Hobart HANDLER 100 User guide

OM-280623A 2017−08

Processes

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source and Wire
Feeder

)

Handler 100

www.HobartWelders.com

File: MIG (GMAW)

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

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

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

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 9..................................................

SECTION 4 − SPECIFICATIONS 10..............................................................

4-1. Serial Number And Rating Label Location 10................................................

4-2. Unit Specifications 10....................................................................

4-3. Duty Cycle And Overheating 10...........................................................

4-4. Volt-Ampere Curves 11..................................................................

SECTION 5 − INSTALLATION 11................................................................

5-1. Selecting A Location 11..................................................................

5-2. Installing Work Clamp 11.................................................................

5-3. Process/Polarity Table 12................................................................

5-4. Installing Wire Spool And Adjusting Hub Tension 12...........................................

5-5. Connecting 115 Volt Input Power 12........................................................

5-6. Installing Contact Tip And Nozzle 13.......................................................

5-7. Threading Welding Wire 14...............................................................

SECTION 6 − OPERATION 15...................................................................

6-1. Controls 15............................................................................

6-2. Operating The Gun 15...................................................................

6-3. Weld Parameter Chart 16................................................................

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 17..........................................

7-1. Routine Maintenance 17.................................................................

7-2. Overload Protection 17..................................................................

7-3. Replacing Gun Contact Tip 17............................................................

7-4. Changing Drive Roll Or Wire Inlet Guide 18.................................................

7-5. Cleaning Gun Liner 19...................................................................

7-6. Replacing Gun Liner 20..................................................................

7-7. Troubleshooting Table 22.................................................................

SECTION 8 − ELECTRICAL DIAGRAM 23........................................................

SECTION 9 − FCAW WELDING GUIDELINES 24..................................................

SECTION 10 − PARTS LIST 32..................................................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

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 Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

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

unit.

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

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

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

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. 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.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

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

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

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

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-280623 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

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

arc to remove welding fumes and gases. 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 If ventilation is poor, wear an approved air-supplied respirator.
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 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

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.

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 mate-

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

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

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.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and 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.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

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

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise lev-

el is high.

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

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

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

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

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

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.

OM-280623 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

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

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

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

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

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

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

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.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM-280623 Page 3

1-4. California Proposition 65 Warnings

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

1-5. 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 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 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

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).

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

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 02269 (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, 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).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. 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 con-
duct 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.

OM-280623 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

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

fre_som_2015−09

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 représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

D Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

. 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.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor­mes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.

OM-280623 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer 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 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

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

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

D Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

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 génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
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 pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (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.

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.

des rayons visibles et invisibles intenses (ultraviolets

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut

être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incen­dies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-280623 Page 6

provoquer leur éclatement. Des étincelles peuvent

chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

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 Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

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 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

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

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

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

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

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

endommagée, elle peut exploser. Du fait que

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

duits inflammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

D Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

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.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

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.

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

constructeur.

D 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.

OM-280623 Page 7

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

provoquer des interférences avec les équi-

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

D Pour réduire la possibilité d’interférence, maintenir les câbles de

D Veiller à souder à une distance de 100 mètres de tout équipement

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

D En cas d’interférences après avoir pris les mesures précédentes,

2-4. Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).

électronique sensible.

conformément à ce mode d’emploi.

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. 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 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 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
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

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

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 02269 (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, 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).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

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: 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

OM-280623 Page 8

câbles d’un côté et à distance de l’opérateur.

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.

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Safe1 2012−05

A

V

Hz

Amperage

Voltage

Positive

Negative

Direct Current

(DC)

Alternating

Current (AC)

Single Phase

Hertz

Input

Off

On

Work Connection

Flux Cored Arc

Welding (FCAW)

FCAW Gun With

Switch

Do Not Switch

While Welding

Wire Feed

Circuit Breaker

Increase

s

X

I
I

I

1eff

I

1max

U

Line Connection

Suitable For

Welding In An

Environment With

Increased Risk Of

Electric Shock

Duty Cycle

Rated Supply

1

2

0

Current

Rated Welding

Current

Maximum

Effective Supply

Current

Rated Maximum

Supply Current

Rated No−Load

Voltage (OCV)

Input Voltage

Output

Single Phase

Transformer

Rectifier

Percent

Protective Earth

(Ground)

Temperature

U
U

IP

Rated Supply

1

2

Voltage

Conventional
Load Voltage

Internal Protection

Rating

OM-280623 Page 9

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the 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.

4-2. Unit Specifications

Rated Welding

Output

80 A @ 18 Volts DC,

20% Duty Cycle

45 A @ 16.25 Volts

DC, 60% Duty Cycle

30 A @ 15.5 Volts DC,

100% Duty Cycle

Wire Type

And Diameter

Amperage

Range

30 − 100

Maximum Open-

Circuit Voltage

DC

40 21.2 2.69 2.45

Flux Cored Wire Feed Speed Range

.030 − .035 in.

(0.8 − 0.9 mm)

4-3. Duty Cycle And Overheating

120

100

Amperes Input at

Rated Load Output

115 V, 60 Hz, Single-

Phase

KVA KW

27 − 99 RPM At No Load

20% duty cycle at 80 amps

2 Minutes Welding 8 Minutes Resting

60% duty cycle at 45 amps

Weight

W/ Gun

44 lb

(20 kg)

Overall

Dimensions

Length: 16 in.

(406 mm)

Width: 10 in.

(254 mm)

Height: 13-1/2 in.

(343 mm)

80

60

40

Output Amperes

20

0

Duty Cycle %

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

Overheating

10 10020 40 60 80

If unit overheats, thermostat(s) opens,
output stops, and cooling fan runs. Wait
fifteen minutes for unit to cool. Reduce
amperage or duty cycle before welding.

0

15

Minutes

6 Minutes Welding 4 Minutes Resting

100% duty cycle at 30 amps

Continuous Welding

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

A or V

OR

Reduce Duty Cycle

OM-280623 Page 10

rduty1 2013−04 − 270 506-A

4-4. Volt-Ampere Curves

30

25

20

15

Voltage

10

5

0

0 102030405060708090100

SECTION 5 − INSTALLATION

5-1. Selecting A Location

Amperage

18 in.

(460 mm)

The volt-ampere curves show the
voltage and amperage output capa­bilities of the welding power source.

Range 4

Range 3

Range 2

Range 1

270 507-A

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

! Do not move or operate unit

1

where it could tip.

1 Grounded Receptacle
Locate unit near correct input

power supply.

18 in.

(460 mm)

5-2. Installing Work Clamp

Tools Needed:

10 mm

3

3

161-062

. Connection hardware must be tight-

ened with proper tools. Do not just

1

4

5
6

2

7

8

hand tighten hardware. A loose
electrical connection will cause
poor weld performance and exces­sive heating of the work clamp.

1 Work Clamp
2 Work Cable From Unit
3 Insulator Grip
Slide one insulating grip over work cable

before connecting to clamp.
4 Nut
5 Lock Washer
6 Flat Washer
7 Screw
8 Work Clamp Tabs
Bend tabs around work cable.
Slide insulating grips over handles.

OM-280623 Page 11

Ref. 802 456

5-3. Process/Polarity Table

Process Polarity

FCAW − Self-shielding wire − no
shielding gas

DCEN − Straight Polarity Gun cable is connected to the

Cable To Gun Cable To Work Clamp

negative (−) output

5-4. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in. (102 mm) And 8 in. (203 mm) Wire Spools

Cable Connections

Work cable is connected to the positive
(+) output

Tools Needed:

When a slight force is needed
to turn spool, tension is set.

5-5. Connecting 115 Volt Input Power

161-072 / 803 012

! Installation must meet all

National and Local Codes −
have only qualified persons
make this installation.

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC

2

1

Section 20.

For 115 volts AC input power, a 20
ampere individual circuit protected
by time-delay fuses or circuit
breaker is required.

1 Plug From Unit
2 Receptacle − NEMA Type

5−15R (Customer Supplied)

Select extension cord of 12 AWG
for up to 50 ft (15 m) or 10 AWG for
50 up to 100 ft (30 m).

OM-280623 Page 12

Input6 2011−03 / Ref. 161−062

5-6. Installing Contact Tip And Nozzle

3

2

1

Flux Nozzle

Use with flux cored wire only. Narrow
design allows access in tight spaces
and provides better visibility of
puddle during welding.

Push nozzle over contact tip and
adapter until it is seated onto adapter.
Contact tip will be exposed
approximately 7/16 in. (11.3 mm)
when installed properly.

! Turn off welding power source.

1 Nozzle
Remove nozzle.
2 Contact Tip
3 Tip Adapter
Thread welding wire through gun (see

Section 5-7).
Slide contact tip over wire and tighten

tip into tip adapter.
Install nozzle.

Tools Needed:

Notes

Ref. 804 241-A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-280623 Page 13

5-7. Threading Welding Wire

Tools Needed:

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll

4

6

6 Gun Cable
Lay gun cable out straight.

1

2

3 5

. Hold wire tightly to keep it

from unraveling.

6 in.

(150 mm)

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

Pull and hold wire; cut off end.

continue to hold wire.

4 in.

(102 mm)

. Loosen knob completely, then rotate

Tighten

pressure adjustment knob in a
clockwise direction until drive roll is
tight against the welding wire.

Adjust drive roll pressure just
tightly enough to prevent wire
from slipping against drive roll
during operation.

Be sure that wire is positioned

in proper feed roll groove.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes
out of gun.

OM-280623 Page 14

Remove gun nozzle and contact tip.

. Tip adapter may also require removal

to allow wire to feed out end of gun.

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

Turn power on.

Tighten

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

161-063 / 161-064 / Ref. 803 444-A / Ref. 205 837

6-1. Controls

SECTION 6 − OPERATION

2

4

1 Voltage Switch

NOTICE − Do not switch under
load.

Use control to select the weld
voltage range. As the thickness of
material increases, a higher voltage
range must be selected (see weld
setting label in welding power
source or in Section 6-3).

When Voltage switch is placed in
the Fan Only position there is no
weld output and wire does not feed.

. Switch must “click” into detent

position for weld output.

2 Wire Feed Control
Use control to select a wire feed

speed. See weld setting label in
welding power source or in Section
6-3.

3 Power Switch
Use switch to turn unit on and off.
4 Over Temperature Light
If unit overheats, light turns on and

output stops. Allow unit to cool be­fore attempting to weld.

Light goes out when unit has cooled
and welding can resume.

6-2. Operating The Gun

1

1

3

Ref. 229 999-A

1 Trigger Switch
Press and hold gun trigger to ener-

gize wire feed motor and begin
welding. Gun trigger must be
pressed (closed) and held for weld­ing to begin.

Release the gun trigger to stop weld
output and wire feed.

Ref. 804 240-A

OM-280623 Page 15

6-3. Weld Parameter Chart

4 / 60

4 / 50

3 / 30

2 / 35

2 / 25

4 / 45

4 / 35

3 / 30

2 / 25

2 / 20

Wire Feed Setting listed is a starting value only − Wire Feed setting can

be fine−tuned while welding. Wire Feed also depends on other variables

such as stick out, travel speed, weld angle, cleanliness of metal, etc.

REPLACEMENT CONSUMABLES

(4.8 mm)

3/16 inch

1/8 inch

(3.2 mm)

(2.5 mm)

12 gauge

(2.1 mm)

14 gauge

Recommended Voltage and Wire Feed Settings for

Thickness of Metal Being Welded. Number on Left of Slash is

Voltage Setting / Number on Right of Slash is Wire Feed Setting.

(1.6 mm)

16 gauge

270659−A

Nozzle Tip Adapter Drive Roll

770487 770402 212379R

1 / 10

1 / 25

(1.2 mm)

18 gauge

Contact Tips

.030” (0.8 mm) − 770177

.035” (0.9 mm) − 770180

of Wire

Diameter

Being Used

.030” (0.8 mm)

.035” (0.9 mm)

E71T−11

Wire Type

Flux Core

CAUTION!

Thicker materials can be welded using proper

Settings are approximate. Adjust as required.

Knob position while welding.

technique, wire joint preparation, and multiple passes.

Being

Welded

Material

Steel

Match contact tip to diameter of wire being used.

Match feedroll groove to diameter of wire being used.

BEFORE OPERATING: NOTE:

Adjust tension knob per instructions in the manual.

Do not change Voltage Switch

Welding Guide for 115 Volt Wire Welding Package

OM-280623 Page 16

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

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

3 Months

Reference

l Damaged Or Unreadable Labels l Repair Or Replace

Cracked Weld Cable

6 Months

OR

~ Drive Rolls ~ Inside Unit

7-2. Overload Protection

1

7-3. Replacing Gun Contact Tip

3

2

1 Supplementary Protector CB1
CB1 protects unit from overload. If

CB1 opens, unit shuts down.
Reset supplementary protector.

161-066

! Turn Off power before replacing

contact tip.

1 Nozzle
Remove nozzle.
2 Contact Tip
3 Tip Adapter
Cut off welding wire at contact tip.

Remove contact tip from tip adapter,
and install new contact tip. Reinstall
nozzle.

1

Tools Needed:

Ref. 804 241-A

OM-280623 Page 17

7-4. Changing Drive Roll Or Wire Inlet Guide

2

1

5

6

3

4

1 Pressure Adjustment Knob
2 Pressure Assembly
Pivot pressure adjustment knob

down, and lift pressure assembly
up.

3 Pivot Tube Plate
4 Securing Screws
5 Pressure Arm Pivot Tube
6 Inlet Wire Guide
Remove screws and pivot tube

plate. Lift out pressure arm pivot
tube, and slide inlet wire guide out of
tube.

Slide replacement wire guide into
tube, and place tube back into drive
assembly. Be sure tip of wire guide
is as close to drive roll as possible
without touching.

Reinstall plate and tighten screws.
7 Retaining Knob
Rotate counterclockwise and

remove knob.

7

8 Drive Roll
The drive roll consists of two

different sized grooves. Each side
is stamped with the proper size.

Select the groove that matches the
wire size on the wire spool. Install
drive roll onto motor shaft so that
correct groove size stamp faces out
away from drive housing.

9 Retaining Knob Opening
Install retaining knob by placing

opening over drive roll (opening
faces rear of unit). Rotate retaining
knob clockwise to secure drive roll.

Position wire into outer groove of
drive roll (see Section 5-7).

.030/.035

VK Groove

Stamped .030/.035

Tools Needed:

OM-280623 Page 18

.024 Groove

Stamped .024

9

8

161-064 / 161-069 / Ref. 802 444-B / 803 442-A

7-5. Cleaning Gun Liner

! Turn Off welding power source.

1 Nozzle
2 Contact Tip
3 Adapter

1

2

3

8 mm

Remove nozzle. Cut off wire
at contact tip, and remove
contact tip and tip adapter.

Head
Tube

Open pressure assembly. Retract
wire from liner onto spool.

. Hold wire tightly to keep it

from unraveling. Secure
end of wire at spool.

Remove four screws from
cover, and remove cover
from wire drive assembly.

Tools Needed:

8 mm

Lay gun cable out straight,
and blow out liner.

Reassemble drive cover
and gun in reverse order
from taking it apart.
Thread wire according
to Section 5-7.

161-064 / 161-070 / 161-071 /804 241-A / 803 838-A

OM-280623 Page 19

7-6. Replacing Gun Liner

! Turn Off welding power source.

Tools Needed:

1

2

3

8 mm

Remove nozzle. Cut off wire at contact tip,
and remove contact tip and tip adapter.

Head
Tube

Open pressure assembly. Retract
wire from liner onto spool.

8 mm / 10 mm

. Hold wire tightly to keep it

from unraveling. Secure
end of wire at spool.

Twist top and bottom handle locking rings
counterclockwise 1/4 turn. Slide bottom ring
down cable and top ring forward over head
tube. Separate gun handle halves.

Remove black sleeving
(if present) from end of
replacement liner.

Install retaining nut on one end of liner. Lay gun
cable straight on a flat surface. Insert bare end of
liner (end without retaining nut) into wire drive end
of cable. Push liner toward gun. If necessary, twist
cable to ease installation.

Loosen liner setscrew.

Remove four screws from
cover, and remove cover
from wire drive assembly.

8 mm

Loosen and remove retaining
nut from liner. Pull liner out of
gun cable. If necessary, twist
cable to ease removal.

161-064 / 161-070 / 161-071 / Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A

OM-280623 Page 20

7-6. Replacing Gun Liner (Continued)

13/16 in.
(21 mm)

When liner exits cable at gun
handle, guide liner into head
tube. Continue to push liner until
it exits end of head tube.

Reinstall cover onto wire
drive assembly, and secure
with four screws.

8 mm

Insert retaining nut into adapter, and adjust liner stickout as
shown. Tighten retaining nut. Reinstall cable end into drive
housing with retaining grooves inserted into the two retaining
ribs. Be sure to position gas hose up. Position liner in groove
so that end is flush with back of groove, adjust if necessary

3/8 in (10 mm)

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

Reassemble gun by placing head tube
and cable into one half of handle. Be
sure trigger is properly installed into
trigger slot.

Slide locking rings over top and
bottom of handle, and secure by
twisting rings clockwise 1/4 turn.

Place other half of handle over
head tube and cable.

8 mm

Thread welding wire through gun (see Section
5-7). Reinstall adapter, contact tip, and nozzle.

OM-280623 Page 21

7-7. Troubleshooting Table

Trouble Remedy

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

Secure power cord plug in receptacle (see Section 5-5).

Replace building line fuse or reset circuit breaker if open.

Place Power switch in On position (see Section 6-1).

Check supplementary protector CB1, and reset if open (see Section 7-2).

No weld output; wire does not feed; fan
motor continues to run.

No weld output; wire does not feed; fan
motor continues to run.

No weld output; wire feeds.

Low weld output.

Electrode wire feeding stops during
welding.

Set the Voltage switch to positions 1, 2, 3, or 4. There is no weld output and wire does not feed when
switch is in Fan Only position (see Section 6-1).

Ensure the gun trigger switch is depressed and held (see Section 6-2).

Check if Over Temperature Light PL1 is On. Light goes on and weld output/wire feeding stops when unit
has overheated. To resume welding, allow fan to cool unit until light goes off (see Sections 4-3 and 6-1).

Be sure that Voltage switch is not set between ranges (see Section 6-1).

Disassemble torch handle and check trigger switch lead connections, tighten or reconnect any loose
connections.

Connect work clamp to get good metal to metal contact.

Check cable connection at work clamp and tighten hardware if necessary (see Section 5-2).

Replace contact tip (see Section 7-3).

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

Place voltage switch in desired position (see Section 6-1).

Check cable connection at work clamp and tighten hardware if necessary (see Section 5-2).

If using an extension cord, check that wire size and length is the proper size for power rating of welding
power source (see Section 4-2).

Ensure wire spool is not out of welding wire.

Readjust hub tension (see Section 5-4).
Adjust drive roll pressure (see Section 5-7).

Check supplementary protector CB1, and reset if open (see Section 7-2).

OM-280623 Page 22

Check if Over Temperature Light PL1 is On. Light goes on and weld output/wire feeding stops when unit
has overheated. To resume welding, allow fan to cool unit until light goes off (see Sections 4-3 and 6-1).

Straighten gun cable and/or replace damaged parts.

Change to proper drive roll groove (see Section 7-4).
Replace contact tip if blocked (see Section 7-3).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).
Check and clear any restrictions at drive assembly and liner (see Section 7-5).

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

270431-C

OM-280623 Page 23

SECTION 9 − FCAW WELDING GUIDELINES

9-1. Typical FCAW Process Connections

Wire Feeder/

Power Source

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a ve­hicle. Place work clamp as
close to the weld as possible.

. The Illustration is representative

of most equipment. Your unit
may differ from that shown.

Gun

Notes

Self-Shielding Flux

Core Wire

Work Clamp

Workpiece

FCAW1 2014−11 − Ref. 803 444-A

OM-280623 Page 24

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

9-2. Typical Control Settings

. Auto−Sett and single-knob control units operate differently than outlined below. See Operation section of Owner’s Manual for specific information

on control settings.

. These settings are guidelines only. Material and wire type, joint design, fit-up, position, etc. af-

fect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld
parameters.

1/8 or 0.125 in.

Convert Material

Thickness to

Amperage (A)

(0.001 in. = 1 ampere)

0.125 in. = 125 A

.035 in

Wire

Size

0.023 in.

0.030 in.

0.035 in.

Recommendation

3.5 in per ampere
2 in per ampere

1.6 in per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

30 − 90 A
40 − 145 A
50 − 180 A

Wire Speed

(Approx.)

3.5 x 125 A = 437 ipm
2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Size

Select Wire Speed

(Amperage)

125 A based on 1/8 in.

material thickness

ipm = inches per minute

Select Voltage

Voltage controls height and
width of weld bead.

Wire speed (amperage) controls weld
penetration (wire speed = burn-off rate)

Ref. 803 441-A

OM-280623 Page 25

9-3. Holding And Positioning Welding Gun

. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)

past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control Gun

Trigger
2 Workpiece
3 Work Clamp
4 Electrode Extension (Stickout)

1

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

Workpiece

2

5

4

0-15

90 90

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

3

OM-280623 Page 26

45

45

End View of Work Angle Side View of Gun Angle

FILLET WELDS

0-15

S-0421-A

9-4. Conditions That Affect Weld Bead Shape

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

(weld current), and voltage.

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

Push Perpendicular Drag or Pull

10

10

Electrode directed
ahead of bead

Electrode pointed
back into bead

Direction Of Welding

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow

Normal Fast

GUN TRAVEL SPEED

S-0634

OM-280623 Page 27

9-5. Gun Movement During Welding

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

a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

Movement Along Seam
2 Weave Bead − Side To Side

Movement Along Seam
3 Weave Patterns

1 2

3

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

S-0054-A

9-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

1

2

9-7. Good Weld Bead Characteristics

2

4

3

4

3

5

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding
Weld a new bead or layer for each

1

1/8 in. (3.2 mm) thickness in metals
being welded.

4 No Overlap
5 Good Penetration into Base

Metal

S-0053-A

OM-280623 Page 28

5

S-0052-B

9-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

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

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

9-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets
in weld metal.

S-0635

Possible Causes Corrective Actions

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

9-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Good Penetration

Increase travel speed.

S-0639

9-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow
fusion between weld metal and
base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

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

maintaining proper welding wire extension and arc characteristics.

OM-280623 Page 29

S-0638

Possible Causes Corrective Actions

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

9-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes Corrective Actions

S-0637

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

welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

9-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

9-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

OM-280623 Page 30

S-0641

9-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces
base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

9-16. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but
wire does not feed.

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match

wire size and type if necessary.

S-0642

Wire curling up in front of the
wire feed rolls (bird nesting).

Welding arc not stable.

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

Restriction in the gun and/or assembly. Check and replace cable, gun, tip adapter, and contact

Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun

Dirty or damaged (kinked) liner. Replace liner.

Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed on
welding power source.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

tip if damaged. Check size of contact tip and cable liner,
replace if necessary.

and diameter, replace if necessary.

end into housing just enough so it does not touch wire
feed rolls.

drive rolls if necessary.

Readjust welding parameters.

OM-280623 Page 31

10-1. Parts List

SECTION 10 − PARTS LIST

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Handler 100

1 280708 Door, Access (Includes) 1... .......... .. ..............................................

270659 Label, Welding Guide 1................ .... ..............................................

236156 Label, Hobart 1................ .... .....................................................

2 280709 Wrapper, Cover (Includes) 1... .......... .. ...........................................

275668 Label, Warning General Precautionary (En/Fr/Sp) 1................ .... .....................

275669 Label, Warning General Precautionary (En/Fr/Sp) 1................ .... .....................

220457 Label, Need Help 1................ .... ..................................................

236156 Label, Hobart 1................ .... .....................................................

3 270622 Hinge, Door Access 2... .......... .. .................................................

4 CB1 270623 Supplementary Protector, Man Reset 1P 25A 250VAC FR 1... ... .. .. ................

5 SR1 270624 Rectifier Assembly, 1PH 125 A 500V PIV 25% Duty Cycle 1... ... .. .. ................

6 S1 270625 Switch, Rocker DPST 16A 250VAC On-None-Off .250 CC 1... .... .. .. ................

7 R1 270626 Pot, CP Plat 1T 0.2W 5K Linear 1... .... .. .. ......................................

8 S2 270627 Switch, Rotary 5 Position 1... .... .. .. ............................................

9 PC1 270628 Circuit Card Assy, Control 1... ... .. .. ............................................

10 270631 Kit, Spool Hub Replacement 1... .......... .. ..........................................

11 270632 Bezel, Rear (Black) 1... .......... .. .................................................

12 280717 Bezel, Front (Black) 1... .......... .. .................................................

13 280718 Knob, Pointer 1.188 Dia 2... .......... .. .............................................

14 FM 270634 Fan, Muffin 115V 50/60Hz 2200 RPM 4.135 Mtg Holes 1... ... .. .. ...................

15 PL1 270682 Light, Ind Amber Lens 125V Snap-In Mtg .500 Mtg Hol 1... ... .. .. ...................

16 270629 H100F2-8 Gun. 030-.035 1... .......... .. ............................................

17 DM1 270630 Drive Assy, Wire 1... ... . .. ....................................................

18 240594 Label, Warning, Electric Shock And Pinch 1... .......... .. ..............................

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.

10-2. Accessories

Part No. Description Remarks

194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg)
270 629 H100F2-8 Gun .030−.035 8 ft (2.4 m) length/.030-.035 (0.8-0.9 mm) Wire Size

10-3. Consumables

Item Hobart Package Part No.

Contact Tip .030 in. (0.8 mm) 770 177 (5 per package)
Contact Tip .035 in. (0.9 mm) 770 180 (5 per package)

Gasless Flux Cored Nozzle 770 487

Tip Adapter 770 402

Replacement Liner .030/.035 in. (0.8/0.9 mm) 210 970R

Replacement Drive Roll .023/.025 in. (0.6 mm) and .030/.035 in (0.8/0.9 mm) V and VK Groove 212 379R

OM-280623 Page 32

Warranty Questions?

Call
1-800-332-3281
7 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, 2017

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

serial number preface of MH 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, Hobart Brothers Co. and Miller Electric Mfg. Co., Appleton,
Wisconsin, warrants to its original retail purchaser that new Hobart
equipment sold after the effective date of this limited warranty is
free of defects in material and workmanship at the time it is shipped
by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart/Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Hobart/Miller must be notified
in writing within thirty (30) days of such defect or failure, at which
time Hobart/Miller will provide instructions on the warranty claim
procedures to be followed. 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

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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* MIG Guns/TIG Torches
* Motor-Driven Guns
* Plasma Cutting Torches
* Regulators
* Relays
* Remote Controls
* Replacement Parts (No labor) − 90 days
* Running Gear/Trailers
* Water Cooling Systems
* Spoolguns

4. 6 Months — Parts
* Batteries

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

no other guarantees or warranties expressed or implied.

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 PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair;
or (2) replacement; or, where authorized in writing by Hobart/Miller
in appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Hobart/Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Hobart’s/Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Hobart/Miller authorized service facility as determined
by Hobart/Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY HOBART/MILLER
IS EXCLUDED AND DISCLAIMED BY Hobart/Miller.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

hobart_warr 2017-01

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
7 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  2017 Hobart Brothers Co.. 2017-01

Hobart Brothers Co.

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

For Assistance:

Call1-800-332-3281