Hobart Trek 180 And H100L4-10 Gun User guide

OM-232 661B 2010−02

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Battery Powered Arc Welding
Power Source And Wire Feeder

Trekt 180

And H100L4-10 Gun

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 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 specification sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1 or
visit our website at www.HobartWelders.com.

For Technical Help call 1-800-332-3281.

Hob_Thank 2009−09

Protect Your Investment!

Register your product at:

HobartWelders.com

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

2-5. Principales normes de sécurité 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Informations relatives aux CEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − BATTERY SAFETY PRECAUTIONS - READ BEFORE USING 11. . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Symbol Usage 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Battery Hazards 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Recycling The Battery 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − DEFINITIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Symbols And Definitions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − SPECIFICATIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Duty Cycle And Overheating 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Volt-Ampere Curves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − INSTALLATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Serial Number And Rating Label Location 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Installing Welding Gun 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Assembling Work Clamp 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Installing Work Cable 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Changing Polarity 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Welding Process/Polarity Table 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Installing Gas Supply 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Selecting A Location And Connecting Input Power 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Installing Wire Spool And Adjusting Hub Tension 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Installing Contact Tip And Nozzle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-11. Threading Welding Wire 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Status Light Explanations 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Charging The Internal Batteries 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Weld Parameter Chart 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Battery Overcurrent Protection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Drive Motor Protection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Changing Drive Roll Or Wire Inlet Guide 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Replacing Gun Contact Tip 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Cleaning Or Replacing Gun Liner 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Replacing Switch And/Or Head Tube 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Troubleshooting Table 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 9 − ELECTRICAL DIAGRAM 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − MIG WELDING (GMAW) GUIDELINES 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Typical MIG Process Connections 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Typical MIG Process Control Settings 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Holding And Positioning Welding Gun 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Conditions That Affect Weld Bead Shape 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5. Gun Movement During Welding 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6. Poor Weld Bead Characteristics 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7. Good Weld Bead Characteristics 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-8. Troubleshooting − Excessive Spatter 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-9. Troubleshooting − Porosity 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-10. Troubleshooting − Excessive Penetration 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-11. Troubleshooting − Lack Of Penetration 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12. Troubleshooting − Incomplete Fusion 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-13. Troubleshooting − Burn-Through 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-14. Troubleshooting − Waviness Of Bead 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-15. Troubleshooting − Distortion 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-16. Common MIG Shielding Gases 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-17. Troubleshooting Guide For Semiautomatic Welding Equipment 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − ACCESSORIES/CONSUMABLES 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

som _2009−08

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

D Do not touch live electrical parts.

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

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

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

there is a danger of falling.

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

unit.

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

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

D Disconnect input power or stop engine before installing or

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

. Indicates special instructions.

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

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

and sparks.

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.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

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

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

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

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

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

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

HOT PARTS can burn.

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

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-232 661 Page 1

FUMES AND GASES can be hazardous.

)

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

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

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

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.

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

glowing embers, and flames.

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

pass them.

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

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

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

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

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

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

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or 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 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

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

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

gas, or liquid vapors (such as gasoline).

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

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

D Do not use welder to thaw frozen pipes.

OM-232 661 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise 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, physical damage, slag, open flames, sparks, and arcs.

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

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct 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 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

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

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

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

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

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

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

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

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

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

MOVING PARTS can injure.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

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.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

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

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

OM-232 661 Page 3

1-4. California Proposition 65 Warnings

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

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.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

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

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

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

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

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

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

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

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may inter­fere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assess­ment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:

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

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

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

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

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

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

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

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-232 661 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

. Indique des instructions spécifiques.

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

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

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

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

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

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

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

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

sans trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

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

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,

dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

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

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

D Installer le poste correctement et le mettre à la terre convenable-

ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.

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

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

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

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

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

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

D Vérifier fréquemment le cordon d’alimentation afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.

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

sante ou mal épissés.

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

avec un câble distinct.

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

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

D Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

en place.

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

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

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

contact avec tout objet métallique.

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

masse à une même borne de sortie de soudage.

fre_som_2009−08

OM-232 661 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

s

e

­r

e

e

les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

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

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher à mains nues les partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

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

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

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais­seurs.

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

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

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

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

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

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

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudag

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

D Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

OM-232 661 Page 6

génère des rayons visibles et invisibles intense

LE SOUDAGE peut provoquer un
incendie ou une explosion.

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

provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

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

D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.

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

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

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

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

D Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.

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

facial.

LES ACCUMULATIONS DE GAZ

t

a
e

r

e

-

risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas

de non-utilisation.

D Veiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction
d’air homologué.

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

D Les porteurs de stimulateurs cardiaques

et autres implants médicaux doivent rester
à distance.

D Les porteurs d’implants médicaux doivent consulter

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

LE BRUIT peut endommager l’ouïe.

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

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

Des bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Si une bouteille est endom-

magée, elle peut exploser. Du fait que les bouteilles

soudage, les manipuler avec précaution.

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

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

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

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

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

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

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

D Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

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

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

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

samment de personnes pour soulever et déplacer les bouteilles.

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

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

de gaz font normalement partie du procédé de

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

Risque D’INCENDIE OU
D’EXPLOSION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

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

D Utiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

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

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

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

mobiles lors de toute opération en hauteur.

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

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

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

D Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cett
manœuvre est à exécuter dans un endroit sû
lorsque l’on porte l’équipement homologué d
protection du visage, des mains et du corps.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les cir-

cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antista-

tiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.

OM-232 661 Page 7

Les PIÈCES MOBILES peuvent
causer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de
protection.

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

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

D Remettre les portes, panneaux, recouvrements ou dispositifs de

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

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

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

constructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

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

provoquer des interférences avec les équi­pements de radio−navigation et de com­munication, les services de sécurité et les ordi­nateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

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

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

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

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

D L’énergie électromagnétique risque de

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

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

compatible électromagnétiquement.

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

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

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, 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.

2-4. Proposition californienne 65 Avertissements

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

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

OM-232 661 Page 8

Pour les moteurs à essence :

Pour les moteurs diesel :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global

Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).

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

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).

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

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site inter­net : www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-232 661 Page 9

OM-232 661 Page 10

SECTION 3 − BATTERY SAFETY PRECAUTIONS - READ BEFORE

USING

7

Protect yourself and others from injury — read and follow these precautions.

3-1. Symbol Usage

Ref. rom _2009−08

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

3-2. Battery Hazards

The symbols shown are used throughout this manual to call
attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.

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

3-3. Recycling The Battery

Dispose of used battery at a designated recycling facility and according to local, state, and federal regulations.

Pb

. Indicates special instructions.

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

During operation, keep everybody, especially children, away.

BATTERY EXPLOSION can injure.

D Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Disconnect negative (−) cable first and connect it last.

OM-232 661 Page 11

SECTION 4 − DEFINITIONS

4-1. Symbols And Definitions

A

Amperage

Positive

Output Voltage Input Off On

Do Not Switch

While Welding

Temperature Trigger Battery Charging Work Connection

5-1. Description

V

Voltage

Direct Current

(DC)

Gas Metal Arc

Welding (GMAW)

Hz

Hertz Negative

Single Phase Input

Wire Feed Battery

SECTION 5 − SPECIFICATIONS

This unit is an all-in-one Mig (GMAW) welding system that operates on utility power or power from the rechargeable
internal batteries. When the unit is connected to utility power for welding, the charger continues charging the batteries
and the unit operates at a typical duty cycle. (The internal charger feeds current through the batteries even during
the welding process.) When the unit operates from battery power only, welding continues until the batteries are nearly
discharged (the Low Battery light goes on). The unit will not weld until the unit is reconnected to utility power and batter­ies are recharged.

. Before first use, charge the batteries in this product for at least two hours (see Section 7-3). Product performance will improve when the batteries

reach full capacity by being charged and discharged several times.

. To extend battery life, recharge batteries after each job and keep unit plugged in when not in use.

5-2. Specifications

Amperes Input

Rated Welding

Output

120 A @ 17 Volts

DC, 20% Duty Cycle

Wire Type

And Diameter

Amperage

Range

25 − 180

Solid/

Stainless

.024 − .035 in

(0.6 − 0.9 mm)

Maximum Open-

Circuit Voltage

DC

30

Flux Cored

.030 − .035 in

(0.8 − 0.9 mm)

While Charging

Batteries

115 V, 60 Hz,

Single-Phase

12

KVA KW

1.38 0.75

102 − 445 IPM (2.6 − 11.3 m/min) At No Load

75 − 415 IPM (1.9 − 10.5 m/min) Feeding Wire

Weight

W/ Gun

51 lb

(23 kg)

Wire Feed Speed Range

17 x 7-7/8 x 13-5/16 in. in.

Overall

Dimensions

(L x W x H)

(432 x 203 x 338 mm)

OM-232 661 Page 12

5-3. Duty Cycle And Overheating

WELD TIME WHILE USING BATTERIES ONLY

100

30
20

10

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. Let unit cool until Over
Temperature light goes out.
Reduce amperage or duty cycle
before welding.

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

5
4

3

WELD TIME (MINUTES)

2

20 Ga.

18 Ga.

16 Ga.

1/8 in.

3/16 in.

1/4 in.

1

0 20 40 60 80 100 120 140 160 180 200

DC AMPERES

WELD TIME WHILE USING A 115 VOLT SUPPLY

200
180
160
140
120
100

80

DC AMPERES

60
40

Overheating

20

0

0 102030405060708090100

% DUTY CYCLE

20% duty cycle at 120 amps

2 Minutes Welding 8 Minutes Resting

0

15

Minutes

OR

Reduce Duty Cycle

A or V

duty1 4/95 − 236 785-A

OM-232 661 Page 13

5-4. Volt-Ampere Curves

30

25

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.

20

15

DC VOLTS

10

5

0

0 20 40 60 80 100 120 140 160 180 200

Notes

MAX

MIN

DC AMPERES

236 786-A

OM-232 661 Page 14

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

SECTION 6 − INSTALLATION

6-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

6-2. Installing Welding Gun

1 Drive Assembly
2 Gun Securing Knob
3 Gun End
Loosen knob. Insert end of gun

through opening in front panel

3

until it bottoms against drive
assembly. Tighten knob.

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

4 Gun Trigger Plug
Insert plug into receptacle. Tighten

threaded collar.
Close door.

1

. Be sure that gun end is tight

against drive assembly.

Incorrect Installation −

Gun Not Seated

2

3

Exposed O-rings will

cause shielding gas

leakage.

Correct Installation −

Gun Fully Seated

4

244 704 / Ref. 244 703

OM-232 661 Page 15

6-3. Assembling Work Clamp

6

Tools Needed:

7/16 in.

. Connection hardware must be

tightened with proper tools. Do
not just hand tighten hardware.
A loose electrical connection
will cause poor weld perfor­mance and excessive heating
of the work clamp.

3

1

2

5

4

1 Nut
2 Work Cable From Unit
3 Work Clamp
4 Screw
5 Work Clamp Tabs
Bend tabs around work cable.
6 Insulating Sleeves
Slide one insulating sleeve over

work cable before connecting to
clamp.

Slide both insulating sleeves over
handles.

802 456-A

6-4. Installing Work Cable

1 Work Cable
Install work cable connector in Work

cable receptacle. Turn connector
clockwise to tighten.

See Sections 6-6 and 6-5 for inform­ation on changing weld polarity.

OM-232 661 Page 16

1

Ref. 244 703

6-5. Changing Polarity

1 Jumper Link Connections For

Direct Current Electrode
Negative (DCEN)

2 Jumper Link Connections For

Direct Current Electrode
Positive (DCEP)

Always read and follow wire
manufacturer’s recommended po­larity. See Process/Polarity Table in
Section 6-6.

12

Close door.

6-6. Welding Process/Polarity Table

Welding Process Polarity

GMAW − Solid wire with shielding gas DCEP − Reverse polarity

FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity

Tools Needed:

3/8 in.

244 705

OM-232 661 Page 17

6-7. Installing Gas Supply

4

7

5

Argon Gas Or

Mixed Gas

Obtain gas cylinder and chain to

1

2

3

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

1 Cap
2 Cylinder Valve
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 gas hose between
regulator/flowmeter gas hose
connection, and fitting on rear of
welding power source.

7 Flow Adjust
Flow rate should be set when gas is

flowing through welding power
source and welding gun. Open
feedhead pressure assembly so
that wire will not feed. Press gun
trigger to start gas flow.

Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s recommended
flow rate.

After flow is set, close feedhead
pressure assembly.

6

Feedhead Pressure Assembly Open Feedhead Pressure Assembly Closed

Tools Needed:

5/8, 1-1/8 in.

OM-232 661 Page 18

244 706

6-8. Selecting A Location And Connecting Input Power

! Do not move or operate unit

where it could tip.

1

18 in.

(460 mm)

18 in.

(460 mm)

1 115 V, 15 A Grounded Receptacle
This unit requires a 115 volt, 15 ampere

individual branch circuit protected by
time-delay fuses or circuit breaker.

2 115 V Input Receptacle
3 Power Cord
Connect power cord from 115 volt groun-

ded receptacle to 115 volt input recept-

acle. Select 16 AWG extension cord for
distances up to 50 ft (15 m) or 14 AWG ex­tension cord for distances from 50 to 100
ft (30 m).

. If an AC inverter is used for the 115

volt AC supply, use an inverter with a
minimum power rating of at least 400
watts. Use an inverter with a power

3

2

244 703

rating of 1000 − 2000 watts to greatly
reduce charging time.

See Section 7-1 and 7-3 for information on
charging the internal batteries.

! Special installation may be

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

OM-232 661 Page 19

6-9. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in. (102 mm)

Wire Spool

Tension is set when a slight
force is needed to turn spool.

Tools Needed:

OM-232 661 Page 20

244 707

6-10. Installing Contact Tip And Nozzle

1

3

2

! Turn off welding power source.

1 Nozzle (See Items 4 And 5 Below)
Remove nozzle.
2 Contact Tip
3 Tip Adapter
Thread welding wire through gun (see

Section 6-11).
Slide contact tip over wire and tighten tip

into tip adapter.
Install nozzle.
4 MIG Nozzle (Standard)
Use with solid or flux cored wire.
Push nozzle over contact tip and adapter

until it is seated onto adapter. End of
contact tip will be flush with end of nozzle
when installed properly.

5 Flux Nozzle (Optional)
Use with flux cored wire only.
The narrow design allows access in tight

spaces and provides better visibility of
puddle during welding

4

5

Tools Needed:

244 708

OM-232 661 Page 21

6-11. Threading Welding Wire

Tools Needed:

1

13

52

4

2

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Gun Conduit Cable

6

Lay gun cable out straight.

. Hold wire tightly to keep it from unraveling.

Open pressure assembly. Make sure

feed roll is set to correct groove to
match wire size (see Section 8-4).

OM-232 661 Page 22

6 in

(150 mm)

Pull and hold wire; cut off end.

3

4 in

(102 mm)

Straighten approximately 3 or 4 in. (76 or 102 mm) of wire before inserting wire

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

. Use pressure indicator scale to set

Tighten

4 5

a desired drive roll pressure. (Start
with a setting of 2 or 3 on the scale.)

1
2
3
4

Pressure

Indicator

Scale

Be sure that wire is positioned in proper feed roll groove.

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

6 7

Remove gun nozzle and contact tip.

Turn power on.

Press gun trigger until wire comes out of gun.
(Keep gun cable as straight as possible.)

8 9

Tighten

WOOD

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

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

1
2
3
4

244 709

OM-232 661 Page 23

7-1. Controls

1

4

3

2

1

5

4

TRIGGER

V

VOLTAGE WIRE FEED

READY LOW BATTERYOVER TEMP CHARGING

WARNING

• UNPLUG TRIGGER

BEFORE TRANSPORTING
OR STORING.

3

SECTION 7 − OPERATION

! Unplug trigger cable be-

fore transporting or stor­ing unit.

2

5

6

7

8

9

10

30

20

10

STATUS

CHARGING

80% CHARGED

100% CHARGED

40

50

60

70

80

90

100

6

7

WORK

Weld Controls

1 Voltage Control
Use control to select weld

voltage. The higher the selected
number, the thicker the material
that can be welded. (See weld
parameter label in welding
power source or in Section 7-4.)

2 Wire Speed Control
Use control to select a wire feed

speed. See weld parameter
label in welding power source or
Section 7-4.

3 Power Switch
Use switch to turn unit on and off.

. The unit will turn off after 15

minutes of inactivity. Reset
unit by turning unit off and
then on again.

Status Lights

. See Section 7-2 for addition-

al information on status
lights and related condi­tions.

4 Ready Light
Light goes on when the power

switch is on and the internal bat­teries have enough power to
weld. The ready light will not turn
on if the Power switch is off, even
when still plugged in for char­ging.

5 Over Temperature Light
Light goes on when unit has

stopped due to overheating.
After unit has cooled the Over
Temperature light goes out, the
Ready Light goes on, and the
unit operates again.

6 Charging Status Light
Light indicates status of the bat-

teries during the charging cycle.

. See Section 7-3 for informa-

tion on charging the internal
batteries.

7 Low Battery Light
Light goes on when unit has

stopped due to low battery out­put. Light goes out and unit is op­erational when batteries are
charged enough to provide weld
output.

OM-232 661 Page 24

232 627 / 232 655

7-2. Status Light Explanations

Status Light Condition

Ready Over Temp

Charge

Status

Low

Battery

Explanation

Unit was turned off or has automatically timed out and shut itself off to
preserve batteries. The unit will shut off after 15 minutes of inactivity.
Turn unit off and then on again to reset unit after automatic timeout.

Unit on and ready to weld (normal condition).

Unit has overheated or exceeded duty cycle. Weld output is disabled.
Allow unit to cool. Over temp condition automatically clears and unit
returns to normal condition.

Battery voltage is too low to weld. Weld output is disabled. Recharge
batteries. If unit is already plugged in, allow sufficient time for batteries to
recharge. Once batteries are recharged to a sufficient level the low bat­tery condition clears and unit returns to normal condition. If unit is not
plugged into utility power, indicator goes out off after 15 minutes to re­duce drain on the batteries.

Indicates gun tip is shorted to work. Weld output is disabled to prevent
damage to torch tip. Momentarily release gun trigger to clear condition
and resume welding.

−−−− −−−− −−−−

−−−−

− −

Symbol Key

Light is off

Light is on continuously

Light is on for one second, off for one second

−−−−

Indicates an internal fault. Contact a Factory Authorized Service Agent.

Indicates batteries are charging.

Indicates batteries are 80% charged. Unit can be unplugged and used for
welding; leave connected to reach 100% charge.

Batteries are fully charged. Unit can be unplugged and used for welding;
leave connected to keep batteries fully charged.

Indicates an internal fault or battery charger is in over temp condition. To
reset, unplug unit and allow to shut down. Plug unit back into 115 V AC
receptacle. If light sequence does not change, contact a Factory Author­ized Service Agent.

− −

Light is one second, off for one second, on for 1/2 second, off for one second

Light is on for 1/10 second, off for 1/10 second, on for 1/10 second, off for two seconds

OM-232 661 Page 25

7-3. Charging The Internal Batteries

Stop welding. Connect unit to 115 V, 15 A grounded receptacle. (See Section 6-8.)

VOLTAGE WIRE FEED

READY LOW BATTERYOVER TEMP CHARGING

Check battery charging status.

To charge batteries to 80% capacity: 15 – 30 minutes (ready to weld again)

Complete battery recharge: 1-1/2 hours

Resume welding when charging is complete.

Charging begins.

STATUS

CHARGING

80% CHARGED

100% CHARGED

! Unplug trigger cable before

transporting or storing unit.

! Special installation may be

required where gasoline or
volatile liquids are present − see

3

1

NEC Article 511 or CEC Section

20.

! Do not charge internal batteries

if batteries show signs of dam-

2

age.

NOTICE − To extend battery life, re-
charge batteries after each job and
keep unit plugged in when not in use.
Avoid storing unit in temperatures
above 100 F (38 C).

. Before first use, charge the batter-

ies in this product for at least two
hours. Product performance will
improve when the batteries reach
full capacity by being charged and
discharged several times.

. The Auto-Power feature monitors

the 115 volt AC supply during the
charging process to prevent over­load. If the unit senses the 115 volt
AC supply is being overloaded,
charging amperage (current draw)
is reduced to match the AC supply.

. If an AC inverter is used for the 115

volt AC supply, use an inverter
with a minimum power rating of at
least 400 watts. Use an inverter
with a power rating of 1000 − 2000
watts to greatly reduce charging
time.

The internal batteries are being
charged whenever the unit is plugged
into a 115 volt AC receptacle (utility
power). When operating on battery
power only, charge the batteries when
the Low Battery Light is on. Battery
charging times are as follows:

S To charge batteries to 80% capa-

city: 15 – 30 minutes (ready to weld
again)

S Complete battery recharge: 1-1/2

hours

1 115 V, 15 A Grounded

Receptacle

This unit requires a 115 volt, 15
ampere individual branch circuit
protected by time-delay fuses or circuit
breaker.

2 115 V Input Receptacle
3 Power Cord
Connect power cord from 115 volt

grounded receptacle to 115 volt input
receptacle.

4 Charging Status Light
Observe Charging Status light during

charging. Light indicates status of bat­teries during the charging cycle.

. See Section 7-2 for additional in-

formation on status lights and re­lated conditions.

244 703 / 232 627 / 232 655

OM-232 661 Page 26

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Over 80,000 trained

since 1930!

OM-232 661 Page 27

7-4. Weld Parameter Chart

Settings are approximate. Adjust as required. Thicker materials can be

welded using proper technique, joint preparation and multiple passes.

Material

Being

Welded

Steel

Wire Type,

and

Polarity Setting

Flux Core

E71T−GS

(DCEN)

Solid Wire

ER70S−6

(DCEP)

Selecting Wire, Gas and Control Settings

Suggested

Shielding Gases

20–30 cfh Flow Rate

No Shielding Gas Required

Good for Windy or

Outdoor Applications

C25 Gas Mixture

75% Ar / 25% CO

Produces Less Spatter

Better Appearance

2

Diameter

of Wire

Being Used

.030” ( 0.8 mm )
.035” ( 0.9 mm )

.024” ( 0.6 mm )
.030” ( 0.8 mm )

.035” ( 0.9 mm )

Changing

Polarity

DCEP

Electrode Positive

For Solid Wire

DCEN

Electrode Negative

For Flux Cored Wire

Welding Gun Consumables

A B C D E

A) Nozzles
.500” orf flush
Flux Cored
B) Tips
.023” ( 0.6mm )
.030” ( 0.8mm )
.035” ( 0.9mm )
C) Retaining Ring
D) Contact Tip Adaptor
E) Head Tube

Liners
.023” / .025”
.030” / .035”

Stock No.

169715
226190

087299
000067
000068
170470
169716
246373

194010
194011

OM-232 661 Page 28

Selecting Wire, Gas and Control Settings

Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded

Number on Left is Voltage Setting / Number on Right is Wire Feed Setting

24 gauge
.024 inch

( 0.6 mm )

— — — 1 / 0 2 / 5 3 / 10 5 / 30 6 / 40 8 / 70 10 / 100 —
— — — — — — — 5 / 20 8 / 40 10 / 50 10 / 60

0 / 20 0 / 30 2 / 40 4 / 40 7 / 60 8 / 80 10 / 100 10 / 100 — — —

— 0 / 10 1 / 10 2 / 20 3 / 30 3 / 40 5 / 50 7 / 50 10 / 60 10 / 60 —
— — — — 3 / 10 5 / 20 6 / 25 7 / 30 9 / 35 10 / 40 —

• Set Tension Knob Setting to 3 at start. Adjust tension per instructions in the manual.

• Wire Speed listed is a starting value only. Wire speed setting can be fine−tuned while welding. Wire speed

also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc.

22 gauge
.030 inch

( 0.8 mm )

20 gauge
.036 inch

( 0.9 mm )

18 gauge
.048 inch

( 1.2 mm )

16 gauge
.060 inch

( 1.5 mm )

14 gauge
.075 inch

( 1.9 mm )

12 gauge
.105 inch

( 2.7 mm )

1/8 inch

( 3.2 mm )

3/16 inch

( 4.8 mm )

1/4 inch

( 6.4 mm )

5/16 inch

( 7.9 mm )

Drive Rolls

Match drive roll groove to diameter of wire being used.

Dual Grooved

Groove

V – Groove

V/VK − Groove

Battery Must Be Recharged After Each Use.

For Maximum Battery Life, Unit Should Be

USE ONLY FACTORY AUTHORIZED BATTERIES

See Owner’s Manual

Wire

Size

.024” − .030” / .035”

( 0.6mm − 0.8mm / 0.9mm )

.030” / .035”

( 0.8mm / 0.9mm)

Plugged In When Not In Use

Stock No. 232612

Stock

No.

237338

246565

LED Status

READY LOW BATTERYOVER TEMP CHARGING

STATUS

Unit is charged, ready to weld

Over Temp has occurred, stop welding
and allow unit to cool down

Batteries Charging
Batteries 80% Charged
Batteries Fully Charged

Low Battery, plug in welder to charge

See Owner’s Manual for Other LED Combinations

232680-B

232 680-B

OM-232 661 Page 29

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

! Disconnect power

before maintaining.

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

3 Months

l Damaged Or Unreadable Labels l Repair Or Replace

Cracked Weld Cable

~ Clean And Tighten Weld
Terminals

6 Months

OR

~ Inside Unit

8-2. Battery Overcurrent Protection

. If a fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent.

. Maintain more often

during severe condi­tions.

Reference

Fuse F3 protects the unit from a battery fault. If F3 opens while the batteries are being charged the charge Status light flashes on and off. If F3 opens
while the unit is welding the Ready light goes out and the unit stops. Have a Factory Authorized Service Agent check F3.

8-3. Drive Motor Protection

The drive motor protection circuit protects the drive motor from overload. If the drive motor does not run, release gun trigger. Wait until protection circuit
resets and allows drive motor to feed wire again.

OM-232 661 Page 30

8-4. Changing Drive Roll Or Wire Inlet Guide

1

3

2

.030/.035

Smooth Groove

Stamped

.030/.035 VK

.030/.035

Knurled Groove

Stamped .030/.035

1 Inlet Wire Guide
Remove guide by pressing on

barbed area or by cutting off one
end (near housing) and pulling it out
of the hole. Push new guide into
hole (from rear) until it snaps into
place.

2 Drive Roll
The drive roll consists of two differ-

ent 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 6-11).

3 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.

8-5. Replacing Gun Contact Tip

244 708

! 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.

2

Tools Needed:

1

244 708

OM-232 661 Page 31

8-6. Cleaning Or Replacing Gun Liner

! Disconnect gun from unit.

1 2

Head Tube

8 mm

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

10 mm

Remove liner.

3

Tools Needed:

Blow out gun casing.

Lay gun cable out
straight before
installing new liner.

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.

8 mm / 10mm

243 839

OM-232 661 Page 32

8-7. Replacing Switch And/Or Head Tube

1

Remove handle locking nut.

4

Secure head tube in vice.

5

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

! 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

Hand-tighten head tube into cable connector.

7

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

8

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

Tools Needed:

19 mm

243 840

OM-232 661 Page 33

8-8. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed;
Ready light is off.

Place Power switch in On position (Section 7-1).

Unit shuts down after 15 minutes of activity. Reset unit by turning unit off and then on again. (The Ready
light goes on.)

Have a Factory Authorized Service Agent check fuse F3.

No weld output; wire does not feed; Low
Battery light is on.

Batteries do not charge; Low Battery
light goes on when the Power switch is
turned on.

Battery charging takes longer than spe­cified.

No weld output; wire does not feed;
Ready light is on.

Cooling fan does not run. Cooling fan runs only when unit needs to be cooled. Fan usually does not run at start-up.

No weld output; wire does not feed; Over
Temp light is on.

No weld output; wire feeds.

Secure power cord in 115 V receptacle and allow batteries to charge (Section 6-8).

Secure power cord in 115 V receptacle and allow batteries to charge (Section 6-8).

If unit is connected to a vehicle power inverter, verify power inverter can supply at least 400 watts
(Section 7-3).

If unit is connected to a vehicle power inverter, reset power inverter. (See power inverter Owner’s
Manual.)

Replace fuse or reset circuit breaker in 115 V receptacle circuit.

If unit is connected to a vehicle power inverter, verify power inverter can supply at least 400 watts.

Batteries may need replacement. Contact a Factory Authorized Service Agent.

Check the gun trigger connection (Section 6-2).

Press gun trigger switch.

Allow cooling fan to cool unit until Over Temp light goes out.

Connect work clamp to get good metal to metal contact.

Verify the correct size contact tip is installed in gun (see Section 8-5).

Weld bead does not penetrate base
metal; filler metal “piles up.”

Erratic welding arc when welding with
flux cored wire.

Erratic welding arc when welding with
solid wire and shielding gas.

OM-232 661 Page 34

Check polarity connections (see Section 6-5).

Verify gun is fully seated in drive assembly and securing knob is tight (Section 6-2).

Set weld polarity to match the weld process (Sections 6-6 and 6-5).

Check size of contact tip in gun, and replace tip if size is incorrect (Section 8-5).

Check wire spool hub tension, and adjust if necessary (see Section 6-9).

Check gun contact tip, and replace if worn (Section 8-5).

Set weld polarity to match the weld process (Sections 6-6 and 6-5).

Check gas supply, hose, regulator, and connections, and ensure gas is flowing (no leaks).

Check wire spool hub tension, and adjust if necessary (see Section 6-9).

Verify gun is fully seated in drive assembly and securing knob is tight (Section 6-2).

Check gun o−rings, and replace if worn or damaged.

Trouble Remedy

Erratic welding arc, discolored weld
bead, and insufficient gas coverage
when welding with solid wire and shield­ing gas.

Wire feeding is inconsistent and causes
arc outages.

Duration of weld output has decreased;
unit needs charging more frequently.

Verify gun is fully seated in drive assembly and securing knob is tight (Section 6-2).

Remove spatter from gun nozzle.
Check gas supply, hose, regulator, and connections, and ensure gas is flowing (no leaks).
If welding outdoors, shield weld area from wind.
Adjust drive roll pressure (Section 6-11).
Check wire spool hub tension, and adjust if necessary (see Section 6-9).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-4 or Section 8-6).
Change to proper drive roll groove (see Section 8-4).
Straighten gun cable and/or replace damaged parts.
Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.
Straighten gun cable and/or replace damaged parts (Section 6-11).
Check gun liner, and replace if damaged or kinked (Section 8-6).
Batteries may need replacement. Contact a Factory Authorized Service Agent.

. To extend battery life, recharge batteries after each job and keep unit plugged in when not in use.

OM-232 661 Page 35

SECTION 9 − ELECTRICAL DIAGRAM

OM-232 661 Page 36

236 783-B

Figure 9-1. Circuit Diagram

SECTION 10 − MIG WELDING (GMAW) GUIDELINES

10-1. Typical MIG Process Connections

! 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.

Regulator/
Flowmeter

Wire Feeder/

Power Source

mig1 2009−12

Shielding Gas

Gun

Gas

Workpiece

Work Clamp

Ref. 801 909-A

OM-232 661 Page 37

10-2. Typical MIG Process Control Settings

. 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.

1/8 or 0.125 in.

Convert Material

Thickness to

Amperage (A)

(0.001 in. = 1 ampere)

0.125 in. = 125 A

.035 in

Wire

Size

0.023 in.

0.030 in.

0.035 in.

Recommendation

3.5 in. per ampere
2 in. per ampere

1.6 in. per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Voltage controls height and
width of weld bead.

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

30 − 90 A
40 − 145 A
50 − 180 A

Wire Speed

(Approx.)

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

1.6 x 125 A = 200 ipm

Select Wire Size

Select Wire Speed

(Amperage)

125 A based on 1/8 in.

material thickness

ipm = inches per minute

Select Voltage

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

OM-232 661 Page 38

10-3. Holding And Positioning Welding Gun

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

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

1

2

5

4

0°-15°

90° 90°

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

45°

0°-15°

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°

End View of Work Angle Side View of Gun Angle

FILLET WELDS

S-0421-A

OM-232 661 Page 39

10-4. Conditions That Affect Weld Bead Shape

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

(weld current), and voltage.

10°

Push

Perpendicular

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

10°

Drag

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow

Normal Fast

GUN TRAVEL SPEED

S-0634

OM-232 661 Page 40

10-5. Gun Movement During Welding

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

a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

1 2

3

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

10-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

1

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

2

10-7. Good Weld Bead Characteristics

2

3

4

3

5

1 Fine Spatter
2 Uniform Bead

1

4

5

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

S-0053-A

S-0052-B

OM-232 661 Page 41

10-8. 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.

10-9. 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.

10-10. 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-232 661 Page 42

Good Penetration

Increase travel speed.

S-0639

10-11. 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.

10-12. 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.

10-13. 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-232 661 Page 43

10-14. 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.

10-15. 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-232 661 Page 44

10-16. Common MIG Shielding Gases

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

10-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but
wire does not feed.

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

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

wire size and type if necessary.

Aluminum

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

Wire feeds, but no gas flows.

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

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.

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

and diameter, replace if necessary.

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

gas hose in gun and cable assembly.

solenoid valve.

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

OM-232 661 Page 45

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-232 661 Page 46

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-232 661 Page 47

SECTION 11 − PARTS LIST

. Hardware is common and

not available unless listed.

15

14 − Fig 11-2

11

12

13

16

26

18

19

17 − Fig 11-3

20

21

22

23

24

25

27

2829

30

31

9

40

10

33

8

7

5

4

39

38

37

6

36

3

34

35

32

1

2

41

OM-232 661 Page 48

245 536-A

Figure 11-1. Main Assembly

Item

No. Quantity

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

1 +232600 Cover, Battery Compartment 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 238031 Label, Warning General Precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 244562 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 232602 Pin, Hinge 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +232601 Cover, Wire Drive Compartment 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 232680 Label, Welding Guide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 232966 Pin, Latch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 232965 Latch, Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 +232656 Baffle, Center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 216830 Label, Warning Electric Shock And Pinch (En/Fr) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 236788 Nut, 312−18 Wing Locking Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 238807 Washer, Finger .344idx.915odx.010t Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 203072 Washer, Flat .331idx0.945odx.079t Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 Fig 11-2 Drive Assy, Wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 231490 Link, Jumper Terminal Board 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 245356 Tubing, PVC .187 Id X .312 OD X 20.500 Clear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 Fig 11-3 Windtunnel, Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 TE1 237060 Terminal Bd, Chgov 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 038887 Stud, Primary Board Brs 10−32 X 1.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 L1 232615 Inductor, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR1 233946 Contactor, 24VDC 1pst On−off DC Rated 80 A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 F3 232629 Fuse, Crtg 200. Amp 150 V Semiconductor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 PC1 232214 Circuit Card Assy, Operator Interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 232603 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 174992 Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 208820 Clamp, Work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 232663 Cable, Work 10 Ft 6awg W/Male (Dinse Type) Conn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 232628 Receptacle, Twist Lock Brass Power Female (Pos) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 Label, Nameplate (Order By Model And Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 232675 Harness, Wrg Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 232595 Base Assy, (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232596 Base, Control Feeder Molded 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232597 Handle, Molded Plastic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232598 Pin, Handle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 BAT1, BAT2 232612 Battery, Stor 12V 16 Amp Hr Tppl Sealed Lead Acid 2. . . . . . . . . . . . . . . . . . . . . . . . . .

33 GS1 220011 Valve, 14VDC 2way Custom Port 1/8 Orf W/Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 232685 Bus Bar, Flexible Braided 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PLG20 232657 Cord Set, 125v 5−15p 14ga 3/C 4ft Sjt Jkt Iec−c19 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 137761 Nut, 750 Npt 1.31hex .27h Nyl Blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 Label, Rear Panel (Order By Model And Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 S1 196575 Switch, Rocker Spst 10a 250 VAC On−none−off .250 QC 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

39 RC20 232654 Conn, Inlet AC Power Iec 320−c20 1.5mm Thk Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 232604 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 232658 Pouch, Cable & Accessories 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

OM-232 661 Page 49

. Hardware is common and

not available unless listed.

8

7

6

5

2

1

3

4

17

16

15

10

9

18

14

12

11

13

232 613-C

Figure 11-2. Wire Drive Assembly

Item

No. Quantity

Dia.

Mkgs.

Part

No.

Description

Figure 11-2. Wire Drive Assembly (Fig 11-1 Item 14)

1 203567 Screw, Shld Stl Pan .250−28 X .310 X 1.120 Shld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 203301 Lever, Pressure Roll 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 189915 Bearing, Ball Rdl Sgl Row 9mm X 26mm X 8mm Wide Sh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 176869 Screw, 010−32x .62 Hex Hd−slt Stl Pld Sq Cone Sems 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 225718 Fastener, Pinned 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 198080 Cup, Spring 185 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 234200 Spring, Cprsn .696 Od X .086 Wire X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 196895 Knob, Tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 058549 Guide, Wire Inlet 1/16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 203424 Pin, Spring Cs .187 X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 230012 Ftg, Hose Nyl Barbed Adapter M 5/32 Tbg X 1/4−28 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 MOT 238818 Motor, Gear 16vdc W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 202500 Housing, Drive Motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 222035 Knob, T 1.562 Bar W/.312−18 Stud 1.000 Lg Plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 246565 Roll, Drive V Groove, .030−.035 Wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 203418 Spring, Torsion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 197172 Screw, 006−32x .37 Hexwhd−pln Silver Tri−lobe 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 246710 Label, Feedhead Hole Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-232 661 Page 50

. Hardware is common and

not available unless listed.

2

1

7

6

5

3

4

232 618-A

Figure 11-3. Wind Tunnel Assembly

Item

No. Quantity

Dia.

Mkgs.

Part

No.

Description

Figure 11-3. Wind Tunnel Assembly (Fig 11-1 Item 17)

1 PC2 240939 Circuit Card Assy, Battery Charger w/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 FM 232673 Fan, Muffin 12VDC 5000 RPM 70 CFM 2.815 Mtg Holes 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

3 244824 Clip, Snap In .187 Hole .030−.312 Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 232672 Windtunnel, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 240943 Circuit Card Assy, Welder w/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 235750 Link, Terminal Connecting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 229327 Screw, M 5− .8X 12 Hex Hd−Phl 8.8 Pld Sems Clr 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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-232 661 Page 51

1

23

4

5

6

12

13

7

8

7

9

11

10

Figure 11-4. H100L4-10 Gun

Item

No.

Dia.

Mkgs.

Part

No.

243 864

Description

Figure 11-4. H100L4-10 Gun

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

1 ♦226 190 NOZZLE, flux cored slip type 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦087 299 TIP, contact scr .023 wire x 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000 067 TIP, contact scr .030 wire x 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000 068 TIP, contact scr .035 wire x 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000 069 TIP, contact scr .045 wire x 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 170 470 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 169 716 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 246 373 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 243 865 NUT, jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 242 832 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 225 410 SWITCH, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 079 878 HOUSING PLUG & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 242 833 CONNECTOR, feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 079 974 O-RING, .500 ID x .103CS rbr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 ♦194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 ♦194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 ♦194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

243 842-A

Quantity

♦OPTIONAL

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

OM-232 661 Page 52

SECTION 12 − ACCESSORIES/CONSUMABLES

12-1. Accessories

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.

12-2. Consumables

Item Hobart Package Part No.* Miller Package Part No. **

Contact Tips

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

.030 in (0.8 mm) 770 177 (5 per package) 000 067 (10 per package)
.035 in (0.9 mm) 770 180 (5 per package) 000 068 (10 per package)

MIG Nozzle (Standard) 770 404 169 715

Gasless Flux Cored Nozzle 770 487 226 190

Tip Adapter 770 402 169 716

Wire Inlet Guide — 058 549

Replacement Liners

.023/.025 in (0.6 mm) 196 139 194 010
.030/.035 in (0.8/0.9 mm) 196 139 194 011
.035/.045 in (0.9/1.2 mm) 196 140 194 012

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

12-3. Replacement Drive Rolls

For All Feed Head Assemblies

PART NO.

237 338 .024 (.6) and .030/.035 (.8 and .9)
246 565 .030/.035 (.8 and .9) V and VK Groove

WIRE DIAMETER

INCHES (mm)

12-4. Regulator/Flowmeter

PART NO. REMARKS

221 037**

770 198*

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

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.

For Argon and Argon mixed shielding gas. Use with

replacement hose 222 874.

OM-232 661 Page 53

Warranty Questions?

Call
1-800-332-3281
7 AM − 5 PM EST

Service

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

Support

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

Assistance

Visit the Hobart website:
www.HobartWelders.com

Effective January 1, 2010

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

serial number preface of MA or newer.

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

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

LIMITED WARRANTY − Subject to the terms and conditions
below, Hobart/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
delivery date of the equipment to the original retail purchaser, and
not to exceed one year after the equipment is shipped to a North
American distributor or eighteen months after the equipment is
shipped to an International distributor.

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

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

2. 3 Years — Parts and Labor
* Drive Systems
* Idle Module
* PC Boards
* Rotors, Stators and Brushes
* Solenoid Valves
* Spot Welder Transformer
* Switches and Controls

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

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

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

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

4. Engines, batteries (except Trek 180) and tires are
warranted separately by the manufacturer.

no other guarantees or warranties expressed or implied.

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

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

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

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

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

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

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

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

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

hobart_warr 2010−01

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

Protect Your Investment!

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

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories

Register your product at:

HobartWelders.com

Personal Safety Equipment

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Hobart Welding Products. 2010−01

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