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OM-243862C
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Semi-Automatic Ar-Cooled Flux Cored
(FCAW And MIG (GMAW) Welding Gun
H100L4–10 Gun
2022-07
www.HobartWelders.com
OWNER’S MANUAL
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From Hobart to You
Thank you and congratulations on choosing Hobart. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
This Owner’s Manual is designed to help you get the most out of your
Hobart products. Please take time to read the Safety Precautions.
They will help you protect yourself against potential hazards on the
worksite. We’ve made installation and operation quick and easy. With
Hobart, you can count on years of reliable service with proper
maintenance. And if for some reason the unit needs repair, there’s a
Troubleshooting section that will help you figure out what the problem
is. The parts list will then help you to decide the exact part you may
need to fix the problem. Warranty and service information for your
particular model are also provided.
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
1-800-332-3281, or visit us at
www.HobartWelders.com on the web.
For Technical Help call 1-800-332-3281.
Register your product at www.HobartWelders.com
Hobart is registered to the ISO
9001 Quality System
Standard.
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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 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4 Principal Safety Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-5 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2 Dangers relatifs au soudage à l'arc .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1 Specifications For H100L4-10 MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2 Duty Cycle And Overheating For MIG (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 4 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-1 Installing Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 5 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5-1 Operating Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6-1 Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6-2 Replacing Switch And/Or Head Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6-3 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6-4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in
the text.
NOTICE – Indicates statements not related to personal injury.
Indicates special instructions.
F
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety
information found in the Principal Safety Standards, and in
welding power source Owner’s Manual. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children,
away.
ELECTRIC SHOCK can kill.
l Always wear dry insulating gloves.
l Insulate yourself from work and ground.
l Do not touch live electrode or electrical parts.
cables.
l Turn off welding power source before changing contact tip or gun
parts.
l Keep all covers and handle securely in place.
is to sample for the composition and quantity of fumes and gases
to which personnel are exposed.
l Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
l Replace worn, damaged, or cracked guns or
FUMES AND GASES can be
hazardous.
l Keep your head out of the fumes.
l Ventilate area, or use breathing device. The rec-
ommended way to determine adequate ventilation
MOVING PARTS can injure.
l Keep away from moving parts.
l Keep away from pinch points such as drive rolls.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
symbols and related instructions below for necessary actions to
avoid these hazards.
WELDING can cause fire or
explosion.
l Do not weld near flammable material.
l Do not weld on containers that have held combus-
tibles, or on closed containers such as tanks,
drums, or pipes unless they are properly prepared according to
AWS F4.1 (see Safety Standards).
l Watch for fire; keep extinguisher nearby.
l Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
BUILDUP OF GAS can injure or kill.
l Shut off compressed gas supply when not in use.
l Always ventilate confined spaces or use approved
air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
l Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
l Wear approved safety glasses with side shields under your
helmet.
l Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
l Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
HOT PARTS can burn.
l Allow gun to cool before touching.
l Do not touch hot metal.
l Protect hot metal from contact by others.
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NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
l Check for noise level limits exceeding those speci-
fied by OSHA.
l Use approved ear plugs or ear muffs if noise level is high.
l Warn others nearby about noise hazard.
WELDING WIRE can injure.
l Keep hands and body away from gun tip when trig-
ger is pressed.
1-3. California Proposition 65 Warnings
WARNING – This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
1-4. Principal Safety Sections
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
READ INSTRUCTIONS.
l Read and follow all labels and the Owner’s Manual
carefully before installing, operating, or servicing
unit. Read the safety information at the beginning
of the manual and in each section.
l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and local codes.
For more information, go to www.P65Warnings.ca.gov.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
SR7 2022–01
1-5. EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF field around the
welding circuit. EMF fields can interfere with some medical implants,
e.g. pacemakers. Protective measures for persons wearing medical
implants have to be taken. For example, restrict access for passers
−by or conduct individual risk assessment for welders. All welders
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures
is recommended.
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SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! – Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles joints
ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut
donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
F
2-2. Dangers relatifs au soudage à l'arc
Les symboles donnés ci-après sont utilisés dans tout le manuel pour attirer l’attention sur les dangers possibles et
pour indiquer le type de danger dont il s’agit. Quand on voit
le symbole, prendre garde et suivre les directives correspondantes pour éviter le danger. Les consignes de sécurité
présentées ci-après ne font que résumer l’information
contenue dans les Normes de sécurité principales, et dans
le Guide d’utilisation de la source de courant de soudage.
Lire et suivre toutes les Normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
l Porter toujours des gants secs et isolants.
l S’isoler de la pièce et de la terre.
l Ne jamais toucher une électrode ou des pièces
électriques sous tension.
l Remplacer les pistolets ou câbles de soudage qui sont endomma-
gés, usés ou craquelés.
l Mettre la soudeuse hors tension avant de remplacer un bec
contact ou des pièces de pistolet.
l S’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
l Garder la tête hors des fumées.
l Aérer la zone de travail ou porter un appareil respi-
recommandé de procéder à un prélèvement pour la composition
et la quantité de fumées et de gaz auxquelles est exposé le
personnel.
l Lire et comprendre les fiches de données de sécurité et les ins-
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
ratoire. Pour déterminer la bonne ventilation, il est
Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout
danger.
Les PIÈCES MOBILES peuvent
causer des blessures.
l Ne pas s’approcher des organes mobiles.
l Ne pas s’approcher des points de coincement tels
que des rouleaux de commande.
Le SOUDAGE peut provoquer un
incendie ou une explosion.
l Ne pas souder à proximité de matériaux
inflammables
l Ne pas effectuer le soudage sur des conteneurs
fermés tels que des réservoirs, tambours, ou conduites, à moins
qu’ils n’aient été préparés correctement conformément à AWS
F4.1 (voir les Normes de Sécurité).
l Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
l Lire et comprendre les fiches de données de sécurité et les ins-
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
l Fermer l’alimentation du gaz comprimé en cas de
non utilisation.
l Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
l Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
l Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-
téger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
l Porter une protection corporelle en cuir ou des vêtements ignifu-
ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
l Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés
si le niveau de bruit est élevé.
l Avertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
l Laisser refroidir le pistolet avant de le toucher.
l Ne pas toucher d’objets métalliques chauds.
par les personnes à proximité.
l Abriter les objets métalliques contre tout contact
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
l Vérifier si les niveaux de bruit excèdent les limites
spécifiées par l’OSHA.
section.
l N’utiliser que des pièces de remplacement provenant du fabricant.
l Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT – Ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
SR7_fre 2022–01
l Éloigner les mains et le corps de la buse du pisto-
let après avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
l Lire et appliquer les instructions sur les étiquettes
et le Mode d’emploi avant l’installation, l’utilisation
ou l’entretien de l’appareil. Lire les informations de
sécurité au début du manuel et dans chaque
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des
champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations
de chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple,
des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
OM-243862 Page 4
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir
ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
Page 9
SECTION 3 – SPECIFICATIONS
6 Minutes Welding 4 Minutes Resting
Continuous Welding
0
15
A or V
OR
Reduce Duty Cycle
Minutes
3-1. Specifications For H100L4-10 MIG Gun
Wire Diameter Range Cooling Method Duty Cycle Rating Weight
100 Amperes, 100% Duty Cycle
.023–.045 in.
(0.6–1.1 mm)
Hard Or Flux Cored Wire
Air Cooled Welding Gun For
GMAW And FCAW Welding
3-2. Duty Cycle And Overheating For MIG (GMAW)
60% Duty Cycle At 100A Using Mixed Gases
Using CO2 Shielding Gas
100 Amperes, 60% Duty Cycle
using Mixed Shielding Gas
Note: Using gasless flux cored
wire reduces gun duty cycle.
Duty Cycle is percentage of 10 minutes that
unit can weld at rated load without
overheating.
If unit overheats, output stops. Wait fifteen
minutes for unit to cool. Reduce amperage or
duty cycle before starting to weld again.
NOTICE – Exceeding duty cycle can damage
unit and void warranty.
Gun With 10 ft (3.0 m) Cable
3.5 lb (1.6 kg)
100% Duty Cycle At 100A Using 100% CO2
Overheating
OM-243862 Page 5
Page 10
4-1. Installing Gun
243 861-A
1
3
2
4
SECTION 4 – INSTALLATION
1 Gun Securing Knob
2 Gun End
Loosen knob. Insert gun end until it bottoms
against drive assembly. Tighten knob.
3 Gun Trigger Plug
Insert into receptacle and tighten threaded
collar.
4 Friction Terminals
Some applications will require cutting off trigger plug and installing 0.250 female friction
terminals to end of leads.
See power source manual for wire threading
procedure.
OM-243862 Page 6
Page 11
5-1. Operating Gun
Ref. 243 838-A
1
SECTION 5 – OPERATION
1 Trigger Switch
When pressed, energized wire feeds and
shielding gas flows.
OM-243862 Page 7
Page 12
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING
3
2
1
4
5
6
5/8 in.
(16 mm)
Liner
Stickout
7
1 2
3 4
chippinghammer
crescent wrench
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
6-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun
Casing
Turn off welding power source/wire
feeder.
Wire size stamped on tip, check and
F
match wire size.
1 Nozzle
2 Contact Tip
3 Contact Tip Adapter
4 Head Tube
5 Gun Liner
6 Compressed Air Nozzle
7 Gun Conduit Cable
Cut off wire and remove gun from unit.
Lay gun cable out straight.
Step 1. Remove nozzle, contact tip, and
contact tip adapter from gun
Step 2. Lay gun cable out straight. Loosen
nut on gun liner and remove liner.
Step 3. Insert air nozzle and blow out conduit with compressed air.
Step 4. Install original gun liner or new liner
if necessary. Tighten gun liner nut and trim
gun liner to length as shown.
Refer to owner’s manual for unit to thread
welding wire and determine drive roll
pressure.
8 mm, 10 mm
OM-243862 Page 8
Page 13
6-2. Replacing Switch And/Or Head Tube
243 840-A
1
2
3
4
5
6
7
8
9
chippinghammer
crescent wrench
Turn Off and disconnect input
power.
1 Handle Hardware
Remove screws (5) and nuts (4)from handle. Remove the screw from opposite side of
handle.
2 Handle Halves
Remove handle halves to expose trigger
switch.
3 Trigger Switch
Remove trigger switch and replace if necessary. The polarity of the trigger leads is not
critical.
If replacing the head tube continue with the
following instructions.
4 Head Tube
Insert head tube in vise.
5 Jam Nut
Loosen jam nut. Remove head tube from
vise and turn head tube by hand.
6 Cable Connector
Hand tighten head tube to cable connector.
7 Vise
Place head tube in vise and tighten nuts with
wrench. Remove from vise.
8 Handle Halves
Position handle halves and install trigger
switch housing.
9 Handle Hardware
Reinstall handle hardware and tighten..
15 mm
OM-243862 Page 9
Page 14
6-3. Routine Maintenance
= Check
= Change
= Clean
= Replace
* To be done by Factory Authorized Service Agent
R
eference
NGO’s
tools/
flathead philips head wrench
knife
heavy-duty workclamp light-duty workclamp wirecutter frontcutter
allen_set
steelbrush nutdriver
chippi
nghammer
imp
d
rill
greasegun
handream
f
ilterwrench
crescent wrench
Weld Terminals
Disconnect power before maintaining.
Maintain more often during severe conditions.
F
ü = Check ◇ = Change m = Clean ¶ = Replace
Each
Spool of
Wire
ü m Nozzle And Contact Tip m Blow Out Gun Casing
Every 3
Months
¶ Unreadable Labels ¶ Damaged Gas Hose ü ¶ Cords ü¶ Cracked Parts
*To be done by factory authorized service agent.
6-4. Troubleshooting
Wire does not feed; wire is not energized; wire feeds unevenly.
Weld Porosity Remove weld spatter buildup in nozzle.
.Wire feeding stops or does not feed
properly during welding.
Trouble Remedy
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 6-2).
Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing. (see Section 6-1).
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.
Straighten gun cable and/or replace damaged parts (see Section 6-2).
Adjust drive roll pressure (see wire feeder manual).
Change to proper drive roll groove (see wire feeder manual).
Readjust hub tension (see wire feeder manual).
Clean or replace liner if dirty or plugged (see Section 6-1).
Replace drive roll or pressure bearing if worn or slipping (see wire feeder manual)
OM-243862 Page 10
Page 15
SECTION 7 – PARTS LIST
243 842-A
1
2 3
4
5
6
7
8
7
11
9
12
13
10
Figure 7-1. Complete Assembly For H100L4-10 MIG Gun
Item No. Dia. Mkgs. Part No. Description Quantity
1 169715 Nozzle, Slip Type .500 Orf Flush 1
1 ♦226190 Nozzle, Flux Cored Slip Type .500 Orf 1
2 ♦087299 Tip, Contact Scr .023 Wire x 1.125 1
2 ♦000067 Tip, Contact Scr .030 Wire x 1.125 1
2 ♦000068 Tip, Contact Scr .035 Wire x 1.125 1
2 ♦000069 Tip, Contact Scr .045 Wire x 1.125 1
3 170470 Ring, Retaining 1
4 169716 Adapter, Contact Tip 1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and
serial number required when ordering parts from your local distributor.
5 242831 Tube, Head 1
6 243865 Nut, Jam 1
7 242832 Handle 1
8 225410 Switch, Trigger 1
9 079878 Housing, Plug And Pins 1
10 242833 Connector, Feeder 1
11 079974 O-Ring, .500 ID x .103 CS Rbr 2
12 ♦194010 Liner, Monocoil .023/.025 Wire x 15 Ft (Consisting of) 1
12 ♦194011 Liner, Monocoil .030/.035 Wire x 15 Ft (Consisting of) 1
12 ♦194012 Liner, Monocoil .035/.045 Wire x 15 Ft (Consisting of) 1
13 079975 —O-Ring, .187 ID x .103 CS Rbr 1
OM-243862 Page 11
Page 16
Notes
Page 17
Effective January 1, 2022 (Equipment with a serial number preface of NC or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war-
ranties expressed or implied.
LIMITED WARRANTY - Subject to the terms and
conditions below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to authorized distributors
that new Miller equipment sold after the effective
date of this limited warranty is free of defects in
material and workmanship at the time it is shipped
by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will
repair or replace any warranted parts or components that fail due to such defects in material or
workmanship. Miller must be notified in writing
within thirty (30) days of such defect or failure, at
which time Miller will provide instructions on the
warranty claim procedures to be followed. Notifications submitted as online warranty claims must
provide detailed descriptions of the fault and troubleshooting steps taken to diagnose failed parts.
Warranty claims that lack the required information
as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.
Miller shall honor warranty claims on warranted
equipment listed below in the event of a defect
within the warranty coverage time periods listed
below. Warranty time periods start on the delivery
date of the equipment to the end-user purchaser,
or 12 months after the equipment is shipped to a
US or Canada distributor, or 18 months after the
equipment is shipped to an international distributor,
whichever occurs first.
1 5 Years Parts — 3 Years Labor
l Original Main Power Rectifiers Only to Include
SCRs, Diodes, and Discrete Rectifier Modules
in non-inverter products
2 3 Years — Parts and Labor Unless Specified
l Auto-Darkening Helmet Lenses (No Labor)
l Engine Driven Welder/Generators (Including
EnPak) (NOTE: Engines are Warranted
Separately by the Engine Manufacturer.)
l Insight Welding Intelligence Products (Except
External Sensors)
l Inverter Power Sources
l Plasma Arc Cutting Power Sources
l Process Controllers
l Semi-Automatic and Automatic Wire Feeders
l Transformer/Rectifier Power Sources
3 2 Years — Parts and Labor
l Auto-Darkening Weld Masks (No Labor)
l Fume Extractors - Capture 5 and Industrial
Collector Series
4 1 Year — Parts and Labor Unless Specified
l ArcReach Heater
l AugmentedArc, LiveArc, and MobileArc Weld-
ing Systems
l Automatic Motion Devices
l Bernard BTB Air-Cooled MIG Guns (No
Labor)
l CoolBelt, PAPR Blower, and PAPR Face
Shield (No Labor)
l Desiccant Air Dryer System
l Field Options (NOTE: Field options are cov-
ered for the remaining warranty period of
the product they are installed in, or for a
minimum of one year — whichever is
greater.)
l RFCS Foot Controls (Except RFCS-RJ45)
l Fume Extractors - Filtair 130, MWX and SWX
Series, ZoneFlow Extraction Arms and Motor
Control Box
l HF Units
l ICE/XT Plasma Cutting Torches (No Labor)
l Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
l Insight Sensors
l Load Banks
l Motor-Driven Guns (except Spoolmate
Spoolguns)
l Positioners and Controllers
l Racks (For Housing Multiple Power Sources)
l Running Gear/Trailers
l Subarc Wire Drive Assemblies
l Supplied Air Respirator (SAR) Boxes and
Panels
l TIG Torches (No Labor)
l Tregaskiss Guns (No Labor)
l Water Cooling Systems
l Wireless Remote Foot/Hand Controls and
Receivers
l Work Stations/Weld Tables (No Labor)
5 6 Months — Parts
l 12 Volt Automotive-Style Batteries
6 90 Days — Parts
l Accessories (Kits)
l ArcReach Heater Quick Wrap and Air Cooled
Cables
l Canvas Covers
l Induction Heating Coils and Blankets, Cables,
and Non-Electronic Controls
l MDX Series MIG Guns
l M-Guns
l MIG Guns, Subarc (SAW) Torches, and Exter-
nal Cladding Heads
l Remote Controls and RFCS-RJ45
l Replacement Parts (No labor)
l Spoolmate Spoolguns
Miller’s True Blue
to:
1. Consumable components; such as contact
tips, cutting nozzles, contactors, brushes,
relays, work station table tops and welding
curtains, or parts that fail due to normal
wear. (Exception: brushes and relays are
covered on all engine-driven products.)
2. Items furnished by Miller, but manufactured by
others, such as engines or trade accessories.
These items are covered by the manufacturer’s
warranty, if any.
3. Equipment that has been modified by any party
other than Miller, or equipment that has been
improperly installed, improperly operated or
®
Limited Warranty shall not apply
misused based upon industry standards, or
equipment which has not had reasonable and
necessary maintenance, or equipment which
has been used for operation outside of the
specifications for the equipment.
4. Defects caused by accident, unauthorized repair, or improper testing.
MILLER PRODUCTS ARE INTENDED FOR
COMMERCIAL AND INDUSTRIAL USERS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at
Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Miller, (3) the
pre-approved cost of repair or replacement at an
authorized Miller service station; or (4) payment of
or credit for the purchase price (less reasonable
depreciation based upon use). Products may not
be returned without Miller’s written approval. Return shipment shall be at customer’s risk and
expense.
The above remedies are F.O.B. Appleton, WI, or
Miller’s authorized service facility. Transportation
and freight are the customer’s responsibility. TO
THE EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS
OF THE LEGAL THEORY. ANY WARRANTY NOT
PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.
Some US states do not allow limiting the duration
of an implied warranty or the exclusion of certain
damages, so the above limitations may not apply
to you. This warranty provides specific legal rights,
and other rights may be available depending on
your state. In Canada, some provinces provide additional warranties or remedies, and to the extent
the law prohibits their waiver, the limitations set out
above may not apply. This Limited Warranty provides specific legal rights, and other rights may be
available, but may vary by province.
Warranty Questions?
Call 1-800-4-A-MILLER for
your local Miller distributor.
Your distributor also gives you...
Service
You always get the fast, reliable response you
need. Most replacement parts can be in your
hands in 24 hours.
Support
Need fast answers to the tough welding questions? The expertise of the distributor and Miller
is there to help you, every step of the way.
Page 18
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date
Distributor
Address
City
State Zip
(Date which equipment was delivered to original customer.)
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Protective Equipment (PPE)
Contact the Delivering Carrier to:
Service and Repair Replacement Parts
Training (Schools, Videos, Books)
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
For Assistance:
Call 1-800-332-3281
ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-07
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