Hobart H100S2-10 GUN User guide

OM-245986C 2018−09

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Semi-Automatic Air-Cooled MIG
(GMAW) Welding Gun

H100S2−10 Gun

www.HobartWelders.com

File: MIG (GMAW)

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1......

1-1. Symbol Usage 1.................................................................

1-2. Arc Welding Hazards 1............................................................

1-3. Proposition 65 Warnings 2.........................................................

1-4. Principal Safety Standards 2.......................................................

1-5. EMF Information 2................................................................

SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW

− À LIRE AVANT UTILISATION 3..............................................................

2-1. Signification des symboles 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 − INSTALLATION 5................................................................

3-1. Specifications 5..................................................................

3-2. Duty Cycle And Overheating 5......................................................

3-3. Installing Gun 6..................................................................

SECTION 4 − OPERATION 6..................................................................

4-1. Operating The Gun 6..............................................................

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 7.........................................

5-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 7...

5-2. Replacing Switch And/Or Head Tube 8...............................................

5-3. Routine Maintenance 9............................................................

5-4. Troubleshooting 9................................................................

SECTION 6 − PARTS LIST 10...................................................................

WARRANTY

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS − READ BEFORE USING

SR7 (MIG) 2018-01

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.

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 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 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.

D Always wear dry insulating gloves.
D Insulate yourself from work and ground.

D Do not touch live electrode or electrical parts.
D Replace worn, damaged, or cracked guns or cables.
D Turn off welding power source before changing contact tip or gun

parts.

D Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes.

D Ventilate area, or use breathing device. The

recommended way to determine adequate
ventilation is to sample for the composition and quantity of fumes
and gases to which personnel are exposed.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

. Indicates special instructions.

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 the
hazards.

WELDING can cause fire or explosion.

D Do not weld near flammable material.
D Do not weld on containers that have held com-

tanks, drums, or pipes unless they are properly prepared ac­cording to AWS F4.1 and AWS A6.0 (see Safety Standards).

D Watch for fire; keep extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

D Wear an approved welding helmet fitted with a proper shade of filter

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).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

bustibles, or on closed containers such as

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in

use.

D Always ventilate confined spaces or use ap-

proved 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.

MOVING PARTS can injure.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

HOT PARTS can burn.

D Allow gun to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.

OM-245986 Page 1

NOISE can damage hearing.

READ INSTRUCTIONS.

Noise from some processes or equipment can
damage hearing.

D Check for noise level limits exceeding those

specified by OSHA.

D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.

WELDING WIRE can injure.

D Keep hands and body away from gun tip when

trigger is pressed.

1-3. 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.

For more information, go to www.P65Warnings.ca.gov.

1-4. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website: www.glo­bal.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

D 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.

D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02169 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern­ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: [phone]) (there are 10 OS­HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).

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 individu-
al 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.

OM-245986 Page 2

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.

SECTION 2 − MESURES DE SÉCURITÉ VISANT LES

PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT

UTILISATION

SR7(MIG)_2018−01_fre

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. Signification des symboles

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.

2-2. Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez vigilant
et suivez les directives mentionnées afin d’éviter tout danger.
Les consignes de sécurité présentées ci-après ne font que résu­mer l’information contenue dans les normes de sécurité énumé­rées dans le manuel d’utilisation du poste de soudage. Veuillez
lire et respecter toutes ces 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.

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

toyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

LE SOUDAGE peut causer un in­cendie ou une explosion.

D Ne pas souder à proximité de matériaux inflam-

mables.

D 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 et AWS A6.0
(voir les Normes de Sécurité).

D Prendre garde aux incendies et toujours avoir un extincteur à

proximité.

D Lire et comprendre les fiches de données de sécurité et les

instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.

UN CHOC ÉLECTRIQUE peut tuer.

D Porter toujours des gants secs et isolants.
D S’isoler de la pièce et de la terre.
D Ne jamais toucher une électrode ou des pièces

électriques sous tension.

D Remplacer les pistolets ou câbles de soudage qui sont endom-

magés, usés ou craquelés.

D Mettre la soudeuse hors tension avant de remplacer un bec

contact ou des pièces de pistolet.

D S’assurer que tous les couvercles et poignées sont fermement

assujettis.

LES VAPEURS ET LES FUMÉES
peuvent être nocives.

D Éloigner sa tête des endroits renfermant des

vapeurs.

D Aérer la zone de travail ou porter un appareil respiratoire. Pour dé-

terminer la bonne ventilation, il est recommandé de procéder à un
prélèvement pour la composition et la quantité de fumées et de gaz
auxquels est exposé le personnel.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les net-

D Quand on n’utilise pas le gaz comprimé de pro-

tection, fermer le robinet de la bouteille.

D Assurer toujours la ventilation des zones fermées ou utiliser un

appareil respiratoire avec alimentation en air.

Les PIÈCES MOBILES peuvent
causer des blessures.

D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LE RAYONNEMENT DE L’ARC peut
brûler les yeux et 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.

D 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).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

OM-245986 Page 3

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si

D Avertir les personnes à proximité au sujet du danger inhérent au

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Laisser refroidir le pistolet avant de le toucher.
D Ne pas toucher d’objets métalliques chauds.
D Abriter les objets métalliques contre tout

contact par les personnes à proximité.

Le BRUIT peut endommager l’ouie.

Le bruit des processus et des équipements peut
affecter l’ouïe.

D Vérifier si les niveaux de bruit excèdent les lim-

ites spécifiées par l’OSHA.

D N’utiliser que les pièces de rechange recommandées par le cons-

D Effectuer l’installation, l’entretien et toute intervention selon les

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.

le niveau de bruit est élevé.

bruit.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

D Éloigner les mains et le corps de la buse du

pistolet après avoir appuyé sur la gâchette.

LIRE LES INSTRUCTIONS.

D 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 section.

tructeur.

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website: www.glo­bal.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

2-5. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. 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:
Limiter par exemple tout accès aux passants ou procéder à une
évaluation des risques individuels 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.

from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02169 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indust­ry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régiona­ux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).

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.

OM-245986 Page 4

SECTION 3 − INSTALLATION

3-1. Specifications

Air-Cooled Welding Gun For GMAW And FCAW Welding
Note: Using gasless flux cored wire reduces gun duty cycle.

H100S2-10 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires
Duty Cycle Rating:
100%: 100 A With CO
60%: 100 A With Mixed Gases
Weight With 10 ft (3 m) Power Cable: 3.5 lb (1.6 kg)

Ref. 246 668-A

3-2. Duty Cycle And Overheating

Shielding Gas

2

. See Section 3-1. Specifications for amperage rating and duty cycle.

Definition

0

10

Minutes

Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.

Overheating

.023 To .045 in. (0.6 To 1.1 mm)

Hard Or Flux Cored Wires

100% Duty Cycle At 100 Amperes

Using CO

Continuous Welding

2

0

Minutes

15

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

.023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires

60% Duty Cycle At 100 Amperes

Using Mixed Gases

6 Minutes Welding 4 Minutes Resting

A or V

OR

Reduce Duty Cycle

sduty1 5/95

OM-245986 Page 5

3-3. Installing Gun

1

1 Gun Securing Knob
2 Gun End
Loosen knob. Insert gun end until it

bottoms against drive assembly.
Tighten knob.

3 Friction Terminals
Connect friction terminals to gun

trigger terminals inside unit.
See power source manual for

threading procedure.

3

2

243 861-A

4-1. Operating The Gun

SECTION 4 − OPERATION

1 Trigger Switch
When pressed, energized wire

feeds and shielding gas flows.

1

OM-245986 Page 6

Ref. 246 668-A

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

5-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun

Casing

! Turn off welding power

source/wire feeder.

1 Nozzle

2

3

Head
Tube

1

2 Contact Tip
3 Tip Adapter

. Wire size stamped on tip − check

and match wire size.

8 mm

Remove nozzle,
contact tip, and
adapter.

Blow out
gun casing.

Cut off wire and
disconnect gun
from feeder.

Unscrew and
remove liner.

Lay gun cable out
straight before
installing new liner.

10 mm

Reassemble gun in
reverse order from
taking it apart.

Tools Needed:

8 mm, 10 mm

Liner

Stickout

5/8 in.

(16 mm)

Install

Liner

. Thread wire according to

welding power source/wire
feeder manual.

246 669-A

OM-245986 Page 7

5-2. Replacing Switch And/Or Head Tube

! Turn Off welding power source

/wire feeder and disconnect gun.

12

Remove screws (5)
and nuts (4).

Remove screw on
opposite side.

4

Secure head
tube in vice.

5

Loosen jam nut.
Remove from vice
and turn head tube
out by hand.

Remove handle halves.

3

Remove switch housing. Install new
switch and connect leads (polarity is
not important). Reassemble in
reverse order. If replacing head tube,
continue to end of figure.

6

Hand-tighten head tube into cable connector.

8

Remove from vice. Reposition handle halves, and
install switch housing.

Tools Needed:

phillips

15 mm

7

Place head tube in vice and tighten until
nuts are tight.

9

Reinstall screws
and nuts.

Reinstall screw on
opposite side.

243 840-A

OM-245986 Page 8

5-3. Routine Maintenance

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

Each
Spool
Of Wire

n~ Nozzle and contact tip ~ Blow out gun casing

Every

3

Months

l Unreadable Labels l Damaged Gas Hose nl Cords nl Cracked Parts

5-4. Troubleshooting

Trouble Remedy

Wire does not feed; wire is not ener­gized; wire feeds unevenly.

! Disconnect power

before maintaining.

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

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

. Maintain more often

during severe conditions.

Reference

Weld porosity.

Wire feeding stops or does not feed
properly during welding.

Check, and if necessary, replace gun trigger switch (see Section 5-2).

Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 5-1).

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.

Straighten gun cable and/or replace damaged parts (see Section 5-1).

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 5-1).

Replace drive roll or pressure bearing if worn or slipping (see wire feeder manual).

OM-245986 Page 9

SECTION 6 − PARTS LIST

1

23

4

5

6

12

13

7

8

7

11

10

9

Figure 6-1. H100S2-10 Gun

Item

No.

Dia.

Mkgs.

Part

No.

245 924

Description

Figure 6-1. H100S2-10 Gun

1 169715 NOZZLE, slip type .500 orf flush 1... .......... .. ......................................

1 +226190 NOZZLE, flux cored slip type 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... .......... .. ...............................................

5 246373 TUBE, head 1... .......... .. ........................................................

6 243865 NUT, jam 1... .......... .. ..........................................................

7 242832 HANDLE 1... .......... .. ...........................................................

8 225410 SWITCH, trigger 1... .......... .. ....................................................

9 246380 HOUSING, power pin 1... .......... .. ................................................

10 245927 CONNECTOR, feeder 1... .......... .. ...............................................

11 197123 O−RING, .312 ID X .062 70 duro buna−n2... .......... .. ..............................

12 +194010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1... ......... .. ....................

12 +194011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1... ......... .. ....................

12 +194012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1... ......... .. ....................

13 079975 O-RING, .187 ID x .103CS rbr 1... .......... .... ......................................

246 670-A

Quantity

+OPTIONAL

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

OM-245986 Page 10

Notes

Ref. AWS/ANSI D1.1

WELD JOINT

TYPES

FILLETGROOVE

WELD POSITION:

FLAT

BUTT

1G

T−JOINT

1F

HORIZONTAL

BUTT

2G

T−JOINT

2F

OVERHEAD

T−JOINT

4F

VERTICAL

BUTT

3G

T−JOINT

3F

Ref. 804 248-A

BUTT

4G

Notes

Warranty Questions?

Call
1-800-332-3281
8 AM − 5 PM EST

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor or
call 1-800-332-3281. The
expertise of the distributor
and Hobart is there to
help you, every step of
the way.

Assistance

Visit the Hobart website:
www.HobartWelders.com

Effective January 1, 2018

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a

serial number preface of MJ or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, dba Hobart Welding Products,
Appleton, Wisconsin, warrants to its original retail purchaser that
new Hobart equipment sold after the effective date of this limited
warranty is free of defects in material and workmanship at the time
it is shipped. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart/Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Hobart/Miller must be notified
in writing within thirty (30) days of such defect or failure, at which
time Hobart/Miller will provide instructions on the warranty claim
procedures to be followed. If notification is submitted as an online
warranty claim, the claim must include a detailed description of the
fault and the troubleshooting steps taken to identify failed
components and the cause of their failure.

Hobart/Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original retail purchaser, and not to exceed twelve
months after the equipment is shipped to a North American
distributor or twelve months after the equipment is shipped to an
International distributor.

1. 5 Years — Parts and Labor
* Original Main Power Rectifiers only to include SCRs,

diodes, and discrete rectifier modules
* Reactors
* Stabilizers
* Transformers

2. 3 Years — Parts and Labor
* Drive Systems
* Idle Module
* PC Boards
* Rotors, Stators and Brushes
* Solenoid Valves
* Spot Welder Transformer
* Switches and Controls
* MIG Flowgauge Regulators (No Labor)

3. 1 Year — Parts and Labor Unless Specified
(90 days for industrial use)

* Accessories
* Batteries (Trek 180 Only)
* Contactors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* HF Units
* MIG Guns/TIG Torches
* Motor-Driven Guns
* Plasma Cutting Torches
* Relays
* Remote Controls
* Replacement Parts (No labor) − 90 days
* Running Gear/Trailers
* Water Cooling Systems
* Spoolguns

no other guarantees or warranties expressed or implied.

4. 6 Months — Parts
* Batteries

5. Engines and tires are warranted separately by the
manufacturer.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, 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 Hobart/Miller, but manufactured by
others, such as engines or trade accessories. These
items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Hobart/Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR COMMERCIAL AND
INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at
Hobart’s/Miller’s option, either: (1) repair; or (2) replacement; or, if
approved in writing by Hobart/Miller, (3) the pre-approved cost of
repair or replacement at an authorized Hobart/Miller service
station; or (4) payment of or credit for the purchase price (less
reasonable depreciation based upon use). Products may not be
returned without Hobart’s/Miller’s written approval. Return
shipment shall be at customer’s risk and expense.

The above remedies are F.O.B. Appleton, WI, or Hobart’s/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 HOBART/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 HOBART/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.

hobart_warr 2018-03

Thank you for purchasing Hobart. Our trained technical support team is
dedicated to your satisfaction. For questions regarding performance, op­eration, or service, contact us!

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Service Center:

Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:

Call 1-800-332-3281
8 AM to 5 PM EST − Monday through Friday

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2018 Miller Electric Mfg. LLC 2018-01

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

For Assistance:

Call 1-800-332-3281