Handler 190 And H100S4-10 Gun

www.HobartWelders.com

TM-260 273B 2013−02

Eff. w/Serial No. MC420249Y

Processes

Arc Welding Power Source AndWire Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

File: MIG (GMAW)

Handler 190 AndH100S4-10 Gun

�

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Serial Number And Rating Label Location 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Unit Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Duty Cycle And Overheating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4. Volt-Ampere Curves 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Installing Nozzle, Contact Tip, And Adapter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Installing Welding Gun 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Work Clamp 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Process/Polarity Table 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. Changing Polarity 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6. Installing Gas Supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7. Serial Number And Rating Label Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Selecting A Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9. Installing Wire Spool And Adjusting Hub Tension 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10. Electrical Service Guide 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11. Connecting Input Power 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12. Connecting Optional Spool Gun 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 4 − OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Weld Parameter Chart For 230 VAC Model 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − THEORY OF OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 − TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Troubleshooting Circuit Diagram For Welding Power Source 22. . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Control Board PC1 Testing Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Control Board PC1 Test Point Values 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 7 − MAINTENANCE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Overload Protection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Drive Motor Protection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Changing Drive Roll Or Wire Inlet Guide 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing 28. . . . . . . . . . . . .7-6. Replacing Switch And/Or Head Tube 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 − PARTS LIST 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Optional Drive Rolls 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5. Options 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Consumables 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hobart is registered tothe ISO 9001 QualitySystem Standard.

TM-260 273 Page 1Handler 190

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICINGProtect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol UsageOM-260 273-A - 2012−10, safety_stm 2011−10

DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE − Indicates statements not related to personal injury.

� Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard.

Only qualified persons should test, maintain, and repair thisunit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Turn Off welding power source and wire feeder

and disconnect and lockout input power usingline disconnect switch, circuit breakers, or by removing plug from re-ceptacle, or stop engine before servicing unless the procedure spe-cifically requires an energized unit.

� Insulate yourself from ground by standing or working on dry insulat-ing mats big enough to prevent contact with the ground.

� Do not leave live unit unattended.

� If this procedure requires an energized unit, have only personnelfamiliar with and following standard safety practices do the job.

� When testing a live unit, use the one-hand method. Do not put bothhands inside unit. Keep one hand free.

� Disconnect input power conductors from deenergized supply lineBEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of input power.

� Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Troubleshooting Section be-fore touching any parts.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

� Use proper static-proof bags and boxes tostore, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

� Do not place unit on, over, or near combustiblesurfaces.

� Do not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

� Wear safety glasses with side shields or faceshield during servicing.

� Be careful not to short metal tools, parts, orwires together during testing and servicing.

HOT PARTS can burn.

� Do not touch hot parts bare handed.� Allow cooling period before working on

equipment.� To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

EXPLODING PARTS can injure.

� Failed parts can explode or cause other parts toexplode when power is applied to inverters.

� Always wear a face shield and long sleeveswhen servicing inverters.

SHOCK HAZARD from testing.

� Turn Off welding power source and wire feederor stop engine before making or changing me-ter lead connections.

� Use at least one meter lead that has a self-retaining spring clip such as an alligator clip.

� Read instructions for test equipment.

FALLING EQUIPMENT can injure.

� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

� Use equipment of adequate capacity to lift andsupport unit.

� If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

� Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94−110) when manu-ally lifting heavy parts or equipment.

TM-260 273 Page 2 Handler 190

MOVING PARTS can injure.

� Keep away from moving parts such as fans.� Keep away from pinch points such as drive

rolls.� Have only qualified persons remove doors,

panels, covers, or guards for maintenance andtroubleshooting as necessary.

� Keep hands, hair, loose clothing, and toolsaway from moving parts.

� Reinstall doors, panels, covers, or guardswhen maintenance is finished and before re-connecting input power.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.

� Wearers of Pacemakers and other ImplantedMedical Devices should keep away from serv-icing areas until consulting their doctor and thedevice manufacturer.

OVERUSE can cause OVERHEATING.

� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before

starting to weld again.� Do not block or filter airflow to unit.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

� Have only qualified persons familiar withelectronic equipment install, test, and serviceH.F. producing units.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

� If notified by the FCC about interference, stop using theequipment at once.

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

READ INSTRUCTIONS.

� Use Testing Booklet (Part No. 150 853) whenservicing this unit.

� Consult the Owner’s Manual for welding safetyprecautions.

� Use only genuine replacement parts from the manufacturer.� Read and follow all labels and the Technical Manual carefully be-

fore installing, operating, or servicing unit. Read the safety in-formation at the beginning of the manual and in each section.

1-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electricand magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, restrict access for passers−by or conduct individual risk as-sessment for welders. All welders should use the following proceduresin order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in thewelding circuit as possible.

5. Connect work clamp to workpiece as close to the weld aspossible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.


SECTION 2 − SPECIFICATIONS

2-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.For future reference, write serial number in space provided on back cover of this manual.

2-2. Unit Specifications

Rated WeldingOutput

AmperageRange

Maximum Open-Circuit Voltage

DC

Amperes Input atRated Load Output

230 V, 60 Hz,Single-Phase

KVA KWWeightW/ Gun

Overall Dimensions

130 A @ 21.5 VoltsDC, 30% Duty Cycle 25 − 190 31 20.5 4.7 3.88

68 lb(31 kg)

Length: 19-1/2 in.(495 mm)

Width: 10-5/8 in.(270 mm)

Height: 12-3/8 in.(314 mm)

Wire TypeAnd Diameter

Solid/Stainless

Flux Cored AluminumWire Feed Speed Range

.023 − .035 in.(0.6 − 0.9 mm)

.030 − .045 in.(0.8 − 1.2 mm)

.030 − .035 in.(0.8 − 0.9 mm)

50 − 740 IPM (1.3 − 18.8 m/min) At No Load40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire

2-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.

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

NOTICE − Exceeding duty cyclecan damage unit or gun and voidwarranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutesduty1 4/95 − 248 832-A

30% duty cycle at 130 amps

3 Minutes Welding 7 Minutes Resting

Ou

tpu

t Am

per

es

Duty Cycle %

10

20

40

60

80100

200

10 20 30 40 50 60 70 80 100

130

175


2-4. Volt-Ampere Curves

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

ssb1.1 10/91 − 248 833-A

0

5

10

15

20

25

30

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Vo

ltag

e

Amperage

123456

7

SECTION 3 − INSTALLATION3-1. Installing Nozzle, Contact Tip, And Adapter

Ref. 243 839-A

! Turn off welding powersource.

1 Nozzle

2 Contact Tip

3 Tip Adapter

� Wire size stamped on tip − checkand match wire size.

Tools Needed:

8 mm

HeadTube

8 mm

1

32


3-2. Installing Welding Gun

260 458-A

1 Drive Assembly

2 MIG Gun

3 Gun Securing Thumbscrew

4 Gun End

Loosen thumbscrew. Insert endthrough opening until it bottomsagainst drive assembly. Tightenthumbscrew.

Welding gun must be insertedcompletely to prevent leakage ofshielding gas.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

6 Spool Gun/MIG Gun Switch

Place switch in MIG Gun position.

Close door.

CorrectIncorrect

� Be sure that gun end is tight against drive assembly.

4

Gun Fully Seated

4

Gun Not Seated

Exposed O-ringswill cause shielding

gas leakage.

Spool Gun

ÉÉÉÉÉÉÉÉÉ

5

MIG Gun6

1 3 24


3-3. Installing Work Clamp

258 550-A

1

2

3

4

5

6

� Connection hardware must be tightened with propertools. Do not just hand tighten hardware. A looseelectrical connection will cause poor weld performanceand excessive heating of the work clamp.

1 Work Clamp

2 Work Cable From Unit

3 Screw

4 Flat Washer

5 Lock Washer

6 Nut

Route work cable through hole inclamp handle. Secure cable withhardware as shown.

Tools Needed:

10 mm


3-4. Process/Polarity Table

Process PolarityCable Connections

Cable To Gun Cable To Work

GMAW − Solid wire with shield-ing gas

DCEP − Reverse polarity Connect to positive (+) out-put terminal

Connect to negative (−) outputterminal

FCAW − Self-shielding wire −no shielding gas

DCEN − Straight Polarity Connect to negative (−)output terminal

Connect to positive (+) outputterminal

3-5. Changing Polarity


1 Lead Connections For DirectCurrent Electrode Negative(DCEN)

2 Lead Connections For DirectCurrent Electrode Positive(DCEP)

Always read and follow wiremanufacturer’s recommendedpolarity, and see Section 3-4.

Close door.

260 459-A

1

2

CHANGINGPOLARITY

DCENElectrode negativefor flux cored wire

DCEPElectrode positive

for solid wire


3-6. Installing Gas Supply

Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter GasHose Connection

6 Welding Power Source GasHose Connection

Connect supplied gas hosebetween regulator/flowmeter gashose connection, and fitting on rearof welding power source.

7 Flow Adjust

Flow rate should be set when gas isflowing through welding powersource and welding gun. Openpressure assembly so that wire willnot feed. Press gun trigger to startgas flow.

Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturer’s recommendedflow rate.

After flow is set, close pressureassembly.

260 460-A

� DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2 shielding gas. See Parts List for optionalCO2 gas regulator/flowmeter.

Pressure AssemblyOpen

Pressure AssemblyClosed

Argon Gas OrMixed Gas

1

2

3

4

5

7

6

Tools Needed:

5/8 or 11/16, 1-1/8 in.


3-7. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or ratedoutput. For future reference, write serial number in space provided on back cover of this manual.

1 Line Disconnect Device

Locate unit near correct input powersupply.

! Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20.

3-8. Selecting A Location

1

18 in(460 mm)

18 in(460 mm)

Location And Airflow

260 711-B / ST-139 445-E

! Do not move or operate unitwhere it could tip.


3-9. Installing Wire Spool And Adjusting Hub Tension

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

1/2 in.

Tools Needed:

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

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 usedwith 8 in. (203 mm)

spool only.

Adapter used with8 in. (203 mm)

spool only.


3-10. Electrical Service Guide Elec Serv 2011−08

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the ratingof the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and630.12.

60 HzSinglePhase

Input Voltage (V) 230

Input Amperes (A) At Rated Output 20.5

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 25

Normal Operating Fuses 3 30

Min Input Conductor Size In AWG 4 14

Max Recommended Input Conductor Length In Feet (Meters)67

(20)

Min Grounding Conductor Size In AWG 4 14

Reference: 2011 National Electrical Code (NEC) (including article 630)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 “Time-Delay” fuses are UL class “RK5” . See UL 248.3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cablerequirements.


3-11. Connecting Input Power

input4 2012−05 − Ref. 803 766-C / 260 711-A

L1L2

230 VAC, 1

7

9

Tools Needed:

2

1

L1L2

1

=GND/PE Earth Ground

6

5

3

4

7


input4 2012−05 − 803 766-C / 260 711-A

! Installation must meet all National andLocal Codes − have only qualified per-sons make this installation.

! Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit. Follow establishedprocedures regarding the installationand removal of lockout/tagoutdevices.

! Always connect green or green/yellowconductor to supply grounding termi-nal first, and never to a line terminal.

See rating label on unit and check input volt-age available at site.

1 Input Power Cord

2 Disconnect Device (switch shown in theOFF position)

3 Disconnect Device Grounding Terminal

4 Disconnect Device Line Terminals

5 Black And White Input Conductor (L1And L2)

6 Green Or Green/Yellow GroundingConductor

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 to dis-connect device line terminals.7 Over-Current ProtectionSelect type and size of over-current protec-tion using Section 3-10 (fused disconnectswitch shown).8 Receptacle (NEMA 6-50R)Connect receptacle as shown.Close and secure door on disconnect device.Follow established lockout/tagout proced-ures to put unit in service.9 Plug (NEMA 6-50P)Connect plug to receptacle.

3-11. Connecting 1-Phase Input Power (Continued)

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.


3-12. Connecting Optional Spool Gun

260 573-A

1 Drive Assembly

2 Spool Gun

3 Gun Securing Thumbscrew

4 Gun End

Loosen thumbscrew. Insert endthrough opening until it bottomsagainst drive assembly. Tightenthumbscrew.

Spool gun must be insertedcompletely to prevent leakage ofshielding gas.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

6 Spool Gun/MIG Gun Switch

Place switch in Spool Gun position.

7 Polarity Changeover TerminalBlock

To make proper polarity connection,see welding power source Owner’sManual.

Close door.

8 Wire Feed Speed Control

Wire feed speed is controlled bywelding power source Wire Speedcontrol (see welding power sourceOwner’s Manual or door chart forappropriate setting).

9 Voltage Control

Arc voltage is controlled by weldingpower source Voltage control (seewelding power source Owner’sManual or door chart forappropriate setting).

10 Trigger

Press trigger to energize weldingpower source contactor, startshielding gas flow, and begin wirefeed.

CorrectIncorrect

� Be sure that gun end is tight against drive assembly.

4

Gun Fully Seated

4

Gun Not Seated

Exposed O-rings will causeshielding gas leakage.

Spool Gun

MIG Gun6

ÇÇÇÇ

10

89

5

1 3 24

7


3-13. Threading Welding Wire

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

Pull and hold wire; cut off end.

Remove gun nozzleand contact tip.

Open pressure assembly. Make surefeed roll is set to correct groove tomatch wire size (see Section 7-4).

Push wire thru guides into gun;continue to hold wire.

� Hold wire tightly to keep itfrom unraveling.

260 587-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. Be sure that Voltage rangeswitch is set to range 1, 2, 3, 4, 5, 6, or 7 tofeed wire. Rotate knob until it “clicks” intodetent. Wire will not feed if range switch isset between ranges.

6 in(150 mm)

Tighten � Use pressure indicatorscale to set a desireddrive roll pressure.

PressureIndicator

Scale

Tighten

Be sure that wire is positionedin proper feed roll groove.

Close and tighten pressure assembly, and let go of wire.

Be sure that tip matches wire diameter.Reinstall contact tip and nozzle.

4 in(120 mm)

6

1 3

4

52


SECTION 4 − OPERATION

4-1. Controls

1 Wire Speed Control

Use control to select a wire feed speed. AsVoltage switch setting increases, wirespeed range also increases (see weldsetting label in welding power source orSection 4-2, as applicable).

2 Power Switch

3 Voltage Switch The higher the selected number, thethicker the material that can be welded(see weld setting label in welding powersource or Section 4-2, as applicable). Donot switch under load.

� Switch must “click” into detentposition.

4 Gun Trigger Receptacle

5 Trigger Switch

When pressed, energized wire feeds andshielding gas flows.

Ref. 248 840-A / Ref. 246 668-A

5

2

3

1

4


4-2. Weld Parameter Chart For 230 VAC Model

248 827-B

Handler 190TM-260 273 Page 18

1 Supplementary Protector CB1

Protects unit from an over-currentcondition by opening primary powerline.

2 Power Switch S1

Turns unit and fan motor FM on andoff.

3 Contactor CR3

Turns weld output on and off.Provides shielding gas flow whenCR3 is energized.

4 Fan Motor FM And ControlTransformer

Controlled by power switch S1. Fancools internal components, andtransformer supplies 24 volts ac toPC1 control circuit.

5 Range Switch S2

Allows selection of a primarywinding tap which provides a weldoutput voltage level.

6 Gas Valve GS1

Provides shielding gas flow whenCR3 is energized.

7 Control Board PC1

Switches weld output on and off bycontrolling CR3. Regulates motorspeed at a percentage set with WireSpeed control R2. Providesdynamic motor braking and startingthrough the motor relay. Provides ableeder resistor for capacitor C1.

8 Thermostat TP1

If main transformer overheats, TP1opens gun switch circuit stoppingall weld output.

9 Gun Trigger Receptacle RC7

Connects gun trigger circuit towelding power source.

10 Wire Speed Control R2

Sets a wire feed motor speed byproviding a reference voltage tomotor control circuit on PC1.

11 Wire Drive Motor

Feeds wire at a speed set by R2.Motor is enabled when Wire DriveSelector Switch S3 is set to MIGGun position.

12 Main Transformer T1

Supplies power to weld outputcircuit. Also supplies 24 volts acmotor power to control board PC1.

13 Rectifier SR1

Changes the ac output from T1 tofull-wave rectified dc output.

14 Output Capacitor C1

Smooths dc weld voltage fromrectifier SR1.

15 Stabilizer Z1

Smooths dc weld current.

SECTION 5 − THEORY OF OPERATION

2

4

6

Single-PhaseLine Input

Power

1

SupplementaryProtector CB1

Power SwitchS1

Gas ValveGS1

LineL1

Fan Motor FMAnd ControlTransformer

Control BoardPC1

7

LineL2

3

Contactor CR3

5

Range SwitchS2

17Wire DriveSelector

Switch S3

TM-260 273 Page 19

TM-260273 Page

Handler 190

AC Or DC Control Circuits

Weld Current Circuit

Welding Wire

Work

14

(Electrode)

12

MainTransformer

T1

13

Rectifier SR1

15

Stablizer Z1

Capacitor C1

16Polarity

ChangeoverBlock

IntegratedWire Drive

Motor

11

8

9

ThermostatTP1

Gun TriggerReceptacle RC7

10

Wire SpeedControl R2

Spool GunWire Drive

Motor

18

16 Polarity Changeover Block

Terminals allow changing betweenDCEP and DCEN processes.

17 Wire Drive Selector Switch S3

Selects operation of integrated wiredrive motor (11) or spool gun wiredrive motor (18).

18 Spool Gun Wire Drive Motor

Feeds wire at speed set by R2.Motor is enabled when Wire DriveSelector Switch S3 is set to SpoolGun position.


SECTION 6 − TROUBLESHOOTING6-1. Troubleshooting Table

� See Section 6-2 for test points and values andSection 9 for parts location.

� Use Miller Testing Booklet (Part No. 150 853)when servicing this unit.

� See the Miller Extranet for service memos thatmay aid in the repair of this product.

Trouble Remedy

No weld output; wire does not feed; fandoes not run.

Secure power cord plug PLG1 in receptacle (see Section 3-11).

Replace building line fuse or reset circuit breaker if open.

Place Power switch S1 in On position (see Section 4-1).

Reset power source supplementary protector if open (see Section 7-2).

No weld output; wire does not feed; fanruns.

Check Voltage switch S2 position. Rotate knob until it “clicks” into detent at desired range setting.

Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit hascooled (see Section 2-3).

Secure gun trigger plug to receptacle RC3 (see Section 3-2).

Be sure that Spool Gun/MIG Gun switch S3 is in correct mode (see Section 3-2 or 3-12).

Check continuity of gun trigger leads. Repair or replace gun if necessary.

Check continuity of Voltage switch S2, and replace if necessary.

Check and tighten terminal screws on Voltage selector switch S2.

Check diodes in main rectifier SR1, and replace if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings and check forproper connections. Check secondary voltages. Replace T1 if necessary.

Check control board PC1 connections and voltages, and replace if necessary.

Wire does not feed; wire is not ener-gized; wire feeds unevenly.

Check contact tip. Check for kinks in gun cable and liner.

Check gun trigger plug connection at welding power source/wire feeder.

Check, and if necessary, replace gun trigger switch (see Section 7-6).

Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 7-5).

Electrode wire feeding stops duringwelding.

Straighten gun cable and/or replace damaged parts (see Section 7-5).

Readjust drive roll pressure (see Section 3-13).

Change to proper groove (see Section 7-4).

Readjust wire spool hub tension (see Section 3-9).

Replace contact tip if blocked (see Section 7-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 and/or 7-5).

Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).

Secure gun trigger plug in receptacle RC3 (see Section 3-2).

Check continuity of gun trigger leads. Repair or replace gun if necessary.

Check and clear any restrictions at drive assembly and liner (see Section 7-4 and/or 7-5).

Check T1 for signs of winding failure. Check continuity across each winding and check for properconnections. Check secondary voltages. Replace T1 if necessary.


Trouble Remedy

Check Control board PC1 and connections, and replace PC1 if necessary (see Section 6-3).

No weld output; wire feeds. Connect work clamp to get good metal-to-metal contact.

Replace gun contact tip (see Section 7-5).

Check thumbscrew securing gun end to feedhead adapter and tighten if necessary.

Weld output present; wire does notfeed.

Switch MIG Gun/Spool Gun selector switch to operate the desired gun. MIG Gun position is for theintegrated wire feed motor operation. Spool Gun position is for the spool gun wire feed motor operation.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place Voltage switch S2 in desired position (see Section 4-1).

If using an extension cord, be sure that it is the proper size for the input voltage and amperage.

Low or erratic wire speed. Readjust weld parameter settings.

Change to correct size drive roll.

Readjust drive roll pressure.

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 and/or 7-5).

Readjust wire reel hub tension.

Check voltage and connections of wire drive motor. Replace motor if necessary.

Improper or no shielding gas flow. Clean or replace gas hose.

Check shielding gas valve GS1 for proper coil voltage and connections. Check continuity of coil. ReplaceGS1 if necessary.

Clear blockage in gun.

Shielding gas flows continuously. Check and remove any debris from gas valve.

Replace contactor CR3.

Weld porosity. Remove weld spatter buildup in nozzle.

Check O-rings on gun connector and replace if damaged.

Make sure inner head tube is tight in cable connector.

Check gun connector to be sure it is fully inserted into drive assembly.

Check shielding gas flow/supply.


6-2. Troubleshooting Circuit Diagram For Welding Power Source

Test Equipment Needed:

V1

V2

V3

V4

V5

V7,R9

V6,R8

V10

V8V9

R13

R11

R1

See also Section 6-3for PC1 data

R10

R12

R2

R3

R4

R5

R6

R7

VoltageSwitch S2Position

Min.IPM

Max.IPM

1

2

3

4

24

44

60

76

424

476

536

604

Wire DiameterAnd Type

*All tests done with .030-.035 liner in H-10 model 10foot welding gun, smooth groove drive roll.Values are nominal depending on drive roll pressureand spool hub tension.

.030/.035 Solidor Flux Core

Wire Speed While Feeding*

5 92 672

6 108 708

7 124 728

Min.RPM

Max.RPM

1

2

3

4

13

17

21

25

125

142

161

177

*All tests done with the pressure assemblyopen, not feeding wire. Values are nominal.

Drive Motor RPM At No Load*

VoltageSwitch S2Position

5 29 195

6 34 204

7 38 208


228 180-A

Voltage Readings

a) Tolerance − ±10 % unlessspecified

b) Wiring Diagram − see Section 8

V1 230 volts ac with power cord plugged in

V2 230 volts ac with Power switch S1 On

V3 24 volts ac with Power switch S1 On

V4 28 volts dc with Power switch S1 On

V5 24 volts ac with gun trigger closed

V6 12.9 volts ac with Voltage switch S2in position 1 and gun trigger closed

14.4 volts ac with Voltage switch S2in position 2 and gun trigger closed15.9 volts ac with Voltage switch S2in position 3 and gun trigger closed17.5 volts ac with Voltage switch S2in position 4 and gun trigger closed


V7 12.9 volts ac with Voltage switch S2in position 1 and gun trigger closed14.4 volts ac with Voltage switch S2in position 2 and gun trigger closed15.9 volts ac with Voltage switch S2in position 3 and gun trigger closed


22.1 volts ac with Voltage switch S2in position 7 and gun trigger closed

V8 17.6 volts dc with Voltage switch S2in position 1 and gun trigger closed19.7 volts dc with Voltage switch S2in position 2 and gun trigger closed

21.8 volts dc with Voltage switch S2in position 3 and gun trigger closed23.9 volts dc with Voltage switch S2in position 4 and gun trigger closed26.0 volts dc with Voltage switch S2in position 5 and gun trigger closed

28.1 volts dc with Voltage switch S2in position 6 and gun trigger closed30.3 volts dc with Voltage switch S2in position 7 and gun trigger closed

Voltage Readings (Continued)

V9 230 volts ac with gun trigger closed

V10 1.8 to 15.0 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 12.2 to 17.0 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 22.7 to 19.2 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 33.2 to 21.3 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 43.7 to 23.4 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 54.2 to 24.2 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 64.8 to 24.6 volts dc from min. to max.of Wire Speed control R2 with Voltage switch S2 in position 7

Resistance Values

a) Tolerance − ±10% unless specified

b) Turn Off unit and disconnect inputpower before checking resistance

R1-R10 All values for T1 are less than 1 ohm

R11 Less than 1 ohm with gun trigger pressed,high resistance with gun trigger open

R12 Less than 1 ohm

R13 Less than 1 ohms at minimum position of Wire Speed control R2, 50k ohms at maximum position of R2


6-3. Control Board PC1 Testing Information

Be sure plugs are secure beforetesting. See Section 6-4 for specificvalues during testing.

1 Control Board PC1

2 Receptacle RC1

3 Receptacle RC4

Test Equipment Needed:

Ref. 804 691-A / 248 284-A

2

1

3


6-4. Control Board PC1 Test Point Values

PC1 Voltage Readings

a) Tolerance − ±10% unlessspecified

b) Reference − to circuit commonunless noted

Voltage Readings:

a) Tolerance − ±10% unless specified b) Reference − as noted

Receptacle Pin Value

RC1 1 +29 volts dc, reference to RC1-11

2 +32 volts dc, reference to RC1-11


4 +28.5 volts dc with gun trigger closed, reference to RC1-11


6 24 volts ac, reference to RC1-14

7 +32 volts dc with MIG Gun/Spool Gun switch S3 in Spool Gun position, reference to RC1-11

8 +17.5 volts dc with gun trigger closed, reference to RC1-16

9 Not used

10 +3.8 volts dc with Wire Speed control R2 at min and gun trigger closed, reference to RC1-11;+16.4 volts dc with Wire Speed control R2 at max and gun trigger closed, reference to RC1-11

11 Not used, PC board common

12 23 volts ac with gun trigger closed, reference to RC1-15


14 24 volts ac, reference to RC1-6

15 23 volts ac with gun trigger closed, reference to RC1-12

16 −17.2 volts dc with gun trigger closed, reference to RC1-8

17 MIG Gun/Spool Gun switch S3 in Spool Gun position and gun trigger closed, reference to RC1-20;+4.8 volts dc with Wire Speed control R2 at min ; +16.3 volts dc with Wire Speed control R2 at max

18 +19 volts dc with MIG Gun/Spool Gun switch S3 in Spool Gun position, reference to RC1-11

19 +4.5 volts dc with MIG Gun/Spool Gun switch S3 in Spool Gun position, reference to RC1-11

20 MIG Gun/Spool Gun switch S3 in Spool Gun position and gun trigger closed, reference to RC1-17;−4.8 volts dc with Wire Speed control R2 at min ; −16.3 volts dc with Wire Speed control R2 at max

RC4 1-2 0 volts dc with gun trigger open+1.9 volts dc with Wire Speed control R2 set to min and gun trigger closed+14.4 volts dc with Wire Speed control R2 set to max and gun trigger closed


SECTION 7 − MAINTENANCE

7-1. Routine Maintenance

! Disconnect powerbefore maintaining.

� Maintain more oftenduring severe conditions.

� = Check � = Change � = Clean � = Replace* To be done by Factory Authorized Service Agent

Reference

Every3Months

� Unreadable Labels � Weld Terminals � Damaged Gas Hose �� Weld Cables

�� Cords �� Gun Cables

Every6Months

OR

� Drive Rolls � Inside Unit

7-2. Overload Protection

802 441

1 Supplementary Protector CB1

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

Reset supplementary protector.1

7-3. 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.


7-4. Changing Drive Roll Or Wire Inlet Guide

258 380-B

1 Inlet Wire Guide Securing Screw

2 Inlet Wire Guide

Loosen thumbscrew. Slide tip as close todrive rolls as possible without touching.Tighten thumbscrew.

3 Drive Roll

The drive roll consists of two differentgrooves. The stamped markings on the endsurface of the drive roll refers to the grooveon the opposite side of the drive roll. Thegroove closest to the motor shaft is theproper groove to thread (see Section 3-13).

� VK (Knurled) groove is used for fluxcored wire and V groove is used for solidwire.

4 Retaining Pin

To secure drive roll, locate open slot andpush drive roll completely over retaining pin,then rotate drive roll (1/4 turn) to closed slot.

5 Drive Roll Tension Knob

Using flux core wire with VK groove, tensionshould be set between 1-1/2 to 2. Highersetting may cause welding wire to deformand not allow proper feeding.

Flux Core Wire − Recommended stickout is1/2 in. (12.7 mm) from gun tip.

Solid Wire − Recommended stickout is 3/8 in.(9.5 mm) from gun tip.

Actual drive roll may differ from thatshown. See Section 9-4 for additionaldrive roll configurations.

.030/.035 VK Grooveis used for Flux Core(Gasless) Wire

.030/.035 V Grooveis used for Solid Wire

Stamped .030/.035VK Grooved

Stamped .030/.035 V

2

Example

4

1

3

5 � Be sure gun is fully inserted into drivehousing. Liner to drive roll distanceshould be within 1/8 in. (3.2 mm). ofeach other.


7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing

243 839-A


1 Nozzle

2 Contact Tip

3 Tip Adapter

� Wire size stamped on tip − checkand match wire size.

Tools Needed:

8 mm, 10 mm

Lay gun cable outstraight beforeinstalling new liner.

Remove nozzle,contact tip, andadapter.

Unscrew andremove liner.

Blow outgun casing.

Cut off wire anddisconnect gunfrom feeder.

5/8 in.(16 mm)

LinerStickout

InstallLiner

Reassemble gun inreverse order fromtaking it apart.

10 mm

HeadTube

8 mm

1

32

� Thread wire according towelding power source/wirefeeder manual.


7-6. Replacing Switch And/Or Head Tube

243 840-A

Tools Needed:

15 mm

Remove screws (5)and nuts (4).

Remove handle halves.

Hand-tighten head tube into cable connector.Place head tube in vice and tighten untilnuts are tight.

Remove from vice. Reposition handle halves, andinstall switch housing.

! Turn Off welding power source/wire feeder and disconnect gun.

Remove switch housing. Install newswitch and connect leads (polarity isnot important). Reassemble inreverse order. If replacing head tube,continue to end of figure.

1 2

3

8

67

Remove screw onopposite side.

Secure headtube in vice.

Loosen jam nut.Remove from viceand turn head tubeout by hand.

4

5

phillips

Reinstall screwsand nuts.

9

Reinstall screw onopposite side.


Notes


SECTION 8 − ELECTRICAL DIAGRAMS

� The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit insidemachine case or contact your distributor for further information.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Welding Power Source MC420249Y and following 248 830-A 248 831-A

Circuit Board PC1 MC420249Y and following 248 286-A ♦♦

♦♦ Not included in this manual


Figure 8-1. Circuit Diagram For Welding Power Source Eff. w/MC420249Y And Following


248 830-A


Figure 8-2. Wiring Diagram For Welding Power Source Eff. w/MC420249Y And Following


248 831-A


AGND

AGND

AGND

20PIN

20PIN

20PIN

AGND

AGND

20PIN

20PIN

20PIN

20PIN

20PIN

20PIN

20PIN

20PIN

20PIN

++

20PIN

+t’

NC

1

4

3

CR2

52

CR

2

12

CR

1

PTC2

11RC1

C1 C2

3

12

Q2

D6

C5

C4

D16

3

12

Q3

R18

R17

R16R15

R14R13

R12

R11

R2

+30V

R4

D8

D7

D14

D10

D9

D13

D12

3

21A1

5 RC1

3 RC1

2 RC1

+29V

9 RC1

1 RC1

4 RC1

+30V

13 RC1

7 RC1

12 RC1

14 RC1

15 RC1

6 RC1

+29V

18

CR

3

+30V

D5

R7

+29V

Figure 8-3. Circuit Diagram For Control Board PC1Eff. w/MC420249Y And Following


248 286-A

AGND

AGND+t’

20PIN

20PIN

20PIN

20PIN

20PIN

2PIN

20PIN

HEATSINK

2PIN

20PIN

AGND

CAP −

CAP +

MOTOR +

MOTOR −

5AMP_50V

VOUT

D2

5AMP_50V

5AMP_50V20RC1

2RC4

5AMP_50V

5AMP_50V

5AMP_50V

HS1

5AMP_50V

4

5

3CR1

D4

2

13

Q1

19RC1

1RC4

R10R9

+29V

D11

R3

R8

C3

D3

R1

D1

5

67

A1

4

8

A1

16RC1

8RC1

17RC1

10RC1

18RC1

VOUT

3

2

4

CR3

6

7

5

CR3

PT

C1

R6

R5

WFS_REF


Notes

www.HobartWelders.com

TM-260 273B 2013−02

Eff. w/Serial No. MC420249Y

Processes

Arc Welding Power Source AndWire Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

File: MIG (GMAW)

Handler 190 AndH100S4-10 Gun

�


SECTION 9 − PARTS LIST

� Hardware is common andnot available unless listed.

258 438-A

1

23

45

67

8

9

10

21

22

23 24

25

2627

28

19

20

11

1213

14

15

16

17

18

29

30

3132

33

34

35

36

37

3839

40

49

50

4142

43

44

45

46

47

48

Figure 9-1. Main Assembly


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-1. Main Assembly

Quantity

1 199 566 Door, Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 196 006 Hinge, Door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 211 887 Hub, Nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 204 608 Nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 202 998 Spring, Cprsn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 203 072 Washer, Flat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 211 339 Hub, Spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 202 726 Adapter, Spool Hub 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 PC1 248 284 Circuit Card Assy, Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 195 999 Base, Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 CB1 210 109 Supplementary Protector, 25 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 196 467 Tubing, PVC .187 ID x .312 OD x 23.00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 GS1 216 398 Valve, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 197 198 Cable Tie, .700-.799 Bundle Dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 152 118 Cord Set, 250v 6−50p 12ga 3/C 7ft Spt−3 Jkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 111 443 Bushing, Strain Relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 137 761 Nut, Gas Valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 FM 196 064 Motor, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 409 953-001 Blade, Fan Cooling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 T1 226 069 Transformer, Power Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 208 015 Handle, Carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 +196 005 Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 204 036 Label, Warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 203 491 Clamp, Capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 C1 193 040 Capacitor, Electrlt 100000uf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Z1 225 891 Reactor Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 SR1 193 316 Rectifier Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 193 193 Bus Bar (Positive) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 +228 706 Baffle, Center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 S3 196 575 Switch, Rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 TE1 193 144 Insulator, Output Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 193 194 Bus Bar (Negative) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 216 830 Label, Warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 134 201 Stand-Off 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 S2 226 813 Switch, Rotary 32A 7 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 R2 209 873 Potentiometer, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 229 738 Panel, Front (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 257 796 Clamp, Work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 196 619 Cable, Work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 S1 196 574 Switch, Rocker Dpst 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 228 400 Knob, Pointer (Voltage) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 211 338 Knob, Pointer (Wfs) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 DM1 257 097 Wire Feed Assy 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 SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-1. Main Assembly (Continued)

Quantity

44 248 827 Label, Weld Chart 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 204 711 Latch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 CR3 217 585 Contactor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Label, Nameplate (Order By Model And Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 048 282 Rcpt W/Skts, (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 228 643 Plate, Stiffener Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 229 794 Label, Spoolgun/Mig Gun 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 037 Regulator/Flowmeter, 10−50 CFH Argon/CO2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 581 Hose, Assembly Gas 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 SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


258 389-A

12

3 4 5

6

14

8

7

11

9

12

13

10

15

16

17

18

19

20

21

22

Figure 9-2. Wire Feed Drive Assembly

DescriptionPartNo.

Dia.Mkgs.

258 389

ItemNo.

Figure 9-2. Wire Feed Drive Assembly

Quantity

1 256 956 Cover, Motor Drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 257 420 Housing, Wire Drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 257 422 Lever,Mtg Pressure Gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 189 915 Bearing, Ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 176 869 Screw, 010−32 x 0.62 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 203 418 Spring, Torsion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 257 790 Screw, .250−28 x .953 Shld .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 082 193 Screw, 010−32 x 0.37 hex hd .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 197 172 Screw, 006−32 x 0.37 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 196 895 Knob,Tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 234 200 Spring, Compression 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 196 896 Cup, Spring Tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 225 718 Fastener, Pinned 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 257 792 Screw, Shld Stl 10−32 x .60 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 256 960 Guide, Inlet .023−.052 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 257 865 Knob,T 1.00 Bar W/10−32 x .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 246 565 Roll, Drive V/VK Groove .030−.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 217 778 Motor, Gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 230 012 Fitting, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 196 109 Cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 602 154 Screw, .250−20 x .50 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 257 864 Knob, T 1.265 Bar w/.250-20 Stud .625 Lg Plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


243 842-A

1 2 3 45

6

7

8

7

12

9

13

14

11

10

Figure 9-3. H100S4-10 Gun

DescriptionPartNo.

Dia.Mkgs.

245 926

ItemNo.

Figure 9-3. H100S4-10 Gun

Quantity

1 169 715 Nozzle, Slip Type .500 Orf Flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 +226 190 Nozzle, Flux Cored Slip Type 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +087 299 Tip, Contact Scr .023 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +000 067 Tip, Contact Scr .030 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +000 068 Tip, Contact Scr .035 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +000 069 Tip, Contact Scr .045 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 170 470 Ring, Retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 169 716 Adapter, Contact Tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 246 373 Tube, Head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 243 865 Nut, Jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 242 832 Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 225 410 Switch, Trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 079 878 Housing Plug & Pins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 246 380 Housing, Power Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 245 927 Connector, Feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 197 123 O−Ring, .312 ID X .062 70 Duro Buna−n 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 +194 010 Liner, Monocoil .023/.025 Wire x 15ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 +194 011 Liner, Monocoil .030/.035 Wire x 15ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 +194 012 Liner, Monocoil .035/.045 Wire x 15ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 079 975 O-Ring, .187 ID x .103Cs Rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model is required when ordering parts from your local distributor.


9-4. Optional Drive Rolls

For All Feed Head Assemblies

PART NO. WIRE DIAMETERINCHES (mm)

237 338 .023/.025 (.6) and .030/.035 (.8 and .9)

202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

246 565 .030/.035 (.8 and .9) V/VK Grooves

9-5. Options

PART NO. DESCRIPTION REMARKS

770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max.

194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max.

245 926 H100S4-10 Replacement Gun 10 ft length/.030-.035 wire size

300 796 SpoolRunner 100 Spool Gun For push/pull wire feeding

195 186 Protective Cover Weatherproof nylon

212 492 Regulator/Flowmeter For use with CO2 shielding gas, 10−50 CFH

144 108 Gas hose, 5 ft For use with regulator/flowmeter 212 492

9-6. Consumables

ITEM HOBART PACKAGE NO.* MILLER PACKAGE NO.**

Contact Tips

.023/.025 in (0.6 mm) 770 174 (5 per package) 087 299 (10 per package)

.030 in (0.8 mm) 770 177 (5 per package) 000 067 (10 per package)



MIG Nozzle (Standard) 770 404 169 715

Gasless Flux Cored Nozzle 770 487 226 190

Tip Adapter 770 402 169 716

Replacement Liners

.023/.025 in (0.6 mm) 196 139 194 010

.030/.035 in (0.8/0.9 mm) 196 139 194 011

.035/.045 in (0.9/1.2 mm) 196 140 194 012

*Available at farm and tool supply retailers.**Available at Hobart/Miller welding distributors.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Hobart Brothers Co. 2013−01

Hobart Brothers Co.An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA

For Assistance:Call1-800-332-3281

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