Handler 125EZ and H-9B Gun Owner's Manual

8/7/2019 Handler 125EZ and H-9B Gun Owner's Manual

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OM-923 223 112C200608

Processes

Arc Welding Power Source AndWire Feeder

Description

Flux Cored (FCAW) Welding

Handler 125 EZ

And H-9B Gun

R

File: Flux Cored (FCAW)


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Hobart Welders manufactures a full line

of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart

distributor to receive the latest full line catalog or individual specification sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1 or

visit our website at www.HobartWelders.com.

For Technical Help call 1-800-332-3281.

Thank you and congratulations on choosing Hobart. Now you can get the

job done and get it done right. We know you dont have time to do it anyother way.

This Owners 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.

Weve 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,

theres a Troubleshooting section that will help

you figure out what the problem is. The partslist 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.

Hobart is registered to theISO 9001:2000 QualitySystem Standard.

Working as hard as youdo every power sourcefrom Hobart is backed bythe best warranty in thebusiness.

From Hobart to You

Hob_Thank 4/05

Register your product a

HobartWelders.com

Protect Your Investmen


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . .2-4. Proposition californienne 65 Avertissements 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Information EMF 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Installing Work Clamp 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Process/Polarity Table 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Polarity 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Installing Wire Spool And Adjusting Hub Tension 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Selecting A Location And Connecting Input Power For 115 VAC Model 13. . . . . . . . . . . . . . . . . . . . . . . .4-6. Installing Contact Tip And Nozzle 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Operating The Gun 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6

MAINTENANCE &TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Overload Protection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Drive Motor Protection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Changing Drive Roll Or Wire Inlet Guide 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Replacing Gun Contact Tip 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6. Cleaning Gun Liner 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7. Replacing Gun Liner 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8. Troubleshooting Table 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTS

SECTION 8 WIRE WELDING GUIDELINES 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Typical FCAW Process Connections 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Typical Control Settings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Holding And Positioning Welding Gun 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4. Conditions That Affect Weld Bead Shape 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5. Gun Movement During Welding 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6. Poor Weld Bead Characteristics 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7. Good Weld Bead Characteristics 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8. TroubleshootingExcessive Spatter 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9. Troubleshooting Porosity 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10. Troubleshooting Excessive Penetration 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11. Troubleshooting Lack Of Penetration 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12. Troubleshooting Incomplete Fusion 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13. Troubleshooting Burn-Through 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14. Troubleshooting Waviness Of Bead 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15. Troubleshooting Distortion 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Troubleshooting Guide For Semiautomatic Welding Equipment 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 PARTS LIST 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY


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OM-923 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05

Y Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Y Marks a special safety message.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

D Do not touch live electrical parts.D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.D Use AC output ONLY if required for the welding process.D If AC output is required, use remote output control if present on

unit.D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conduc-tor first double-check connections.

D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it directly

with a separate cable.D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-chines at the same time since double open-circuit voltage will bepresent.

D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-typewelding power sources after removal of inputpower.D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Material Safety Data Sheets (MSDSs)and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.


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OM-923 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

D Wear an approved welding helmet fitted with a proper shade of fil-ter lenses to protect your face and eyes when welding or watching(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-rial (leather, heavy cotton, or wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.D Do not weld where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and fire

hazards.D Do not use welder to thaw frozen pipes.D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,they can throw off slag.D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun ortorch.D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.D Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.Noise from some processes or equipment candamage hearing.

D Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder explosion will result.D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is inuse or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.


7/44


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OM-923 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS 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, 1 Battery March Park, Quincy, MA022699101 (phone: 6177703000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:8004636727 or in Toronto 4167474044, website: www.csain-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 100368002 (phone: 2126424900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:6177703000, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Officesphone for Region 5, Chicago, is3123532220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees 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 beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables 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 before welding or going nearwelding operations. If cleared by your doctor, then following the aboveprocedures is recommended.


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OM-923 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONfre_som _3/05

Y Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

Symbole graphique davertissement ! Attention ! Cette pro-cdure comporte des risques possibles ! Les dangers ven-tuels sont reprsents par les symboles graphiques joints.

Y Indique un message de scurit particulier

. Signifie NOTE ; nest pas relatif la scurit.

Ce groupe de symboles signifie Avertissement ! Attention ! RisquesdLECTROCUTION, ORGANES MOBILES et PARTIESCHAUDES. Consulter les symboles et les instructions affrentesci-dessous concernant les mesures prendre pour supprimerles dangers.

2-2. Dangers relatifs au soudage larc

Y Les symboles reprsents ci-dessous sont utiliss dans ce manuelpour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructions enmatire de scurit indiques ci-dessous ne constituent quunsommaire des instructions de scurit plus compltes fourniesdans les normes de scurit numres dans la Section 2-5. Lire etobserver toutes les normes de scurit.

Y Seul un personnel qualifi est autoris installer, faire fonction-ner, entretenir et rparer cet appareil.

Y Pendant le fonctionnement, maintenir distance toutes les per-sonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr la

sortie. Le circuit dalimentation et les circuits internes de la machinesont galement sous tension lorsque lalimentation est sur Marche.Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalliques en contactavec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger.

D Ne pas toucher aux pices lectriques sous tension.D Porter des gants isolants et des vtements de protection secs et sans

trous.D Sisoler de la pice couper et du sol en utilisant des housses ou destapis assez grands afin dviter tout contact physique avec la pice couper ou le sol.

D Ne pas se servir de source lectrique courant lectrique dans les zo-nes humides, dans les endroits confins ou l o on risque de tomber.

D Se servir dune source lectrique courant lectrique UNIQUEMENT sile procd de soudage le demande.

D Si lutilisation dune source lectrique courant lectrique savre n-cessaire, se servir de la fonction de tlcommande si lappareil en estquip.

D Dautres consignes de scurit sont ncessaires dans les conditionssuivantes : risques lectriques dans un environnement humide ou si lonporte des vtements mouills ; sur des structures mtalliques telles quesols, grilles ou chafaudages ; en position coince comme assise, ge-noux ou couche ; ou sil y a un risque lev de contact invitable ouaccidentel avec la pice souder ou le sol. Dans ces conditions, utiliserles quipements suivants, dans lordre indiqu : 1) un poste souder DC tension constante ( fil), 2) un poste souder DC manuel (lectrode)ou 3) un poste souder AC tension vide rduite. Dans la plupart dessituations, lutilisation dun poste souder DC fil tension constanteest recommande. En outre, ne pas travailler seul !

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

D Installer le poste correctement et le mettre la terre convenablementselon les consignes du manuel de loprateur et les normes nationales,provinciales et locales.

D Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurerque le fil de terre du cordon dalimentation est bien raccord la bornede terre du sectionneur ou que la fiche du cordon est raccorde uneprise correctement mise la terre.

D En effectuant les raccordements dentre, fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

D Vrifier frquemment le cordon dalimentation afin de sassurer quilnest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nupeut entraner la mort.

D Lquipement doit tre hors tension lorsquil nest pas utilis.D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante

ou mal pisss.D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice, la terre

ou une lectrode provenant dune autre machine.D Ne pas toucher des porte lectrodes connects deux machines enmme temps cause de la prsence dune tension vide double.

D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

D Porter un harnais de scurit si lon doit travailler au-dessus du sol.D Sassurer que tous les panneaux et couvercles sont correctement en

place.D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de lasoudure.

D Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

D Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage.

Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur quand on a couplalimentation.D Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructions indi-ques dans la partie Entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereuse pour la sant.

LES FUMES ET LES GAZ peuventtre dangereux.

D Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces va-peurs.

D lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau delarc pour lvacuation des fumes et des gaz de soudage.

D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approu-v.

D Lire et comprendre les spcifications de scurit des matriaux (MSDS) etles instructions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

D Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours un sur-veillant dment form de se tenir proximit. Des fumes et des gaz desoudage peuvent dplacer lair et abaisser le niveau doxygne provo-quant des blessures ou des accidents mortels. Sassurer que lair derespiration ne prsente aucun danger.

D Ne pas souder dans des endroits situs proximit doprations de d-graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons delarc peuvent ragir en prsence de vapeurs et former des gaz haute-ment toxiques et irritants.

D Ne pas souder des mtaux munis dun revtement, tels que lacier gal-vanis, plaqu en plomb ou au cadmium moins que le revtement naitt enlev dans la zone de soudure, que lendroit soit bien ventil et enportant un respirateur alimentation dair. Les revtements et tous lesmtaux renfermant ces lments peuvent dgager des fumes toxi-ques en cas de soudage.


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Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brlures dans les yeux et sur la peau.

Des tincelles sont projetes pendant le soudage.

LES RAYONS DARC peuvent entra-ner des brlures aux yeux et la peau.

D Porter un casque de soudage approuv muni de verres filtrants ap-propri pour protger visage et yeux pendant le soudage (voir ANSIZ49.1 et Z87.1 numr dans les normes de scurit).

D Porter des lunettes de scurit avec crans latraux mme sous vo-tre casque.

D Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissements etles tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

D Porter des vtements confectionns avec des matires rsistanteset ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuventtre projetes de larc de soudure. La projection

dtincelles, des pices chaudes et des quipements chauds peuventprovoquer des incendies et des brlures. Le contact accidentel dellectrode avec des objets mtalliques peut provoquer des tincelles,une explosion, une surchauffe ou un incendie. Avant de commencerle soudage, vrifier et sassurer que lendroit ne prsente pas dedanger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

D Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soi-gneusement avec des protections homologues.

D Ne pas souder dans un endroit o des tincelles peuvent tomber surdes substances inflammables.

D Se protger, ainsi que toute autre personne travaillant sur les lieux,contre les tincelles et le mtal chaud.

D Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

D Afin dliminer tout risque de feu, tre vigilant et garder toujours unextincteur la porte de main.

D Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

D Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-

rs correctement conformment AWS F4.1 (voir les normes descurit).D Brancher le cble de masse sur la pice le plus prs possible de la

zone de soudage pour viter le transport du courant sur une longuedistance par des chemins inconnus ventuels en provoquant desrisques dlectrocution, dtincelles et dincendie.

D Ne pas utiliser le poste de soudage pour dgeler des conduitesgeles.

D En cas de non-utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

D Porter des vtements de protection exempts dhuile tels que desgants en cuir, une veste rsistante, des pantalons sans revers, desbottes et un casque.

D Avant de souder, retirer toute substance combustible de ses pochestelles quun allumeur au butane ou des allumettes.

D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51Bpour travaux de soudage et prvoir un dtecteur dincendie et un ex-tincteur proximit.

DES PARTICULES VOLANTESpeuvent blesser les yeux.D Le soudage, lcaillement, le passage de la

pice la brosse en fil de fer, et le meulagegnrent des tincelles et des particulesmtalliques volantes. Pendant la priode derefroidissement des soudures, elles risquentde projeter du laitier.

D Porter des lunettes de scurit avec crans latraux ou un cranfacial.

LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort.D Fermer lalimentation du gaz protecteur en cas

de non-utilisation.D Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

DES PICES CHAUDES peuvent

provoquer des brlures graves.D Ne pas toucher des parties chaudes mainsnues.

D Prvoir une priode de refroidissement avantdutiliser le pistolet ou la torche.

D Ne pas toucher aux pices chaudes, utiliser les outils recom-mands et porter des gants de soudage et des vtements paispour viter les brlures.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.D Porteurs de stimulateur cardiaque, rester

distance.D Les porteurs dun stimulateur cardiaque doi-

vent dabord consulter leur mdecin avant desapprocher des oprations de soudage larc,de gougeage ou de soudage par points.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

D Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles degaz font normalement partie du procd de soudage,les manipuler avec prcaution.

D Protger les bouteilles de gaz comprim dune chaleur excessi-ve, des chocs mcaniques, des dommages physiques, du lai-tier, des flammes ouvertes, des tincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support sta-tionnaire ou dans un porte-bouteilles pour les empcher de tom-ber ou de se renverser.

D Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

D Ne jamais placer une torche de soudage sur une bouteille gaz.D Une lectrode de soudage ne doit jamais entrer en contact avec

une bouteille.D Ne jamais souder une bouteille pressurise risque dexplosion.D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifi-que ; les maintenir ainsi que les lments associs en bon tat.

DDtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

D Le couvercle du dtendeur doit toujours tre en place, sauf lors-que la bouteille est utilise ou quelle est relie pour usage ult-rieur.

D Utiliser les quipements corrects, les bonnes procdures et suf-fisamment de personnes pour soulever et dplacer les bouteil-les.

D Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scuri-t.

LES BOUTEILLES peuvent explosersi elles sont endommages.


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2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLO-SION.D Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables.D Ne pas installer lappareil proximit de

produits inflammables.D Ne pas surcharger linstallation lectrique sassurer que

lalimentation est correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.D Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

D Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

LEMPLOI EXCESSIF peut SUR-CHAUFFER LQUIPEMENT.D Prvoir une priode de refroidissement ;

respecter le cycle opratoire nominal.D Rduire le courant ou le facteur de marche

avant de poursuivre le soudage.D Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATIQUESpeuvent endommager les circuitsimprims.D tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices.D Utiliser des pochettes et des botes antistati-

ques pour stocker, dplacer ou expdier descartes PC.

DES ORGANES MOBILES peuventprovoquer des blessures.D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.D Ne pas appuyer sur la gchette avant den

avoir reu linstruction.D Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique en enga-geant le fil de soudage.

DES ORGANES MOBILES peuventprovoquer des blessures.D Sabstenir de toucher des organes mobiles tels

que des ventilateurs.D Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

D Seules des personnes qualifies sont autorises enlever les

portes, panneaux, recouvrements ou dispositifs de protectionpour lentretien.D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.D Lire le manuel dutilisation avant dutiliser ou

dintervenir sur lappareil.D Utiliser uniquement des pices de rechange

Miller/Hobart.

LE RAYONNEMENT HAUTEFRQUENCE (HF) risque de provoquerdes interfrences.

D Le rayonnement haute frquence (HF) peutprovoquer des interfrences avec les quipe-ments de radio-navigation et de communica-tion, les services de scurit et les ordinateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstal-lation.

D Lutilisateur est tenu de faire corriger rapidement par un lectri-cien qualifi les interfrences rsultant de linstallation.

D Si le FCC signale des interfrences, arrter immdiatementlappareil.

D Effectuer rgulirement le contrle et lentretien de linstallation.D Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs unedistance correcte et uti liser une terre et un blindage pour rduireles interfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.D Lnergie lectromagntique peut gner le

fonctionnement dappareils lectroniquescomme des ordinateurs et des robots.

D Veiller ce que tout lquipement de la zone desoudage soit compatible lectromagntiquement.

D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

D Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

D En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation decbles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Y Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiques dontltat de Californie reconnat quils provoquent des malformationscongnitales et, dans certains cas, des cancers. (Code de sant etde scurit de Californie, chapitre 25249.5 et suivants)

Y Les batteries, les bornes et autres accessoires contiennent duplomb et des composs base de plomb, produits chimiquesdont ltat de Californie reconnat quils provoquent des can-cers et des malformations congnitales ou autres problmes deprocration. Se laver les mains aprs manipulation.

Pour les moteurs essence :Y Les gaz dchappement des moteurs contiennent des produits

chimiques dont ltat de Californie reconnat quils provoquentdes cancers et des malformations congnitales ou autres pro-blmes de procration.

Pour les moteurs diesel :Y Les gaz dchappement des moteurs diesel et certains de leurs

composants sont reconnus par ltat de Californie commeprovoquant des cancers et des malformations congnitales ou au-tres problmes de procration.


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2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, site In-ternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society Standard AWSF4.1 de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite1004, Arlington, VA 22202-4102 (tlphone : 703-412-0900, site Internet: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, deCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (tlphone :800-463-6727 ou Toronto 416-747-4044, site Internet :www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, de American National Standards Institute, 11 West42nd Street, New York, NY 10036-8002 (tlphone : 212-642-4900, siteInternet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association, P.O.

Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (tlphone :617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Industry,Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, andPart 1926, Subpart J, de U.S. Government Printing Office, Superinten-dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10bureaux rgionauxle tlphone de la rgion 5, Chicago, est312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

Considrations sur le soudage et les effets de basse frquence et deschamps magntiques et lectriques.Le courant de soudage, pendant son passage dans les cbles de souda-ge, causera des champs lectromagntiques. Il y a eu et il y a encore uncertain souci propos de tels champs. Cependant, aprs avoir examin

plus de 500 tudes qui ont t faites pendant une priode de recherchede 17 ans, un comit spcial ruban bleu du National Research Council aconclu : Laccumulation de preuves, suivant le jugement du comit, napas dmontr que lexposition aux champs magntiques et champs lec-triques haute frquence reprsente un risque la sant humaine .Toutefois, des tudes sont toujours en cours et les preuves continuent tre examines. En attendant que les conclusions finales de la recherchesoient tablies, il vous serait souhaitable de rduire votre exposition auxchamps lectromagntiques pendant le soudage ou le coupage.Pour rduire les champs magntiques sur le poste de travail, appliquerles procdures suivantes :

1. Maintenir les cbles ensemble en les tordant ou en les enveloppant.

2. Disposer les cbles dun ct et distance de loprateur.

3. Ne pas courber pas et ne pas entourer pas les cbles autour devotre corps.

4. Garder le poste de soudage et les cbles le plus loin possible devous.

5. Connecter la pince sur la pice aussi prs que possible de la sou-dure.

En ce qui concerne les stimulateurs cardiaquesLes porteurs de stimulateur cardiaque doivent consulter leur mdecinavant de souder ou dapprocher des oprations de soudage. Si le mde-cin approuve, il est recommand de suivre les procdures prcdentes.


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SECTION 3 SPECIFICATIONS

3-1. Specifications

Rated WeldingOutput

MaximumAmperage

Maximum Open-Circuit Voltage

DC

Amperes Input atRated Load Output115 V, 60 Hz, Single-

Phase

KVA KWWeightW/ Gun

OverallDimensions

90 A @ 19 Volts DC,20% Duty Cycle

63 A @ 21 Volts DC,20% Duty Cycle*

125 2920

15*

2.90

2.20*

2.50

1.77*

50 lb(22.7 kg)

Length: 16-7/8 in(429 mm)

Width: 9-7/8 in(251 mm)

Height: 12-1/8 in(308 mm)

Flux Cored Wire Feed Speed Range

Wire TypeAnd Dia .030 .035 in

(0.8 0.9 mm)183295 IPM (4.6 7.5 m/min) At No Load

112 236 IPM (2.8 6.0 m/min) Feeding Wire

* CSA Rating

3-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

Y Exceeding duty cycle candamage unit or gun and voidwarranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutesduty1 4/95210 517-A

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting

1 4 20 40 60 1002 6 810

20

40

60

80

100

200

135

10

Duty Cycle %

OutputAmperes


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SECTION 4 INSTALLATION4-1. Installing Work Clamp

1 Nut2 Work Cable From Unit3 Work Clamp4 Screw5 Work Clamp Tabs

Bend tabs around work cable.6 Insulator Grip

Slide one insulating grip over workcable before connecting to clamp.

Slide insulating grips over handles.

Ref. 802 456

1

2

3

45

Tools Needed:

7/16 in

6

. Connection hardware must be tightened with proper tools. Do not justhand tighten hardware. A loose electrical connection will cause poorweld performance and excessive heating of the work clamp.

7/16 in

4-2. Process/Polarity Table

Cable ConnectionsProcess Polarity

Cable To Gun Cable To Work Clamp

FCAW Self-shielding wire no shielding gas

DCEN Straight Polarity Connect to negative ()output terminal

Connect to positive (+) outputterminal

4-3. Polarity

. Polarity must be set for DCEN(flux core wire) only.1 Lead Connections For Direct

Current Electrode Negative(DCEN)

Always read and follow wiremanufacturers recommendedpolarity, and see Section 4-2.

Close door.

Ref. 210 428

1


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4-4. Installing Wire Spool And Adjusting Hub Tension

When a slight force is neededto turn spool, tension is set.

1/2 in

Tools Needed:

Ref. 802 971-C / 803 012 / 803 013 -B

Installing 8 in (203 mm) Wire Spool

Installing 4 in (102 mm) Wire Spool

When a slight force is neededto turn spool, tension is set.

Retaining ring used

with 8 in (203 mm)spool only.

Adapter used with8 in (203 mm)

spool only.

. Only applies to units equipped withoptional hub kit.

. Overtightening hub tension maycause wire feed problems.


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4-5. Selecting A Location And Connecting Input Power For 115 VAC Model

1 Rating Label2 Grounded Receptacle

A 115 volt, 20 ampere individualbranch circuit protected by time-de-lay fuses or circuit breaker is re-quired.

3 Plug From Unit

Select extension cord of 14 AWGfor up to 50 ft (15 m) or 12 AWG for50 up to 200 ft (61 m).Y Special installation may be

required where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

804 122-C

Y Do not move or operate unitwhere it could tip.

18 in(460 mm)

18 in(460 mm)

12

3


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OM-923 Page 14

4-6. Installing Contact Tip And Nozzle

Tools Needed:

Ref. 804 241-A

Y Turn off welding power source.

1 Nozzle

Remove nozzle.

2 Contact Tip

3 Tip Adapter

Thread welding wire through gun (seeSection 4-7).

Slide contact tip over wire and tightentip into tip adapter.

Install nozzle.1

2 3

Flux Nozzle MIG NozzleUse with flux cored wire only.Narrow design allows access intight spaces and provides bettervisibility of puddle during welding.

Use with solid or flux cored wire.

Push nozzle over contact tip andadapter until it is seated ontoadapter. Contact tip will beexposed approximately 7/16 in(11.3 mm) when installed properly.

Push nozzle over contact tip andadapter until it is seated ontoadapter. End of contact tip will beflush with end of nozzle wheninstalled properly.


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OM-923 Page 15

4-7. Threading Welding Wire

1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Gun Cable

Lay gun cable out straight.

Tools Needed:

Pull and hold wire; cut off end.

4 in(102 mm)

Remove gun nozzle and contact tip.

Open pressure assembly. Push wire thru guides into gun liner;continue to hold wire.

. Hold wire tightly to keep itfrom unraveling.

804 123-A

WOOD

Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Press gun trigger until wire comesout of gun.

Turn power on.

INPUTPOWER

6 in(150 mm)

Tighten. Loosen knob completely, then rotate

pressure adjustment knob in aclockwise direction until drive roll is

tight against the welding wire.Adjust drive roll pressure justtightly enough to prevent wirefrom slipping against drive rollduring operation.

Tighten

Be sure that wire is positionedin proper feed roll groove.

Close and tighten pressureassembly, and let go of wire.

Be sure that contact tip matches wire diameter.Reinstall tip adapter, if applicable, contact tipand nozzle.

. Tip adapter may also require removalto allow wire to feed out end of gun.

+

+

61 2 3 5

4

+


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OM-923 Page 16

SECTION 5 OPERATION5-1. Controls

1 Material Thickness SelectorSwitch

Use switch to select the materialthickness range. Do not switchunder load.

.Switch must click into detentposition for weld output.

2 Power Switch

Ref. 230 001-A

1

2


21/44

OM-923 Page 17

5-2. Operating The Gun

Ref. 804 240-A

1 Trigger Switch

When pressed, energized wirefeeds.

1


22/44

OM-923 Page 18

SECTION 6 MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Repair orreplacecrackedweld cable.

Clean andtighten weldterminals.

6 Months

Blow out or

vacuum inside.During heavyservice, cleanmonthly.

Or

6-2. Overload Protection

804 127-A

1 Supplementary Protector CB1

CB1 protects unit from overload. IfCB1 opens, unit shuts down.

Reset supplementary protector.1

6-3. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release guntrigger and wait until protection circuit resets allowing drive motor to feed wire again.


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OM-923 Page 19

6-4. Changing Drive Roll Or Wire Inlet Guide

1 Pressure Adjustment Knob2 Pressure Assembly

Pivot pressure adjustment knobdown, and lift pressure assemblyup.

3 Pivot Tube Plate4 Securing Screws5 Pressure Arm Pivot Tube

6 Inlet Wire GuideRemove screws and pivot tubeplate. Lift out pressure arm pivottube, and slide inlet wire guide out oftube.

Slide replacement wire guide intotube, and place tube back into driveassembly. Be sure tip of wire guideis as close to drive roll as possiblewithout touching.

Reinstall plate and tighten screws.

7 Retaining Knob

Rotate counterclockwise andremove knob.

8 Drive Roll

The drive roll consists of twodifferent sized grooves. Each sideis stamped with the proper size.

Select the groove that matches thewire size on the wire spool. Installdrive roll onto motor shaft so thatcorrect groove size stamp faces outaway from drive housing.

9 Retaining Knob Opening

Install retaining knob by placingopening over drive roll (openingfaces rear of unit). Rotate retainingknob clockwise to secure drive roll.

Position wire into outer groove ofdrive roll (see Section 4-7).

Tools Needed:

804 123-A / 804 129-A

.024 Groove.030/.035

VK Groove

Stamped .024Stamped .030/.035

3 4

56

5/16 in

8

9

+

1

2

+

7

+


24/44

OM-923 Page 20

6-5. Replacing Gun Contact Tip

Tools Needed:

Ref. 804 241-A


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 contact tip. Reinstall

nozzle.

1

23


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OM-923 Page 21

6-6. Cleaning Gun Liner

804 241-A / Ref. 804 123-A / 804 128-A / Ref. 803 837-A


1 Nozzle

2 Contact Tip

3 Adapter

HeadTube

Tools Needed:

8 mm

Lay gun cable out straight,and blow out liner.

Remove nozzle. Cut off wireat contact tip, and removecontact tip and tip adapter.

. Thread wire according toSection 4-7.

Reassemble drive coverand gun in reverse orderfrom taking it apart.

Open pressure assembly. Retractwire from liner onto spool.

. Hold wire tightly to keep itfrom unraveling. Secureend of wire at spool.

Remove screws (3) fromcover, and remove coverfrom wire drive assembly.

8 mm

1

2

3

+

+

+


26/44

OM-923 Page 22

6-7. Replacing Gun Liner

Ref. 804 241-A / 804 123-A / 803 837-A / 803 899-A

Tools Needed:

8 mm / 10 mm

Remove nozzle. Cut off wireat contact tip, and removecontact tip and tip adapter.

Open pressure assembly. Retractwire from liner onto spool.

. Hold wire tightly to keep itfrom unraveling. Secureend of wire at spool.

Twist top and bottom handle locking ringscounterclockwise 1/4 turn. Slide bottom ringdown cable and top ring forward over headtube. Separate gun handle halves.

Loosen liner setscrew.

Loosen and removeretaining nut from liner.Pull liner out of guncable. If necessary, twistcable to ease removal.


Install retaining nut on one end of liner. Laygun cable straight on a flat surface. Insertbare end of liner (end without retaining nut)into wire drive end of cable. Push linertoward gun. If necessary, twist cable toease installation.

Remove screws (3) fromcover, and remove coverfrom wire drive assembly.

8 mm Remove black sleeving fromend of replacement liner.

HeadTube

8 mm

1

23

+

+


27/44

OM-923 Page 23

6-7. Replacing Gun Liner (Continued)

When liner exits cable at gunhandle, guide liner into headtube. Continue to push liner untilit exits end of head tube.

Slide locking rings over top andbottom of handle, and secure bytwisting rings clockwise 1/4 turn.

Place other half of handle overhead tube and cable.

Be sure that cable is straight.Tighten liner setscrew. Cutliner so that 3/8 in (10 mm)sticks out of head tube. Filedown any sharp points onliner after cutting to length.

3/8 in (10 mm)

Reassemble gun by placing head tubeand cable into one half of handle. Besure trigger is properly installed intotrigger slot.

Thread welding wire throughgun (see Section 4-7). Reinstalladapter, contact tip, and nozzle.

Reinstall cover onto wiredrive assembly, and securewith screws (3).

Insert retaining nut into adapter, and adjust liner stickout asshown. Tighten retaining nut. Reinstall cable end into drivehousing with retaining grooves inserted into the two retainingribs. Be sure to position gas hose up. Position liner in grooveso that end is flush with back of groove, adjust if necessary

13/16 in(21 mm)

8 mm

8 mm

+


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OM-923 Page 24

6-8. Troubleshooting Table

Trouble Remedy

Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.welding.

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 Authorized Service Agent check drive motor.

No weld output; wire does not feed; fan

Secure power cord plug in receptacle (see Section 4-5).oes not run.

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; fanmotor continues to run.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat resets whenunit 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 looseconnections.

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 weldingpower source (see Section 3-1).


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OM-923 Page 25

SECTION 7 ELECTRICAL DIAGRAM

230 951-A

Figure 7-1. Circuit Diagram


30/44

OM-923 Page 26

SECTION 8 WIRE WELDING GUIDELINES

8-1. Typical FCAW Process Connections

Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Wire Feeder/Power Source

Workpiece

Gun

Work Clamp

fcaw 1/2003 / Ref. 803 444-A

Self-Shielding FluxCore Wire


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OM-923 Page 27

8-2. Typical Control Settings

These settings are guidelines only. Material and wire type, joint design, fitup,position, etc. affect settings. Test welds to be sure they comply to specifications.

NOTE

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

30 90 A

40 145 A

50 180 A

Convert MaterialThickness toAmperage (A)

Material thickness determines weldparameters.

.035 in

Recommendation Wire Speed(Approx.)

1/8 or 0.125 in

(0.001 in = 1 ampere)0.125 in = 125 A

Wire Size Amperage Range

0.023 in

0.030 in

0.035 in

Select Wire Size

WireSize

0.023 in

0.030 in

0.035 in

3.5 in per ampere

2 in per ampere

1.6 in per ampere

Select Wire Speed(Amperage)

125 A based on 1/8 inmaterial thickness

ipm = inches per minute

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

Metal thickness select will controlboth voltage and wire feed speed byselecting metal thickness.


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OM-923 Page 28

8-3. Holding And Positioning Welding Gun

Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,and tip of wire is positioned correctly on seam.

NOTE

1 Hold Gun and Control GunTrigger

2 Workpiece3 Work Clamp4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)5 Cradle Gun and Rest Hand on

Workpiece

23

5

4

90 90

0-15

45

45

1

0-15

S-0421-A

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

End View of Work Angle Side View of Gun Angle

FILLET WELDS

Drag


33/44

OM-923 Page 29

8-4. Conditions That Affect Weld Bead Shape

Weld bead shape depends on gun angle, direction of travel, electrode extension(stickout), travel speed, thickness of base metal, wire feed speed (weld current),and voltage.

NOTE

Slow

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

ELECTRODE EXTENSIONS (STICKOUT)

GUN ANGLES AND WELD BEAD PROFILES

10 10

GUN TRAVEL SPEED S-0634

Push Perpendicular Drag or Pull

Short Normal Long

Short Normal Long

Normal Fast

Electrode directedahead of bead

Electrode pointedback into bead

Direction Of Welding

. The Drag or Pull technique is generally recommended when welding with flux-cored tubular wire.


34/44

OM-923 Page 30

8-5. Gun Movement During Welding

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide groove weld joints or bridging across gaps, a weave bead ormultiple stringer beads works better.

NOTE

1 Stringer Bead

SteadyMovement Along Seam2 Weave Bead Side To Side

Movement Along Seam3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During Welding4 Bad Overlap5 Poor Penetration

5

42 3

1

S-0053-A

8-7. Good Weld Bead Characteristics

1 Fine Spatter2 Uniform Bead3 Moderate Crater During

WeldingWeld a new bead or layer for each1/8 in (3.2 mm) thickness in metalsbeing welded.

4 No Overlap5 Good Penetration into Base

Metal

S-0052-B

2 3

1

4

5


35/44

OM-923 Page 31

8-8. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Metal Thickness Selector switch set toohigh.

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 lubricant on welding wire from feeder or liner.

8-9. Troubleshooting Porosity

Porositysmall cavities or holes resulting from gas pocketsin weld metal.

S-0635


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

Good Penetration

Excessive Penetration weld metal melting through base metaland hanging underneath weld.

Excessive PenetrationS-0639


Excessive heat input. Set Metal Thickness Selector switch to a lower selection.

Increase travel speed.


36/44

OM-923 Page 32

8-11. Troubleshooting Lack Of Penetration

Lack Of Penetration shallowfusion between weld metal andbase metal.

Lack of Penetration Good PenetrationS-0638


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum 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 withbase metal or a preceeding weld bead.

S-0637


Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.

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-Throughweld metal melting completely through base metalresulting in holes where no metal remains.

S-0640


Excessive heat input. Set Metal Thickness Selector switch to a lower selection.

Increase and/or maintain steady travel speed.


37/44

OM-923 Page 33

8-14. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not coverjoint formed by base metal.

S-0641


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 forcesbase metal to move.

Base metal movesin the direction of

the weld bead.S-0642


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.w re oes not ee .

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matchwire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, tip adapter, and contacttip 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.w re ee ro s r nest ng .

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner lengthand 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 worndrive 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 onwelding power source.

Change Metal Thickness Selector switch setting.

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.


38/44

OM-923 Page 34

SECTION 9 PARTS LIST

. Hardware is common andnot available unless listed.

804 124-B

1

2

3

4

5

6

6

7

8

910

11

12

13

14

15

16

17

18

19

36

20

21

22

23

24

25

26

27

30

28

29

31

32

33

34

35

37

Figure 8-1. Main Assembly


39/44

OM-923 Page 35

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Main Assembly

Quantity

1 210 432 CASE SECTION, front/bottom/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 530 BLANK, snap-in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 210 433 BAFFLE, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 +210 434 WRAPPER, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 210 435 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 213 643 BEZEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 196 006 HINGE, door access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 222 457 CIRCUIT CARD ASSY, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 134 201 STANDOFF 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 209 356 RECTIFIER, assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 209 392 BUS BAR, output positive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 193 194 BUS BAR, output negative 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 210 109 SUPPLEMENTARY PROTECTOR, man reset 1P 25A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . .13 111 443 BUSHING, strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 147 545 CORD SET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 208 015 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 209 467 MOTOR, fan 115VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 210 413 BLADE, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 209 213 TRANSFORMER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 203 868 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 196 575 SWITCH, rocker spst 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 229 432 SWITCH, rotary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 207 079 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 210 398 BUSHING, snap-in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 209 412 BUSHING, snap-in .500 dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 209 532 DRIVE, assy wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 193 144 INSULATOR, output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 202 726 ADAPTER, spool hub 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 202 998 SPRING, cprsn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 204 608 NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 203 072 WASHER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 225 397 H-9B GUN, 8 ft .023-.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 223 790 LABEL, setup guide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 204 036 LABEL, warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 208 820 CLAMP, work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 196 619 CABLE, work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 210 530 BLANK, snapin nyl 1.250 mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 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 Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


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OM-923 Page 36

1

804 243-A

2

3

5 See Table 8-1

4

6

7

7

Figure 8-2. H-9B Gun

DescriptionPartNo.

225 397

ItemNo.

Figure 8-2. H-9B Gun

Quantity

1 169 715 NOZZLE, slip type .500 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 226 190 NOZZLE, flux cored slip type 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 169 716 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 225 410 SWITCH, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 210 970 LINER, monocoil .023/.035 wire x 8ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 087 299 TIP, contact scr .023 wire x 1.125. . . . . . . . . . . . . . . . .

5 000 067 TIP, contact scr .030 wire x 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 000 068 TIP, contact scr .035 wire x 1.125. . . . . . . . . . . . . . . . .6 226 010 NUT, liner retainer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 226 080 HANDLE ASSY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement 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 5196 132 Tip, contact scr .035 wire Pkg of 5

196 137 Nozzle, slip type .500 orf flush Qty 1

196 135 Adapter, contact tip Qty 1

WELD-IT PART NO. DESCRIPTION REMARKS

770 174 Tip, contact scr .023 wire Pkg of 5




41/44

OM-923 Page 37

803 442-B4

5

1

6

7

8

9

2

3

Figure 8-3. Wire Drive Assembly

QuantityDescriptionPartNo.

209 532

ItemNo.

Figure 8-3. Wire Drive Assembly

1 212 377 BEARING, idler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 212 379 ROLL, drive .024-.030/.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 212 383 RETAINER, feedroll 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 212 368 GUIDE, wire inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 212 384 COVER, torch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 212 385 KNOB, tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 212 387 SPRING, compression 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 212 388 CUP, spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 212 389 SCREW, torch cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement 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 Maneuverabil ity

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.


42/44

Notes


43/44

Warranty Questions?

Call1-800-332-32817 AM 6 PM EST

hobart_warr 2006

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor or

call 1-800-332-3281. Theexpertise of the distributorand Hobart is there tohelp you, every step ofthe way.

AssistanceVisit the Hobart website:www.HobartWelders.com

Effective January 1, 20065/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with

serial number preface LG 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 conditionsbelow, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin,warrants to i

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