1 125 2 000068 TIP contact scr 035 wire x 1 125 2 000069 TIP contact scr 045 wire x 1 125 Dire 169 715r sx ADAPTER CONMACLIID a oui e RSR ER E o bo DL deb 1 Ui aes T0470 2 A 1 Bi acts 169718 2 TUBE DO de cu si iia tii desti dte 1 HPLC p 169 739 INIT IOCKING handle viana ea bean ee leis eiii eee UR 2 o A 194524 NUT Jam rra aan QUOI tO mem ROCHE metet mr 1 noblesse 1697070 HANDLE sio rca dame SiG fee hes cc a 2 DENN E 169 741 STRAIN RELIEF Cable i sd d Li E a nah ine ere oe a ee e vies 2 TI EM 190433 42 GORD trigge
6. 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 after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well venti
7. e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable 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 possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimenta tion lectrique 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 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 un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un r
8. Wire Speed 90 80 70 60 50 40 35 25 12 E70S 6 Voltage Tap 6 5 4 3 3 2 2 1 1 1 75 Argon 030 25 CO 20 cfh Wire Speed 85 75 65 55 50 45 35 20 5 0 Voltage Tap 6 5 4 3 3 2 2 1 1 035 Wire Speed 80 70 60 45 40 30 20 10 0 Voltage Tap 6 5 5 4 4 3 2 1 030 i 7 2 1 LL E71T GS Wire Speed 80 0 65 99 90 30 0 0 Peon Voltage Tap 6 5 4 3 3 2 1 035 Wire Speed 60 50 40 30 25 20 10 Voltage Tap 5 4 4 4 3 3 3 2 2 2 023 Wire Speed 95 85 80 60 50 50 50 30 20 20 ER 308 Stainless Steel Voltage Tap 5 5 4 3 3 2 2 2 1 a 90 HE 030 7 5 Argon 2 5 D 5 Wire Speed 70 70 70 50 45 50 45 40 0 20 cfh Voltage Tap 6 5 5 4 3 2 2 2 035 Wire Speed 65 40 40 30 30 25 20 10 Do not change Voltage switch position while welding Wire Speed is a starting value only and can be adjusted while welding Weld conditions also depend on other variables such as stickout travel speed weld angle cleanliness of metal etc OM 929 Page 17 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance 3 Months Replace unreadable labels 6 Months Blow out or vacuum inside During heavy service clean monthly Clean and tighten weld terminals Repair or replace cracked weld cable Remove drive roll and apply l
9. e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place 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 Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained
10. tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin 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 Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition 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 con clusions 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 OM 929 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar ap
11. 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 Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement 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 Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 929 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel
12. Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits 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 Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU f D EXPLOSION e Ne pas p
13. FFLE w COMPONENTS 1 uc SH1 184674 RECTIFIER consisting of l Nata 170 757 EAT SINK TOCINA A tn 2 12 C1 4 048420 CAPACITOR cer disc Otuf 1000VDC 4 13 D2 4 168 348 DIODE rect 150A 300 V RP 2 VA ans 026 947 STAND OFF insul 250 20 x 1 000 Ig 2 15 D1 3 168349 DIODE rect 150A 300V SP 2 16 EPA ce 171600 2 s ERIM OS TAL NG a a ls 1 AAA 164 716 oce WIND TUNNEL x ient eset OEC aod qui X Pec CR CR ole o eme m Ss 1 18 FM 148808 MOTOR fan 230V 50 60 Hz 1 A 150 783 BLADE fan 9 000 5wg 39 deg w mtg hardware 1 Diana 152 625 BRACKET mtg fan rectifier 1 A EEEE EES 152 862 3 GROMMET SER 250 A Ge CA e eR eR En 8 Mo 184715 BRACKET bottle retainer oe Ren Rm m Rem e e 1 cR P 184658 vss PANEL TOO o eatis sd tue ce waa fero outta de noi Ad datura e oc 1 S o aa LABEL A iid acre att eee nee d d nd odd ere iem ur OU tss eer bU 164665 se BRACKET Dotlle 4 Go CELER ae bie OEIL RUP ORE SEN 1 NP LCR RS Er 188 441 lt CHAIN SMS 3 ite na ede seal Dae alas 1 O PEG 161072 CORD SE 250 Le A oy aa P A pcm e NR ets 1 TR rc EH 111 443 BUSHING strain relief 240 510 OD
14. ION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles i ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants RN e UN CHOC LECTRIQUE peut tuer ne Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension des que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension
15. NG 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 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 retail 4 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Numbe
16. OM 929 196 903B February 2000 Specifications Covered by this Manual 500 438 WELDING PRODUCTS processes Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Description cv Arc Welding Power Source and Wire Feeder BETA MIG 1800 And M 15 Gun im OWNER S MANUAL Visit our website at 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 ME 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 gt Z installation and operation quick and easy With Hobart you can count on years of reliable service with proper WARRANTY maintenance And if for some reason the unit Working as hard as you E do every power source Hobart is registered to the needs repair there s a Troubleshooting section from Hobart is backed by ISO 9001 Quality System that will help you figure out what the problem the best warranty in the Standard business is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTEHED QUALITY SYSTEM Hobart Welders manufactures a full line of wel
17. amp 1435 2060 8500 models Ironman 250 Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial No KK200262 and newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser
18. and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e 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 som nd 4 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent
19. ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V r
20. ders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local to receive the latest full line catalog or gt distributor Your distributor TP can also supply you with individual catalog sheets To locate your nearest Welding Process Manuals such as SMAW GTAW distributor or service agency call 1 577 Hobartl GMAW and GMAW P WELDING PRODUCTS 4 WARNING This product when used for welding or cutting 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 The following terms are used interchangeably throughout this manual Stick SMAW OM 929B TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING jet 1 2 1 3 1 4 1 5 Symbol US ad Hn AIC Welding Hazard A rs Additional Symbols For Installation Operation And Maintenance Principal Safety Standards e ee a a e EMPDIOTIQU OE ups palta ae es oe leet Se Sea A td eoda Se ee SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 1 2 1 3 1 4 1 5
21. ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn
22. e with handle locking nut If replacing head tube continue to end of figure 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto 7 Place head tube in vice and tighten new head tube Hand tighten head until nuts are tight tube into connector cable qa M 8 Remove from vice Reposition handle and install switch housing Secure with handle locking nut Tools Needed Ref ST 800 795 C OM 929 Page 20 4 5 Replacing Gun Contact Tip Tools Needed ES gt A Turn Off unit ry E 1 Nozzle A 2 Contact Tip A v Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Ref 800 797 C 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll Install correct drive roll for wire size and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Ref ST 801 875 Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle See Section 2 10 Check and replace power switch if necessary Check circuit breakers CB1 and or CB2 and reset if necessary see Section 4 2 Replace building line fuse or reset circuit breaker if open See Section 2 10 Secure gun plu
23. espirateur 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 oxy g ne provoquant des blessures ou des accidents mortels S assu rer 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 former 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 si n cessaire 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 OM 929 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pou
24. fied 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 Millers 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 Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDI
25. g in receptacle or repair leads or replace trigger switch See Sections 2 4 and 4 4 Thermostat TP1 open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 2 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip See Section 4 5 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 10 Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct size drive roll see Section 4 6 Readjust drive roll pressure see Section 2 11 Replace inlet guide contact tip and or liner if necessary see Section 4 6 OM 929 Page 21 4 8 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts see Section 4 3 Adjust drive roll pressure see Section 2 11 Readjust hub tension see Section 2 7 Check circuit breakers CB1 and or CB2 and reset if necessary see Section 4 2 Replace contact tip if blocked see Section 4 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 4 6 Replace drive roll if worn or slipping See Section 4 6 Secure gun plug in receptacle or repair leads or replace trigger switch See Section 4 4 and or 4 3
26. ifier et s assu rer 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 conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e 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 som nd fre 4 98 Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel
27. ight coat of oil or grease to drive motor shaft OM 929 Page 18 A Turn Off unit 1 Circuit Breaker CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 Circuit Breaker CB2 CB2 protects the trigger circuit from overload If CB2 opens weld output stops Check gun switch and trigger leads Correct problem Press button to reset circuit breaker Close door Ref 802 472 4 3 Cleaning Or Replacing Gun Liner Tools Needed COP C SELLE 5 16 in 10 mm Disconnect gun first Remove nozzle contact tip and adapter 5 16 in 10 mm N gt gt Remove liner A Lay gun cable out straight LR before installing new liner A 7 C STA NU To Reassemble Gun Insert new liner VA Install and tighten wire outlet guide Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Blow out gun casing Install adapter contact tip and nozzle Ref ST 800 797 C OM 929 Page 19 4 4 Replacing Switch And Or Head Tube ee 1 Remove handle locking nut Disconnect gun first 3 Slide handle 2 Remove switch housing Note If installing new switch push switch lead connectors onto terminal of new switch polarity is not important Install switch back into handle and secur
28. ion found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away Lr ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit 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
29. l distributor OM 929 Page 25 gt Hardware is common and not available unless listed ST 801 877 C Figure 6 2 Center Baffle w Components OM 929 Page 26 Item Dia Part No Mkgs NO Description Quantity Figure 6 2 Center Baffle w Components Fig 6 1 Item 10 T rr 170 201H NUT retaining w warning label 1 TRE A 164 799 SPACER SOOO i435 add old 1 Ru aid Seas IESO s WASHER tal Keyed a sb em BUREAU E dE ded 1 TCR 184 739 cunt SPRINOGECDIS Sivan ue rte d diese carie riens 1 TE quU 405 448 WASHER friction 1 pus Douce ea duet 104 7095 BRAGISET siena too dit oe eave pen 1 TEM en nn 405 370 SUB SR e ente eec oci tie o ieee due Ait dna dea eam dents 1 Re 374 546 SHAFT spool support 2 eee IB 1 UTE Ww 602 246 x WASHER Mat oodd hat detre t tanie eau 1 ray O pene ses 194 566 R EL SUPPORT 31422123 1 cct a itr io ORA eco e detti site eed 1 see tic shouts ces 196 875 225 BAFFLE CeIn acaswetiecat wile taa 1 RER eee C6 184681 CAPACITOR ASSEMBLY consisting of 1 Eus fo ae ene ee eee 082 902 STRIP mtg center capacitor 1 css dere de Ed 092 186 lt STRIP tntgicapacltor encia 2 RSR AA 178 796 CAPACITOR elctlt 20000uf 6 RERE 083 147 GROMMET scr No 8 10 6 Riad
30. lacer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tel
31. lated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 929 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays mF burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection f WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is n
32. le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 929 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser
33. nder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do 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 OVERUSE can cause OVERHEATING INN e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit Le STATIC ESD can damage PC boards J 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 2 em 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
34. onductor Length In Feet Meters d E Min Grounding Conductor Size In AWG Kcmil 10 10 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 929 Page 13 2 10 Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power 2 Plug A Do not move 3 Receptacle or operate unit Connect plug to receptacle ANR t eouie up 4 Input And Grounding 18 in 457 mm of Conductors space for airflow Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 2 9 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 LILI TZ y x R LA Always connect grounding conductor first 230 VAC 1 v 801 876 B OM 929 Page 14 2 11 Threading Welding Wire gt o a Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight NO oO fF ND Tools Needed C XP C Xe Ref 802 472 802 480 EF Hold wire tightly to keep it from unraveling Open pressure assembly Pull and hold wire cut off end Push
35. or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors Rotors Stators and Brushes 2 3 Years Parts and Labor Drive Systems PC Boards Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories 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 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 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 modi
36. ot possible tightly cover them with approved covers e 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 e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 and fire hazards 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 e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding a FLYING METAL 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 OM 929 Page 2 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 respi
37. r Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment 2000 Hobart Welding Products 1 00 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 WELDING PRODUCTS
38. r assembly eu 3 nto dist tad c ed de iene ek EE e da RET 1 ia ba aces 079974 OXRSING 500 ID X 1096 S TBE s corr EE MS made nm MAIRE 2 15 06194010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 6194011 LINER monocoil 030 035 wire x 15ft consisting of 1 15 0194012 LINER monocoil 035 045 wire x 15ft consisting of 1 se lO eas 0799751 O0 RING 197 1D 2620109 GOADE sarta Ewa ad monat hs 1 d access 196 255 ta WITGA MIOS 2 Rae MR Ee dam t posed Sette ee us 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 OM 929 Page 28 Warranty Questions Call 1 877 HOBART1 for your local Hobart distributor 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 WELDERS HOBART 3 31 WARRANTY Effective October 1 1999 5 3 1 WARRANTY applies to all Handler 135 and 175 models Airforce 250 250A and 375 models and Champion 10 000 models This warranty also applies to the Beta Mig 1800 Ch
39. r regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds LE SOUDAGE peut provoquer un PER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les 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 es Se proteger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protection
40. rator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding 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 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 place over valve except when cyli
41. s homologu s Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur a proxi mite Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t 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 pa r s correctement conform ment a AWS F4 1 voir les normes de s curit Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es 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 re vers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et
42. s que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appa reil 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 distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L
43. t mn Ode rl un PES Weld Parameters uni A ne aie e ea os de die ed SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Ftoutine MalpterialieG 25 559 22 9 5 E tro toe e a bee md ooo Ead des CCU Breakers su RE ad OE TREE Gleaninig Or Replacing Gun Liner zs in ie RS RIM Nan ed Replacing Switch And Or Head Tube Replacing GUM Contact iia Changing Drive Roll And Wire Inlet Guide Welding Troubleshooting Table Wire Drive Gun Troubleshooting Table SECTIONS ELECTRICAL DIAGRAM 5v oasis al as MON er ia hee eek SECTION 6 PARTS LIST WARRANTY Roo A O1 O1 O1 Oo OO N SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage i Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols C7 Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety informat
44. te par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INTRODUCTION 2 1 Specifications Max Open Amps Input at Rated Output 60 Hz Single Phase Circuit Rated Output Voltage 200 V 230 V KVA KW 150 A at 23 VDC 30 26 6 5 60 Duty Cycle 33 1 6 1 4 0 27 0 13 Wire Type and Diameter Wire Feed Speed Dimensions Weight Solid Steel 90 650 IPM H 29 7 8 in 759 mm 195 lb Stainless Steel Aluminum Flux Cored 2 3 16 5 m min W 15 1 8 in 384 mm 88 kg D 33 3 8 in 848 mm 023 035 in 030 035 in 030 045 in 0 6 0 9 mm 0 8 0 9 mm 0 8 1 2 mm While idling 2 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load RATED OUT PUT without overheating Be EE ee ee ee ee ee If unit overheats thermostat s C S opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding Exceeding duty cycle can damage unit and void warranty WELD AMPERES DUTY CYCLE 60 Duty Cycle At 150 Amperes 6 Minutes Welding 4 Minutes Resting p 5 gt Reduce Duty Cycle Overheating Minutes duty1 4 95 181 009 OM 929 Page 9 2 3 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit C
45. ting has 5 8 18 right hand threads 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturers recommended flow rate see Section 3 2 This flow gauge can be adjusted between 5 and 25 cfh 4 CO Adapter Customer Supplied 5 O Ring Install adapter with O ring between regulator flow gauge and CO cylinder Tools Needed 3 1 1 8 5 8 in Ref 801 789 Ref 149 827 B Ref 158 697 A 2 7 Installing Wire Spool And Adjusting Hub Tension Small Spool Adapter When a slight force is needed to turn spool tension is set Tools Needed 9 16 in C P 801 790 OM 929 Page 12 2 8 Changing Input Voltage From 230 Volts To 200 Volts Cut cable ties as necessary 1 230 Volt Lead 2 Tubing Locate lead marked 230 VAC Slide tubing down and disconnect lead splice Fold tubing over 230 volt lead stub and secure 3 200 Volt Lead Locate lead marked 200 VAC Slide tubing down and connect 200 volt lead stub to top half of the for mer 230 volt lead and secure with existing hardware Slide tubing over connection and secure Tools Needed EF YZ2 C8 5 16 3 8 in Ref 801 878 B 2 9 Electrical Service Guide Input Voltage 200 230 Input Amperes At Rated Output 30 26 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 35 30 Normal Operating 3 45 40 Min Input Conductor Size In AWG Kcmil 10 10 Max Recommended Input C
46. tional Fire Protection Association Batterymarch Park Quincy MA 02269 OM 929 Page 3 1 5 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 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 929 Page 4 1 Keepcables close together by twisting or taping them 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 Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECT
47. urves of other settings fall be tween curves shown TAP 6 IEC LOAD LINE ML ME Y 5 O gt E d Hi O gt 2 O 150 LOAD CURRENT AMPS va_curvel 4 95 180 824 2 4 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door mr AN EI pu y Ref 802 285 A OM 929 Page 10 2 5 Setting Gun Polarity For Wire Type Shown As Shipped Set For Electrode Positive DCEP For Solid Steel Or Aluminum Wires GMAW Process Wire Drive Assembly Work Clamp Lead To Lead To Positive Negative Output Output Terminal Terminal GUN POLARITY CHANGEOVER CONNECTIONS Reverse Lead Connections For Electrode Negative DCEN For Flux Cored Wires FCAW Process Drive Assembly Becomes Negative S 185 249 Tools Needed YT 3 4 in Polarity Changeover Label Wire Drive Assembly Positive Output Terminal Negative Output Terminal Always read and follow wire manufacturers recommended polarity Close door Ref 802 472 OM 929 Page 11 2 6 Installing Gas Supply Chain gas cylinder to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Regulator Flow Gauge Install so face is vertical 2 Gas Hose Connection Fit
48. wire thru guides into gun continue to hold wire O Lv gt LI OFF ON INPUT POWER Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire gt NUE gt 3 Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire comes out of gun Reinstall Tighten knob enough to prevent slipping Close door contact tip and nozzle OM 929 Page 15 SECTION 3 OPERATION 3 1 Controls 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number 4 the thicker the material that can be welded see welding guide and Section 3 2 3 Welding Guide 4 Power Switch OFF ON INPUT POWER WIRE FEED SPEED VOLTAGE CONTROL Ref 196 876 A OM 929 Page 16 3 2 Weld Parameters Material Thickness Wire Type Wire Shielding Gas Diameter Re 3 8in 1 4in 3 16in 1 8 in And Flow Rate inch 9 5 6 4 4 8 3 2 12ga 14ga 16ga 18ga 20ga 22ga mm mm mm mm Voltage Tap 6 5 4 3 3 2 2 1 1 023 Wire Speed 100 80 65 55 45 35 25 15 5 E70S 6 Voltage Tap 6 5 4 3 3 2 2 1 1 e CO 030 20 cfh Wire Speed 80 70 60 55 45 35 25 15 5 Voltage Tap 6 5 4 3 3 2 2 2 035 Wire Speed 70 60 50 45 40 30 20 10 Voltage Tap B 5 4 3 3 2 2 1 1 1 023
49. xs W 189486 CONTACTOR def prp 40A 3P 1 17 CB1 183 492 CIRCUIT BREAKER man reset 1P 10A 250VAC 1 cunt Oacae POT 2171985 CIRCUIT CARD control 0 20 ia E ae ENA 1 re PLG10 165 745 CONNECTOR amp SOCKETS 1 Pr Che R2 091 685 RESISTOR WW fxd 50W 25 ohm 1 wig 20 ses GRT es 072817 as RELAY enc 24VAC DPDT nuesto ia 1 bad d e eed tes 097 416 TERMINAL pwr output black 1 ONCE TNT 097421 TERMINAL pwr output red 1 ped 23 esas O79 199014 CAPACITOR ASSEMBLY nicas 2 TEE COR 196625 DRIVE ASSY wire consisting of 1 To MAE I uu MIO G0 h ccu MOTOR gea 22 3 SURE Ra ELE termine RO Ra m doe 1 AO sadi dauid bs 203 091 irc GREW Teedroll 2332 edi dr das 1 cr POR 079 633 FITTING hose brs barbed nipple 1 O anthesis Abs 193 681 BLOCK connector gun 1 O rd 126 052 KNOB T 2000 Ar citada ida 1 Mc die stem eae 193 707 36 GUIDE wire adapter Jia ucc dca a a x e WS 1 DO les ie vers 104 341 sesa MEAD TECG Lus ex xh ORI Ica qr Ios OE quo mb o 1 de ie ded edad 203 025 GUIDE wire inlet 1 RS C M ee eee 184 742 ROLL drive V groove
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