Hobart Welding Products HANDLER H-10 GUN, HANDLER 180 User Manual [en, fr]

OM-925 217 694B

August 2004

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source And
Wire Feeder

R

Handler 140 / 180

And H-10 Gun

Visit our website at

www.HobartWelders.com

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.

This Owner’s Manual is designed to help you get the most out of your
Hobart products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Hobart you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will help
you figure out what the problem is. The parts
list will then help you to decide the exact part

Hobart is registered to the
ISO 9001:2000 Quality
System Standard.

you may need to fix the problem. Warranty and
service information for your particular model
are also provided.

Working as hard as you
do − every power source
from Hobart is backed by
the best warranty in the
business.

Hobart Welders manufactures a full line
of welders and welding related equipment.
For information on other quality Hobart products, contact your local Hobart
distributor to receive the latest full line catalog or individual catalog sheets.

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

Hob_Thank 7/03

TABLE OF CONTENTS

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

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

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

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

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

SECTION 4 − SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Duty Cycle And Overheating 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Gun 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Installing Work Clamp 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Process/Polarity Table 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Changing Polarity 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Installing Gas Supply 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Selecting A Location And Connecting Input Power For 115 VAC Model 15 . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Selecting A Location And Connecting Input Power For 230 VAC Model 16 . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Electrical Service Guide For 230 VAC Model 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Installing Wire Spool And Adjusting Hub Tension 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Threading Welding Wire 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATION 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Controls 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Weld Parameter Chart For 115 VAC Model 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Weld Parameter Chart For 230 VAC Model 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Overload Protection 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Drive Motor Protection 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Changing Drive Roll Or Wire Inlet Guide 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Replacing Gun Contact Tip 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Cleaning Or Replacing Gun Liner 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Replacing Switch And/Or Head Tube 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Troubleshooting Table 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAM 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 9 − MIG WELDING (GMAW) GUIDELINES 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Typical MIG Process Connections 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Typical MIG Process Control Settings 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Holding And Positioning Welding Gun 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Conditions That Affect Weld Bead Shape 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Gun Movement During Welding 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Poor Weld Bead Characteristics 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Good Weld Bead Characteristics 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8. Troubleshooting − Excessive Spatter 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9. Troubleshooting − Porosity 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10. Troubleshooting − Excessive Penetration 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-11. Troubleshooting − Lack Of Penetration 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-12. Troubleshooting − Incomplete Fusion 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-13. Troubleshooting − Burn-Through 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-14. Troubleshooting − Waviness Of Bead 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-15. Troubleshooting − Distortion 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-16. Common MIG Shielding Gases 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

som _8/03

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y 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.

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

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input

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 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 and ground this equipment according to its

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

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 Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.

power circuit and machine internal circuits are also

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

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 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.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

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

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

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 exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the

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

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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

OM-925 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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 a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

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

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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 closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

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 and fire hazards.

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

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, 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.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDS can affect pacemakers.

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

going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding 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, slag, open flames, sparks, and arcs.

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

support or cylinder rack to prevent falling or tipping.

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

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

D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety
Standards.

OM-925 Page 2

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 UNIT can cause injury.

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.

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.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

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.

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 cause injury.

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

rolls.

WELDING WIRE can cause injury.

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.

1-4. California Proposition 65 Warnings

Y 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.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

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.

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-925 Page 3

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: [phone], website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi­ami, FL 33126 (phone: [phone], website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web­site: www.cganet.com).

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

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).

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

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000, website: www.nfpa.org and www. sparky.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, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-925 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT

UTILISATION

som_fre 8/03

2-1. Signification des symboles

Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.

Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-

Y Identifie un message de sécurité particulier.

. Signifie « NOTA » ; n’est pas relatif à la sécurité.

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

lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les me­sures à prendre pour éviter tout danger.

Y Les symboles ci-après sont utilisés tout au long du présent

manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,

en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.

Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension

d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.

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

trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.

D Ne pas se servir d’une source de courant alternatif dans les zones humi-

des, les endroits confinés ou là où on risque de tomber.

D Ne se servir d’une source de courant alternatif QUE si le procédé de souda-

ge l’exige.

D Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-

vir de la fonction de télécommande si l’appareil en est équipé.

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

lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor­mes de sécurité).

D Installer et mettre à la terre correctement l’appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.

D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu-

rer 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 Pour exécuter les branchements d’entrée, fixer d’abord le conducteur

de mise à la terre adéquat et contre−vérifier les connexions.

D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est

ni endommagé ni dénudé ; le remplacer immédiatement s’il est en­dommagé − tout câble dénudé peut causer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou

mal épissés.

D Ne pas s’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 d’une autre machine.

dès que l’appareil est en fonctionnement. Le circuit

D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−

champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.

D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur

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

D Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un

même terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.

D Arrêter les convertisseurs, débrancher le courant électrique et dé-

charger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.

D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à adduction

d’air agréé.

D Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-

tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.

D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un

respirateur à adduction d’air. Demander toujours à un surveillant dû­ment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respira­ble.

D Ne pas souder 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 de métaux munis d’un revêtement, tels que la tôle

d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti­lé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dé­gager des fumées toxiques lorsqu’on les soude.

OM-925 Page 5

LES RAYONS DE L’ARC peuvent cau­ser des brûlures oculaires et cuta­nées.

Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) suscep­tibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.

D Porter un masque de soudage muni d’un filtre de la nuance adéquate

pour se protéger le visage et les yeux pendant le soudage ou pour re­garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).

D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat

éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.

D Porter des vêtements de protection en matière durable et ignifuge

(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incen­die ou une explosion.

Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées

pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauf­fement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.

D Se protéger et protéger les tiers de la projection d’étincelles et de mé-

tal chaud.

D Ne pas souder à un endroit où des étincelles peuvent tomber sur des

substances inflammables.

D Placer 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 agréées.

D Des étincelles et des matières en fusion peuvent facilement passer

même par des fissures et des ouvertures de petites dimensions.

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

mité.

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

cloison peut déclencher un incendie de l’autre côté.

D Ne pas souder des récipients fermés tels que des réservoirs, des fûts

ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution 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 au raz du tube−contact.

D Porter des vêtements de protection exempts d’huile tels que des

gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.

D Avant de souder, retirer tout produit combustible de ses poches, tel

qu’un briquet au butane ou des allumettes.

de l’arc de soudure. La projection d’étincelles, les

LES PARTICULES PROJETÉES peu­vent blesser les yeux.

D Le soudage, le burinage, le passage de la pièce à

la brosse métallique et le meulage provoquent

ques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.

D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le

masque de soudage.

l’émission d’étincelles et de particules métalli-

LES ACCUMULATIONS DE GAZ peu­vent causer des blessures ou même
la mort.

D Couper l’alimentation en gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien ventiler les espaces confinés ou porter un respira-

teur à adduction d’air agréé.

LES PIÈCES CHAUDES peuvent cau­ser des brûlures graves.

D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimu­lateurs cardiaques.

D Les personnes qui portent un stimulateur cardiaque

doivent se tenir à distance.

D Ils doivent consulter leur médecin avant de s’appro-

cher d’un lieu où on exécute des opérations de sou­dage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit de certains processus et équipements peut
affecter l’ouïe.

D Porter des protecteurs d’oreille agréés si le niveau

sonore est trop élevé.

Les BOUTEILLES endommagées
peuvent exploser.

Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des

chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.

D Placer les bouteilles debout en les fixant dans un support stationnaire

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

D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-

cuits électriques.

D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bou-

teille de gaz.

D Ne jamais souder une bouteille contenant du gaz sous pression − elle

risquerait d’exploser.

D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.

D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-

tion ou de branchement de la bouteille

D Lire et suivre les instructions concernant les bouteilles de gaz compri-

mé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.

normalement partie du procédé de soudage, les

OM-925 Page 6

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de

l’appareil.

Risque D’INCENDIE OU D’EXPLO­SION

D Ne pas placer l’appareil sur une surface inflam-

mable, ni au−dessus ou à proximité d’elle.

D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimen-

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

LA CHUTE DE L’APPAREIL peut
blesser.

D N’utiliser que l’anneau de levage pour lever l’ap-

pareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.

D Utiliser un engin de capacité adéquate pour lever

D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que

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

l’appareil.

L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

reprendre le soudage.

LES ORGANES MOBILES peuvent
causer des blessures.

D Se tenir à l’écart des organes mobiles comme les

ventilateurs.

D Maintenir fermés et bien fixés les portes,

panneaux, recouvrements et dispositifs de
protection.

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

D Le rayonnement haute fréquence peut causer

des interférences avec les équipements de radio­navigation et de communication, les services de
sécurité et les ordinateurs.

D Ne demander qu’à des personnes qualifiées familiarisées avec les

équipements électroniques de faire fonctionner l’installation.

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

qualifié les interférences causées par l’installation.

D Si la Federal Communications Commission signale des interféren-

ces, arrêter immédiatement l’appareil.

D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sour-

ces de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interféren­ces éventuelles.

LE SOUDAGE À L’ARC peut causer
des interférences.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

D Mettre un bracelet antistatique AVANT de mani-

puler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de
circuits imprimés.

LES PIÈCES MOBILES peuvent cau­ser des blessures.

D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels

que les dévidoirs.

LES FILS DE SOUDAGE peuvent cau­ser des blessures.

D Ne pas appuyer sur la gâchette avant d’en avoir

reçu l’instruction.

D Ne pas diriger le pistolet vers soi, vers d’autres

personnes ou vers toute pièce mécanique en en­gageant le fil de soudage.

D L’énergie électromagnétique peut causer des

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

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

ble au point de vue électromagnétique.

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

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

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

électronique sensible.

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

mément au présent manuel.

D En cas d’interférences après exécution des directives précédentes, 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 CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’appro­cher des opérations de soudage à l’arc, de gou­geage ou de soudage par points.

OM-925 Page 7

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca­nadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna­tional.org).

Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé­phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.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, de l’U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnéti­ques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs élec­tromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumula­tion de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la re­cherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, res­pecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom­mandé de respecter les consignes ci-dessus.

OM-925 Page 8

SECTION 3 − DEFINITIONS

Wire Type

Wire Type

3-1. Symbols And Definitions

A

Amperage

Positive

Output Voltage Input Off On

Do Not Switch
While Welding

4-1. Specifications

A. 115 VAC Model

Rated Welding

Output

90 A @ 19 Volts DC,

20% Duty Cycle

63 A @ 21 Volts DC,

20% Duty Cycle*

Wire Type

And Diameter

* CSA Rating

Amperage

25 − 140

Stainless

.023 − .035 in

(0.6 − 0.9 mm)

V

Voltage

Direct Current

(DC)

Gas Metal Arc

Welding (GMAW)

Hz

Hertz Negative

Single Phase Input

Wire Feed

SECTION 4 − SPECIFICATIONS

Amperes Input at

Rated Load Output

115 V, 60 Hz, Single-

Phase

20

15*

.030 in

(0.8 mm)

KVA KW

2.90

2.20*

50 − 740 IPM (1.3 − 18.8 m/min) At No Load

40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire

Range

Solid/

Maximum Open-

Circuit Voltage

DC

28

Flux Cored Aluminum

.030 − .035 in

(0.8 − 0.9 mm)

Weight

W/ Gun

Length: 19-1/2 in

2.50

1.77*

Wire Feed Speed Range

57 lb

(26 kg)

Height: 12-3/8 in

Overall

Dimensions

(495 mm)

Width: 10-5/8 in

(270 mm)

(314 mm)

B. 230 VAC Model

Rated Welding

Output

130 A @ 20 Volts

DC, 30% Duty Cycle

At 60 Hz Input − 20%

Duty Cycle At 50 Hz

Input

Wire Type

And Diameter

Amperage

Range

25 − 180

Solid/

Stainless

.023 − .035 in

(0.6 − 0.9 mm)

Maximum Open-

Circuit Voltage

DC

30 20 4.60 3.75

Flux Cored Aluminum

.030 − .045 in

(0.8 − 1.2 mm)

Amperes Input at

Rated Load Output

230 V, 50/60 Hz,

Single-Phase

.030 − .035 in

(0.8 − 0.9 mm)

KVA KW

Wire Feed Speed Range

50 − 740 IPM (1.3 − 18.8 m/min) At No Load

40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire

Weight

W/ Gun

68 lb

(31 kg)

Overall

Dimensions

Length: 19-1/2 in

(495 mm)

Width: 10-5/8 in

(270 mm)

Height: 12-3/8 in

(314 mm)

OM-925 Page 9

4-2. Duty Cycle And Overheating

A. 115 VAC Model

200

140

100

80

60

40

Output Amperes

20

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

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.

Y Exceeding duty cycle can

damage unit or gun and void
warranty.

10

B. 230 VAC Model

200
180

130
100

80
60

40

20

Output Amperes

10

10 20 30 40 50

410

1

2

6808

20

40 60 100

Duty Cycle %

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting

60 70 80 100

Duty Cycle %

Overheating

OM-925 Page 10

30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz

3 Minutes Welding 7 Minutes Resting

0

15

Minutes

A or V

OR

Reduce Duty Cycle

duty1 4/95 − 217 623-A / 217 757-A

4-3. Volt-Ampere Curves

A. 115 VAC Model

30.0

25.0

20.0

15.0

Voltage

10.0

5.0

0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Amperage

RANGE 1

RANGE 3

RANGE 2

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.

RANGE 4

B. 230 VAC Model

30.0

25.0

20.0

RANGE 3

15.0

Voltage

RANGE 1

10.0

5.0

0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Amperage

RANGE 2

RANGE 4

ssb1.1 10/91 − 217 624-A / 217 758-A

OM-925 Page 11

SECTION 5 − INSTALLATION

5-1. Installing Welding Gun

5-2. Installing Work Clamp

1

Tools Needed:

3/8, 7/16 in

1 Drive Assembly
2 Gun Securing Thumbscrew

4

2

3

1

4

2

3

5

6

3 Gun End
Loosen thumbscrew. Insert end

through opening until it bottoms
against drive assembly. Tighten
thumbscrew.

Welding gun must be inserted
completely to prevent leakage of
shielding gas.

4 Gun Trigger Leads
Insert leads, one at a time, through

gun opening on front panel.
Connect female friction terminals to
matching male terminals in unit.
Polarity is not important.

Close door.

803 711-A

1 Insulating Sleeves
2 Nut
3 Work Cable From Unit
Slide one insulating sleeve over

work cable before connecting to
clamp.

4 Work Clamp
5 Screw
6 Work Clamp Tabs
Bend tabs around work cable.

Slide insulating sleeves over
handles.

OM-925 Page 12

802 456-A

5-3. Process/Polarity Table

P

Polari

rocess

GMAW − Solid wire with shield­ing gas

FCAW − Self-shielding wire −
no shielding gas

5-4. Changing Polarity

ty

Cable To Gun Cable To Work

Cable Connections

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

put terminal

DCEN − Straight Polarity Connect to negative (−)

output terminal

CHANGING

POLARITY

DCEN

Electrode negative for

flux cored wire

1

Connect to negative (−) output
terminal

Connect to positive (+) output
terminal

1 Lead Connections For Direct

Current Electrode Negative
(DCEN)

2 Lead Connections For Direct

Current Electrode Positive
(DCEP)

Always read and follow wire
manufacturer’s recommended
polarity, and see Section 5-3.

Close door.

DCEP

Electrode positive for

solid wire

2

Ref. 209 228 / Ref. 209 229

OM-925 Page 13

5-5. Installing Gas Supply

. DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2 shielding gas. See Parts List for optional
CO2 gas regulator/flowmeter.

4

7

5

Argon Gas Or

Mixed Gas

6

Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.

1 Cap
2 Cylinder Valve

1

2

3

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

3 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.
5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on rear
of welding power source.

7 Flow Adjust
Turn flow adjust screw to increase

or decrease gas flow. Flow rate
should be set when gas is flowing
through welding power source and
welding gun. Turn Range switch to
Purge or Fan Only position. Press
gun trigger to start gas flow. Typical
flow rate is 20 cfh (cubic feet per
hour). Check wire manufacturer’s
recommended flow rate.

Tools Needed:

OM-925 Page 14

5/8, 1-1/8 in

Ref. 802 028-A / 802 441

5-6. Selecting A Location And Connecting Input Power For 115 VAC Model

1 Rating Label
2 Grounded Receptacle
A 115 volt, 20 ampere individual

branch circuit protected by
time-delay fuses or circuit breaker
is required.

3 Plug From Unit
Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for
50 up to 200 ft (61 m).

Y Special installation may be

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

18 in

(460 mm)

1

18 in

(460 mm)

2

3

803 712-B

OM-925 Page 15

5-7. Selecting A Location And Connecting Input Power For 230 VAC Model

1 Rating Label
Supply correct input power.
2 Plug (NEMA 6-50P)
3 Receptacle (NEMA 6-50R)
Connect plug to receptacle.

18 in (457 mm) of
space for airflow

4

4 Line Disconnect Device
See Section 5-8.

Y Special installation may be

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

Y Always connect

grounding
conductor first.

= GND/PE

Y Do not move or operate unit

where it could tip.

L1

L2

1

2

3

L2

L1

230 VAC, 1

OM-925 Page 16

ssb2.2* 1/94 − 803 713-B

5-8. Electrical Service Guide For 230 VAC Model

Input Voltage 230
Input Amperes At Rated Output 20
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG 14

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG 14

Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

2

3

25
30

67

(20)

5-9. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in (102 mm) Wire Spool

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

Installing 8 in (203 mm) Wire Spool

Retaining ring used

with 8 in (203 mm)

spool only.

Tools Needed:

Adapter used with

8 in (203 mm)

spool only.

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

1/2 in

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

OM-925 Page 17

5-10. Threading Welding Wire

Tools Needed:

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

4

6 Gun Conduit Cable
Lay gun cable out straight.

6

Open pressure assembly. Make sure

feed roll is set to correct groove to
match wire size (see Section 7-4).

Tighten

13

52

. Hold wire tightly to keep it

from unraveling.

6 in

(150 mm)

Pull and hold wire; cut off end.

. Use pressure indicator

scale to set a desired
drive roll pressure.

1
2
3
4

Pressure

Indicator

Scale

(102 mm)

Push wire thru guides into gun;

continue to hold wire.

4 in

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-925 Page 18

Remove gun nozzle
and contact tip.

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

Turn power on. Be sure that Voltage range
switch is set to range 1, 2, 3, or 4 to feed wire.
Rotate knob until it “clicks” into detent. Wire
will not feed if range switch is set between
ranges or if set in the “PURGE” position.

Tighten

1
2
3

WOOD

4

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Ref. 803 714-A

6-1. Controls

SECTION 6 − OPERATION

1

43

2

DO NOT SWITCH
WHILE WELDING

NE PAS CHANGER
DE PROCÉDÉ

2

1 Wire Speed Control

Use control to select a wire feed speed. As
Voltage switch setting increases, wire
speed range also increases (see weld
setting label in welding power source or
Sections 6-2 or 6-3, as applicable).

2 Power Switch

PURGE1

V

3

3 Voltage Switch
The higher the selected number, the

thicker the material that can be welded
(see weld setting label in welding power
source or Sections 6-2 and 6-3, as
applicable). Do not switch under load.

. Switch must “click” into detent position

1, 2, 3, 4, or purge for proper contact.

4

Ref. 217 617-A

4 Voltage Switch - “Purge” Position
In purge position, fan runs but there is no

weld output or wire feed. Use “PURGE”
setting when adjusting gas flow at the
regulator.

OM-925 Page 19

6-2. Weld Parameter Chart For 115 VAC Model

OM-925 Page 20

217 618-A

OM-925 Page 21

6-3. Weld Parameter Chart For 230 VAC Model

OM-925 Page 22

217 754-B

OM-925 Page 23

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

unreadable

labels.

6 Months

Blow out or

vacuum inside.

During heavy

service, clean

monthly.

Or

7-2. Overload Protection

Repair or
replace
cracked
weld cable.

1

Clean and
tighten weld
terminals.

1 Circuit Breaker CB1
CB1 protects unit from overload. If

CB1 opens, unit shuts down.
Reset breaker.

802 441

7-3. Drive Motor Protection

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

OM-925 Page 24

7-4. Changing Drive Roll Or Wire Inlet Guide

1

2

Tools Needed:

4

.023/.025 Groove.030/.035 Groove

1 Inlet Wire Guide Securing

Screw
2 Inlet Wire Guide
Loosen screw. Slide tip as close to

drive rolls as possible without
touching. Tighten screw.

3 Drive Roll

3

The drive roll consists of two differ­ent sized grooves. The stamped
markings on the end surface of the
drive roll refers to the groove on the
opposite side of the drive roll. The
groove closest to the motor shaft is
the proper groove to thread (see
Section 5-10).

4 Retaining Pin
To secure drive roll, locate open slot

and push drive roll completely over
retaining pin, then rotate drive roll
(1/4 turn) to closed slot.

Stamped .024

7-5. Replacing Gun Contact Tip

Stamped .030/.035

Ref. 803 714-A

Y Turn Off power before

replacing contact tip.

1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.

Remove nozzle.
Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

2

1

Ref. 802 399-A

OM-925 Page 25

7-6. Cleaning Or Replacing Gun Liner

Y Disconnect gun from unit.

Tools Needed:

8 mm / 10mm

8 mm

Head Tube

Remove nozzle, contact tip,
adapter, gas diffuser, and wire
outlet guide.

10 mm

Remove liner.

OM-925 Page 26

Lay gun cable out straight
before installing new liner.

Blow out gun casing.

To Reassemble Gun:

Insert new liner.
Install wire outlet guide so that 1/8

in (3 mm) of liner sticks out. Hand
tighten outlet guide, and then
tighten two full turns more.

Cut liner off so that 3/4 in (19 mm)
sticks out of head tube.

Install gas diffuser, adapter, contact
tip, and nozzle.

Ref. 802 446-A

7-7. Replacing Switch And/Or Head Tube

1

Remove handle
locking nut.

4

Secure head
tube in vice.

Y Turn Off welding power source

/wire feeder and disconnect gun.

3

Slide handle.

2

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

Tools Needed:

5

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

Hand-tighten head tube into cable connector.

8

Remove from vice. Reposition handle and install
switch housing. Secure with handle locking nut.

7

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

19 mm

Ref. ST-800 795-C

OM-925 Page 27

7-8. Troubleshooting Table

d

Trouble Remedy

No weld output; wire does not feed; fan

oes not run.

Secure power cord plug in receptacle (see Section 5-6).

Replace building line fuse or reset circuit breaker if open.

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

Reset welding power source circuit breaker if open.

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

No weld output; wire feeds.

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

Electrode wire feeding stops during
welding.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
unit has cooled (see Section 4-2).

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

Voltage range switch set in “PURGE” position. Set switch to position 1, 2, 3, or 4.

Secure gun trigger leads (see Section 5-1).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 7-5).

Check for proper polarity connections (see Section 5-4).

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

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

Straighten gun cable and/or replace damaged parts.
Adjust drive roll pressure (see Section 5-10).
Change to proper drive roll groove (see Section 7-4).
Readjust hub tension (see Section 5-9).
Replace contact tip if blocked (see Section 7-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 or Section 7-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).
Secure gun trigger leads or repair leads (see Section 5-1).
Check and clear any restrictions at drive assembly and liner (see Section 5-10 or Section 7-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten

if necessary.

Have nearest Factory Authorized Service Agent check drive motor.

OM-925 Page 28

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For 115 VAC Model

217 621-A

OM-925 Page 29

OM-925 Page 30

217 755-A

Figure 8-2. Circuit Diagram For 230 VAC Model

SECTION 9 − MIG WELDING (GMAW) GUIDELINES

9-1. Typical MIG Process Connections

Regulator/

Flowmeter

Wire Feeder/

Power Source

Y 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.

Shielding Gas

Gas Hose

Gun

Work Clamp

Workpiece

light mig 5/97 / Ref. 803 715-A

OM-925 Page 31

9-2. Typical MIG Process Control Settings

NOTE

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

Material thickness determines weld
parameters.

.035 in

Wire Size Amperage Range

0.023 in

0.030 in

0.035 in

1/8 or 0.125 in

30 − 90 A
40 − 145 A
50 − 180 A

Convert Material

Thickness to

Amperage (A)

(0.001 in = 1 ampere)

0.125 in = 125 A

Select Wire Size

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

Wire Speed

(Approx.)

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

1.6 x 125 A = 200 ipm

Voltage controls height
and width of weld bead.

Select Wire Speed

(Amperage)

125 A based on 1/8 in

material thickness

ipm = inches per minute

Select Voltage

OM-925 Page 32

Ref. 803 710-A

9-3. Holding And Positioning Welding Gun

NOTE

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

2

5

4

0°-15°

90° 90°

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3

3 Work Clamp
4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

45°

45°

End View of Work Angle Side View of Gun Angle

FILLET WELDS

0°-15°

S-0421-A

OM-925 Page 33

9-4. Conditions That Affect Weld Bead Shape

NOTE

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.

10°

Push

Perpendicular

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

10°

Drag

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow

Normal Fast

GUN TRAVEL SPEED

S-0634

OM-925 Page 34

9-5. Gun Movement During Welding

NOTE

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 2

3

9-6. Poor Weld Bead Characteristics

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

2

9-7. Good Weld Bead Characteristics

2

4

3

1 Large Spatter Deposits

1

4

3

5

1

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

S-0053-A

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding
Weld a new bead or layer for each

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

4 No Overlap
5 Good Penetration into Base

Metal

5

OM-925 Page 35

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.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

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

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

9-9. Troubleshooting − Porosity

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

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

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

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

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

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

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.

OM-925 Page 36

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

S-0638

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

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

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

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

maintaining proper welding wire extension and arc characteristics.

Keep arc on leading edge of weld puddle.

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

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.

S-0637

Possible Causes Corrective Actions

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.

S-0640

Increase and/or maintain steady travel speed.

OM-925 Page 37

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.

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.

S-0641

S-0642

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.

OM-925 Page 38

9-16. Common MIG Shielding Gases

t feed

(bird

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.

Application

Gas

Argon X

Argon + 25% CO

80% or greater Argon +

balance CO2 or Oxygen

100% CO

Tri-Mix

1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO

2

2

2

Spray Arc Steel Short Circuiting Steel

X X

2

X

1

X

Short Circuiting

Stainless Steel

X

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but
wire does no

.

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.

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

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

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

Aluminum

Wire curling up in front of the
wire feed rolls

Wire feeds, but no gas flows.

nesting).

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.

Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, and

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas

Incorrect primary voltage connected to welding power
source.

and diameter, replace if necessary.

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

gas hose in gun and cable assembly.

solenoid valve.

Check primary voltage and relink welding power source
for correct voltage.

OM-925 Page 39

Problem RemedyProbable Cause

Welding arc not stable.

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.

drive rolls if necessary.

Readjust welding parameters.

OM-925 Page 40

Notes

OM-925 Page 41

SECTION 10 − PARTS LIST

13

12

52

22

53

21

20

18

14

11

10

15

16

17

9

19

26

27

. Hardware is common and

not available unless listed.

23

24

25

8

7

6

5

4

3

34

31

49

2

1

32

33

48

47

30

29

36

44

43

35

54

28

37

39

38

40

OM-925 Page 42

50

46

51

45

Figure 10-1. Main Assembly

42

41

803 716-B

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. Main Assembly

1 199 566 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 196 006 HINGE, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 211 887 HUB, nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 204 608 NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 202 998 SPRING, cprsn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 203 072 WASHER, flat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 211 339 HUB, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 202 726 ADAPTER, spool hub 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 217 072 CIRCUIT CARD ASSY, control (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 217 078 CIRCUIT CARD ASSY, control (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 195 999 BASE, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 210 109 CIRCUIT BREAKER, 25 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 196 467 TUBING, PVC .187 ID x .312 OD x 24.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 216 397 VALVE, gas (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 216 398 VALVE, gas (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 197 198 CABLE TIE, .700-.799 bundle dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 147 545 CORD SET, 125V 5−15P 14GA 3/C 7ft SPT−3 jkt (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . .

15 152 118 CORD SET, 250V 6−50P 12GA 3/C 7ft SPT−3 jkt (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . .

16 111 443 BUSHING, strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 137 761 NUT, gas valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 196 063 MOTOR, fan (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 196 064 MOTOR, fan (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 409 953-001 BLADE, fan cooling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 217 096 TRANSFORMER, power assy (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 217 389 TRANSFORMER, power assy (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 208 015 HANDLE, carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +196 005 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 204 036 LABEL, warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 203 491 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 193 039 CAPACITOR, electlt 53000uf (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 193 040 CAPACITOR, electrlt 100000uf (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 203 868 REACTOR ASSY (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 203 874 REACTOR ASSY (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 193 191 RECTIFIER ASSY (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 193 316 RECTIFIER ASSY (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 193 193 BUS BAR (positive) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 217 831 BAFFLE, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 405 576-001 BUSHING, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 193 144 INSULATOR, output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 193 194 BUS BAR (negative) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 216 830 LABEL, warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 134 201 STAND-OFF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 409 477 SWITCH, rotary 25A 5 position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 209 873 POTENTIOMETER, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 217 062 PANEL, front (purple) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 214 739 PANEL, front (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 010368 CLAMP, work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 196 619 CABLE, work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 196 575 SWITCH, rocker SPST (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-925 Page 43

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. Main Assembly (Continued)

40 196 574 SWITCH, rocker DPST (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 207 079 KNOB, pointer (voltage) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 211 338 KNOB, pointer (WFS) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 217 778 MOTOR, gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 193 189 CONNECTOR, gun 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 196 654 SCREW, thumb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 196 009 FITTING, gas barbed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 202 925 ROLL, feed .024 in, .030/.035 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 194 508 HEAD, feed assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 203 025 GUIDE, wire inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 217 618 LABEL, weld chart (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 221 079 LABEL, weld chart (115 VAC model) (French) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 217 754 LABEL, weld chart (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 221 080 LABEL, weld chart (230 VAC model) (French) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 204 711 LATCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 217 584 CONTACTOR (115 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 217 585 CONTACTOR (230 VAC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 203 572 LABEL, warn gen precaution (EN/FR models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 LABEL, nameplate (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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

OM-925 Page 44

1

2

34

5

6

7

9

8

11

10

Figure 10-2. H-10 Gun

Item

No.

Part

No.

195 957

Figure 10-2. H-10 Gun

1 169 715 NOZZLE, slip type .500 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦087 299 TIP, contact scr .023 wire x 1.125. . . . . . . . . . . . . . . . . . . .

2 ♦000 067 TIP, contact scr .030 wire x 1.125. . . . . . . . . . . . . . . . . . . .

2 ♦000 068 TIP, contact scr .035 wire x 1.125. . . . . . . . . . . . . . . . . . . .

2 ♦000 069 TIP, contact scr .045 wire x 1.125. . . . . . . . . . . . . . . . . . . .

3 169 716 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 170 470 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 169 718 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 169 738 NUT, locking handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 169 719 NUT, jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ♦194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ♦194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ♦194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ♦194 014 LINER, monocoil 4/64 AL wire x 10ft nyl(consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 197 123 O-RING, .312 ID x .062 70 Dura BUNA-N 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 196 255 SWITCH, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 447

QuantityDescription

♦OPTIONAL

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

OM-925 Page 45

10-3. Optional Drive Rolls

For All Feed Head Assemblies

PART NO.

202 925 .023/.025 (.6) and .030/.035 (.8 and .9)
202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

WIRE DIAMETER

INCHES (mm)

10-4. Options

PART NO. DESCRIPTION REMARKS

770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max.
194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max.
195 957 H-10 Replacement Gun 10 ft length/.030-.035 wire size
195 186 Protective Cover Weatherproof nylon
212 492 Regulator/Flowmeter For use with CO2 shielding gas, 10−50 CFH

NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.

OM-925 Page 46

Warranty Questions?

Call
1-877-HOBART1
for your local
Hobart distributor.

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.

Effective January 1, 2003

5/3/1 WARRANTY applies to all Handler 125, 135 and 175 models, Airforce 250, 250A, 375, 400

and 625 models, and Champion 4500 and 10,000 models, Beta-Mig 1800, Champ 1435, 2060, 8500

models, Ironman 210 and 250 models, Stickmate models, Tigmate models, and HSW-15 and

HSW-25 spot welder models effective with Serial No. KK200262 and 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/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.

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 date
that the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years — Parts and Labor

* Original Main Power Rectifiers
* Transformers
* Stabilizers
* Reactors

2. 3 Years — Parts and Labor

* Drive Systems
* PC Boards
* Rotors, Stators and Brushes
* Idle Module
* Solenoid Valves
* Switches and Controls
* Spot Welder Transformer

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

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

4. Engines, batteries 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, slip rings, drive rolls, gas diffusers, plasma
torch tips and electrodes, weld cables, and tongs and
tips, or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Hobart
Engine-Driven models.)

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 retail 8/03

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

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor,
retail or service location:

Call 1-877-Hobart1 or visit our website at
www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier to:

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

Hobart Welding Products

An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281
For Literature Or Nearest Dealer:
Call 1-877-Hobart1

PRINTED IN USA  2003 Hobart Welding Products. 1/03