Professional Documents
Culture Documents
August 2004
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Hob_Thank 7/03
TABLE OF CONTENTS
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
OM-925 Page 1
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion. D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks, going near arc welding, gouging, or spot
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
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. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
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 Wear approved ear protection if noise level is
high.
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 CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see
gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
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.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
OM-925 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-925 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
(phone: 305-443-9353, website: www.aws.org). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
sparky.org). 617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
OSHA, Occupational Safety and Health Standards for General Indus-
from Compressed Gas Association, 1735 Jefferson Davis Highway,
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
site: www.cganet.com).
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices−−phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 312−353−2220,website: www.osha.gov).
OM-925 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
OM-925 Page 5
LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu-
ser des brûlures oculaires et cuta- vent causer des blessures ou même
nées. la mort.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) suscep- D Couper l’alimentation en gaz protecteur en cas de
tibles de causer des brûlures oculaires et cutanées. non utilisation.
Des étincelles sont projetées pendant le soudage. D Veiller toujours à bien ventiler les espaces confinés ou porter un respira-
D Porter un masque de soudage muni d’un filtre de la nuance adéquate teur à adduction d’air agréé.
pour se protéger le visage et les yeux pendant le soudage ou pour re-
garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque. LES PIÈCES CHAUDES peuvent cau-
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat ser des brûlures graves.
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc. D Ne pas toucher les pièces chaudes à main nue.
D Porter des vêtements de protection en matière durable et ignifuge
D Prévoir une période de refroidissement avant
(cuir ou laine) et des chaussures de sécurité.
d’utiliser le pistolet ou la torche.
LE SOUDAGE peut causer un incen-
die ou une explosion. LES CHAMPS MAGNÉTIQUES peuvent
Le soudage effectué sur des récipients fermés tels que perturber le fonctionnement des stimu-
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées lateurs cardiaques.
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des D Les personnes qui portent un stimulateur cardiaque
incendies et des brûlures. Le contact accidentel de l’électrode avec tout doivent se tenir à distance.
objet métallique peut causer des étincelles, une explosion, un surchauf-
fement ou un incendie. Avant de commencer le soudage, vérifier et D Ils doivent consulter leur médecin avant de s’appro-
s’assurer que l’endroit ne présente pas de danger. cher d’un lieu où on exécute des opérations de sou-
dage à l’arc, de gougeage ou de soudage par points.
D Se protéger et protéger les tiers de la projection d’étincelles et de mé-
tal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des LE BRUIT peut affecter l’ouïe.
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m Le bruit de certains processus et équipements peut
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse- affecter l’ouïe.
ment avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer D Porter des protecteurs d’oreille agréés si le niveau
même par des fissures et des ouvertures de petites dimensions. sonore est trop élevé.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
mité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une Les BOUTEILLES endommagées
cloison peut déclencher un incendie de l’autre côté. peuvent exploser.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à Les bouteilles de gaz protecteur contiennent du gaz
l’AWS F4.1 (voir les normes de sécurité). sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
D Brancher le câble sur la pièce le plus près possible de la zone de sou- normalement partie du procédé de soudage, les
dage pour éviter que le courant ne circule sur une longue distance, par manipuler avec précaution.
des chemins inconnus, et ne cause des risques d’électrocution et d’in-
cendie. D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
D Ne pas utiliser le poste de soudage pour dégeler des conduites ge- chocs mécaniques, du laitier, des flammes nues, des étincelles et des
lées. arcs.
D En cas de non utilisation, enlever la baguette d’électrode du porte− D Placer les bouteilles debout en les fixant dans un support stationnaire
électrode ou couper le fil au raz du tube−contact. ou dans un porte−bouteilles pour les empêcher de tomber ou de se
D Porter des vêtements de protection exempts d’huile tels que des renverser.
gants en cuir, une chemise en tissu épais, des pantalons sans revers, D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
des chaussures montantes et un masque. cuits électriques.
D Avant de souder, retirer tout produit combustible de ses poches, tel D Ne jamais poser une torche de soudage sur une bouteille de gaz.
qu’un briquet au butane ou des allumettes. D Ne jamais mettre une électrode de soudage en contact avec une bou-
teille de gaz.
LES PARTICULES PROJETÉES peu- D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
vent blesser les yeux. D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
D Le soudage, le burinage, le passage de la pièce à état, ainsi que les pièces connexes.
la brosse métallique et le meulage provoquent D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
l’émission d’étincelles et de particules métalli-
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-
ques. Pendant leur refroidissement, les soudures risquent de projeter du
tion ou de branchement de la bouteille
laitier.
D Lire et suivre les instructions concernant les bouteilles de gaz compri-
D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le mé, les équipements associés et les publications P−1 de la CGA,
masque de soudage.
mentionnées dans les normes de sécurité.
OM-925 Page 6
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
OM-925 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna-
(téléphone : (305) 443−9353, site Web : www.aws.org). tional.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, norme American Welding Society AWS norme ANSI Z87.1, de l’American National Standards Institute, 11 West
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
33126 (téléphone : (305) 443−9353, site Web : www.aws.org). site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, norme NFPA 51B, de la National Fire Protection Association,
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-
www.sparky.org). phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
OSHA, Occupational Safety and Health Standards for General Indus-
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-
site Web : www.cganet.com).
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca- 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
nadian Standards Association, Standards Sales, 178 boulevard 353−2220, site Web : www.osha.gov).
OM-925 Page 8
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
A Amperage V Voltage
Hz Hertz Negative
Direct Current
Positive Single Phase Input
(DC)
SECTION 4 − SPECIFICATIONS
4-1. Specifications
A. 115 VAC Model
Amperes Input at
Maximum Open-
Rated Welding Amperage Rated Load Output Weight Overall
Circuit Voltage KVA KW
Output Range 115 V, 60 Hz, Single- W/ Gun Dimensions
DC
Phase
Length: 19-1/2 in
90 A @ 19 Volts DC, (495 mm)
20% Duty Cycle 20 2.90 2.50 57 lb
Width: 10-5/8 in
25 − 140 28 (26 kg)
63 A @ 21 Volts DC, (270 mm)
15* 2.20* 1.77*
20% Duty Cycle* Height: 12-3/8 in
(314 mm)
Solid/ Flux Cored Aluminum
Wire Feed Speed Range
Wire Type Stainless
And Diameter .023 − .035 in .030 − .035 in .030 in 50 − 740 IPM (1.3 − 18.8 m/min) At No Load
(0.6 − 0.9 mm) (0.8 − 0.9 mm) (0.8 mm) 40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire
* CSA Rating
OM-925 Page 9
4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
A. 115 VAC Model opens, output stops, and cooling
fan runs. Wait fifteen minutes for
200
unit to cool. Reduce amperage or
duty cycle before welding.
140
Y Exceeding duty cycle can
100
Output Amperes
40
20
10
1 2 4 6 8 10 20 40 60 80 100
Duty Cycle %
80
60
40
20
10
10 20 30 40 50 60 70 80 100
Duty Cycle %
30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 217 623-A / 217 757-A
OM-925 Page 10
4-3. Volt-Ampere Curves
A. 115 VAC Model The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
30.0 of other settings fall between the
curves shown.
25.0
20.0
RANGE4
Voltage
15.0 RANGE3
RANGE2
RANGE1
10.0
5.0
0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Amperage
30.0
25.0
20.0 RANGE 4
RANGE 3
Voltage
15.0 RANGE 2
RANGE 1
10.0
5.0
0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
Amperage
OM-925 Page 11
SECTION 5 − INSTALLATION
5-1. Installing Welding Gun
1 Drive Assembly
2 Gun Securing Thumbscrew
3 Gun End
4
Loosen thumbscrew. Insert end
through opening until it bottoms
against drive assembly. Tighten
2 thumbscrew.
Welding gun must be inserted
3
completely to prevent leakage of
shielding gas.
4 Gun Trigger Leads
Insert leads, one at a time, through
gun opening on front panel.
Connect female friction terminals to
matching male terminals in unit.
1 Polarity is not important.
Close door.
803 711-A
802 456-A
OM-925 Page 12
5-3. Process/Polarity Table
Cable Connections
Process Polarity
Cable To Gun Cable To Work
GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output
ing gas put terminal terminal
FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output
no shielding gas output terminal terminal
DCEP
Electrode positive for
solid wire
OM-925 Page 13
5-5. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap
with CO2 shielding gas. See Parts List for optional 2 Cylinder Valve
CO2 gas regulator/flowmeter.
1 Remove cap, stand to side of valve,
and open valve slightly. Gas flow
4 blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
2
Install so face is vertical.
7 5 Regulator/Flowmeter Gas
Hose Connection
6 Welding Power Source Gas
Hose Connection
3 Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on rear
5 of welding power source.
7 Flow Adjust
Turn flow adjust screw to increase
or decrease gas flow. Flow rate
should be set when gas is flowing
Argon Gas Or through welding power source and
Mixed Gas welding gun. Turn Range switch to
Purge or Fan Only position. Press
gun trigger to start gas flow. Typical
flow rate is 20 cfh (cubic feet per
6
hour). Check wire manufacturer’s
recommended flow rate.
Tools Needed:
5/8, 1-1/8 in
OM-925 Page 14
5-6. Selecting A Location And Connecting Input Power For 115 VAC Model
1 Rating Label
2 Grounded Receptacle
2 A 115 volt, 20 ampere individual
18 in branch circuit protected by
1 (460 mm) time-delay fuses or circuit breaker
is required.
3 Plug From Unit
Select extension cord of 14 AWG
for up to 50 ft (15 m) or 12 AWG for
3 50 up to 200 ft (61 m).
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in
(460 mm)
803 712-B
OM-925 Page 15
5-7. Selecting A Location And Connecting Input Power For 230 VAC Model
1 Rating Label
Supply correct input power.
2 Plug (NEMA 6-50P)
3 Receptacle (NEMA 6-50R)
Connect plug to receptacle.
18 in (457 mm) of 4 Line Disconnect Device
space for airflow See Section 5-8.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
4
Section 20.
L1
Y Always connect
grounding
conductor first.
= GND/PE L2
3
2
1
L2 L1
230 VAC, 1
OM-925 Page 16
5-8. Electrical Service Guide For 230 VAC Model
Input Voltage 230
Input Amperes At Rated Output 20
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2 25
Normal Operating 3 30
Min Input Conductor Size In AWG 14
67
Max Recommended Input Conductor Length In Feet (Meters)
(20)
Min Grounding Conductor Size In AWG 14
Tools Needed:
1/2 in
803 012 / 803 013 -B / Ref. 802 971-C
OM-925 Page 17
5-10. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Gun Conduit Cable
4
Lay gun cable out straight.
Tools Needed:
1 2 3 5
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly. Make sure Pull and hold wire; cut off end. Push wire thru guides into gun;
feed roll is set to correct groove to continue to hold wire.
match wire size (see Section 7-4).
1 Pressure
2 Indicator
3 Scale
4
Be sure that wire is positioned Remove gun nozzle Turn power on. Be sure that Voltage range
in proper feed roll groove. and contact tip. switch is set to range 1, 2, 3, or 4 to feed wire.
Close and tighten pressure Rotate knob until it “clicks” into detent. Wire
assembly, and let go of wire. will not feed if range switch is set between
ranges or if set in the “PURGE” position.
Tighten
1
2
3
WOOD 4
Press gun trigger until wire comes Be sure that tip matches wire diameter. Feed wire to check drive roll pressure.
out of gun. Reinstall contact tip and nozzle. Tighten knob enough to prevent slipping.
Cut off wire. Close door.
OM-925 Page 18
SECTION 6 − OPERATION
6-1. Controls
1 2
3 4
DO NOT SWITCH
2
WHILE WELDING
NE PAS CHANGER
DE PROCÉDÉ
1 PURGE
3 4
Ref. 217 617-A
OM-925 Page 19
6-2. Weld Parameter Chart For 115 VAC Model
OM-925 Page 20
217 618-A
OM-925 Page 21
6-3. Weld Parameter Chart For 230 VAC Model
OM-925 Page 22
217 754-B
OM-925 Page 23
SECTION 7 − MAINTENANCE &TROUBLESHOOTING
7-1. Routine Maintenance
3 Months
6 Months
Blow out or
vacuum inside.
During heavy Or
service, clean
monthly.
802 441
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun
trigger and wait until protection circuit resets allowing drive motor to feed wire again.
OM-925 Page 24
7-4. Changing Drive Roll Or Wire Inlet Guide
Tools Needed:
OM-925 Page 25
7-6. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit.
8 mm / 10mm
Head Tube
Remove nozzle, contact tip,
adapter, gas diffuser, and wire
outlet guide.
8 mm
10 mm
Remove liner.
To Reassemble Gun:
Insert new liner.
Install wire outlet guide so that 1/8
Lay gun cable out straight
in (3 mm) of liner sticks out. Hand
before installing new liner.
tighten outlet guide, and then
tighten two full turns more.
Blow out gun casing. Cut liner off so that 3/4 in (19 mm)
sticks out of head tube.
Install gas diffuser, adapter, contact
tip, and nozzle.
OM-925 Page 26
7-7. Replacing Switch And/Or Head Tube
1 Remove handle
locking nut.
3 Slide handle.
4 Secure head
tube in vice.
Tools Needed:
OM-925 Page 27
7-8. Troubleshooting Table
Trouble Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-6).
does not run
run.
Replace building line fuse or reset circuit breaker if open.
No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
motor continues to run. unit has cooled (see Section 4-2).
Check Voltage range switch position. Rotate knob until it “clicks” into detent at desired range setting.
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.
Low weld output. Connect unit to proper input voltage or check for low line voltage.
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding
welding.
Adjust drive roll pressure (see Section 5-10).
Change to proper drive roll groove (see Section 7-4).
Readjust hub tension (see Section 5-9).
Replace contact tip if blocked (see Section 7-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 or Section 7-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).
Secure gun trigger leads or repair leads (see Section 5-1).
Check and clear any restrictions at drive assembly and liner (see Section 5-10 or Section 7-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten
if necessary.
OM-925 Page 28
SECTION 8 − ELECTRICAL DIAGRAM
217 621-A
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gas Hose
Shielding Gas
Gun
OM-925 Page 31
9-2. Typical MIG Process Control Settings
NOTE These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
OM-925 Page 32
9-3. Holding And Positioning Welding Gun
NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
0°-15°
90° 90°
GROOVE WELDS
45° 0°-15°
45°
OM-925 Page 33
9-4. Conditions That Affect Weld Bead Shape
NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
10°
Push
10°
Perpendicular Drag
OM-925 Page 34
9-5. Gun Movement During Welding
NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
S-0054-A
2 3 4
5
S-0053-A
5
S-0052-B
OM-925 Page 35
9-8. Troubleshooting − Excessive Spatter
S-0636
Wire feed speed too high. Select lower wire feed speed.
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.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0635
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Excessive heat input. Select lower voltage range and reduce wire feed speed.
OM-925 Page 36
9-11. Troubleshooting − Lack Of Penetration
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0637
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
S-0640
Excessive heat input. Select lower voltage range and reduce wire feed speed.
OM-925 Page 37
9-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-925 Page 38
9-16. 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
Argon X
Argon + 25% CO2 X
80% or greater Argon +
X X1
balance CO2 or Oxygen
100% CO2 X
Tri-Mix2 X
1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO2
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting)
nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
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
gas hose in gun and cable assembly.
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
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
OM-925 Page 39
Problem Probable Cause Remedy
Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
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 Readjust welding parameters.
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.
OM-925 Page 40
Notes
OM-925 Page 41
SECTION 10 − PARTS LIST
22
not available unless listed.
53
21
20
18
14
15
19
16
23
17
24
25
26
13
12
27
11
10
52
28
8
7
6
5
29
4
3
35
34
37
36
31
49
32
30
2
39
33
38
48
54
43
1
40
47
44
50
41
46
42
45
51
803 716-B
OM-925 Page 42
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-925 Page 43
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-925 Page 44
1 2 3 4
5
9
8
11
10
802 447
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-925 Page 45
10-3. Optional Drive Rolls
For All Feed Head Assemblies
WIRE DIAMETER
PART NO.
INCHES (mm)
202 925 .023/.025 (.6) and .030/.035 (.8 and .9)
202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)
10-4. Options
PART NO. DESCRIPTION REMARKS
770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max.
194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max.
195 957 H-10 Replacement Gun 10 ft length/.030-.035 wire size
195 186 Protective Cover Weatherproof nylon
212 492 Regulator/Flowmeter For use with CO2 shielding gas, 10−50 CFH
NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.
OM-925 Page 46
Effective January 1, 2003
5/3/1 WARRANTY applies to all Handler 125, 135 and 175 models, Airforce 250, 250A, 375, 400
Warranty Questions?
and 625 models, and Champion 4500 and 10,000 models, Beta-Mig 1800, Champ 1435, 2060, 8500
Call models, Ironman 210 and 250 models, Stickmate models, Tigmate models, and HSW-15 and
1-877-HOBART1 HSW-25 spot welder models effective with Serial No. KK200262 and newer.
for your local This limited warranty supersedes all previous Hobart warranties and is exclusive with
Hobart distributor. no other guarantees or warranties expressed or implied.
Hobart products are serviced by Hobart or Miller Authorized Service Agencies.
LIMITED WARRANTY − Subject to the terms and conditions Hobart’s 5/3/1 Limited Warranty shall not apply to:
Service below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin,
You always get the fast, warrants to its original retail purchaser that new Hobart 1. Consumable components such as contact tips, cutting
reliable response you equipment sold after the effective date of this limited warranty is nozzles, slip rings, drive rolls, gas diffusers, plasma
free of defects in material and workmanship at the time it is torch tips and electrodes, weld cables, and tongs and
need. Most replacement tips, or parts that fail due to normal wear. (Exception:
shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU
parts can be in your OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, brushes, slip rings, and relays are covered on Hobart
hands in 24 hours. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND Engine-Driven models.)
Support FITNESS.
2. Items furnished by Hobart/Miller, but manufactured by
Need fast answers to the Within the warranty periods listed below, Hobart/Miller will repair others, such as engines or trade accessories. These items
tough welding questions? or replace any warranted parts or components that fail due to are covered by the manufacturer’s warranty, if any.
Contact your distributor or such defects in material or workmanship. Hobart/Miller must be
call 1-800-332-3281. The notified in writing within thirty (30) days of such defect or failure, at 3. Equipment that has been modified by any party other than
which time Hobart/Miller will provide instructions on the warranty Hobart/Miller, or equipment that has been improperly
expertise of the distributor claim procedures to be followed. installed, improperly operated or misused based upon
and Hobart is there to industry standards, or equipment which has not had
help you, every step of Hobart/Miller shall honor warranty claims on warranted reasonable and necessary maintenance, or equipment
equipment listed below in the event of such a failure within the
the way. which has been used for operation outside of the
warranty time periods. All warranty time periods start on the date specifications for the equipment.
that the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND
distributor or eighteen months after the equipment is sent to an USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
International distributor. TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
1. 5 Years — Parts and Labor
* Original Main Power Rectifiers In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair;
* Transformers or (2) replacement; or, where authorized in writing by
* Stabilizers Hobart/Miller in appropriate cases, (3) the reasonable cost of
repair or replacement at an authorized Hobart/Miller service
* Reactors station; or (4) payment of or credit for the purchase price (less
reasonable depreciation based upon actual use) upon return of
2. 3 Years — Parts and Labor the goods at customer’s risk and expense. Hobart’s/Miller’s
* Drive Systems option of repair or replacement will be F.O.B., Factory at
* PC Boards Appleton, Wisconsin, or F.O.B. at a Hobart/Miller authorized
service facility as determined by Hobart/Miller. Therefore no
* Rotors, Stators and Brushes compensation or reimbursement for transportation costs of any
* Idle Module kind will be allowed.
* Solenoid Valves TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Switches and Controls REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE
* Spot Welder Transformer LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
3. 1 Year — Parts and Labor Unless Specified PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
(90 days for industrial use) OTHER LEGAL THEORY.
* Motor-Driven Guns ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* MIG Guns/TIG Torches ANY IMPLIED WARRANTY, GUARANTY OR
* Relays REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Contactors OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
* Regulators MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
* Water Coolant Systems ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
* Flowgauge and Flowmeter Regulators (No Labor) FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY
* HF Units HOBART/MILLER IS EXCLUDED AND DISCLAIMED BY
* Running Gear/Trailers Hobart/Miller.
* Plasma Cutting Torches Some states in the U.S.A. do not allow limitations of how long an
* Remote Controls implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
* Replacement Parts (No labor) exclusion may not apply to you. This warranty provides specific
* Accessories legal rights, and other rights may be available, but may vary from
state to state.
* Field Options
(NOTE: Field options are covered for the remaining In Canada, legislation in some provinces provides for certain
warranty period of the product they are installed in, or additional warranties or remedies other than as stated herein,
for a minimum of one year — whichever is greater.) and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
4. Engines, batteries and tires are warranted separately by the provides specific legal rights, and other rights may be available,
manufacturer. but may vary from province to province.
hobart retail 8/03
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact the Delivering Carrier to: 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.