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Hobart Handler 135 Owners Manual
Hobart Handler 135 Owners Manual
August 2002
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
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-944 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,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
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-944 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-944 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
OM-944 Page 4
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
OM-944 Page 5
LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris-
voquer des brûlures dans les yeux et quent de provoquer des blessures ou
sur la peau. même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas de
(ultraviolets et infrarouges) susceptibles de provoquer non utilisation.
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
pendant le soudage. rateur d’adduction d’air homologué.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est DES PIÈCES CHAUDES peuvent pro-
trop élevé. voquer des brûlures graves.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re- D Ne pas toucher des parties chaudes à mains nues
garder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements de protection constitué dans une matière dura- d’utiliser le pistolet ou la torche.
ble, résistant au feu (cuir ou laine) et une protection des pieds.
OM-944 Page 6
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
OM-944 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés connexes, norme
20402. CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS Safe Practices For Occupation And Educational Eye And Face Protec-
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL tion, norme ANSI Z87.1, de l’American National Standards Institute,
33126 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, de la National Fire Protec- Cutting and Welding Processes, norme NFPA 51B, de la National Fire
tion Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-944 Page 8
SECTION 2 – SPECIFICATIONS
2-1. 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: 18-7/8 in
90 A @ 19 Volts DC, (479 mm)
20% Duty Cycle 20 2.90 2.50 55 lb
Width: 10-5/8 in
30 – 135 28 (25 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/
Wire Feed Speed Range
Stainless Aluminum
Wire Type .024 – .030 in .030 – .035 in
And Dia (0.6 – 0.8 mm) (0.8 – 0.9 mm)/ 370 – 840 IPM (9.2 – 21.8 m/min) At No Load
.030 190 – 800 IPM (4.9 – 20.8 m/min) Feeding Wire
(0.8 mm)
* CSA Rating
OM-944 Page 9
2-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes 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.
135
Y Exceeding duty cycle can
100 damage unit or gun and void
80 warranty.
Output Amperes
60
40
20
10
1 2 4 6 8 10 20 40 60 80 100
Duty Cycle %
20% duty cycle at 90 amps
130
100
Output Amperes
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 – 196 617 / 196 618
OM-944 Page 10
2-3. 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
of other settings fall between the
curves shown.
30.0
25.0
OUTPUT VOLTS
20.0
Range 4
15.0
Range 3
Range 2
10.0 Range 1
5.0
0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
LOAD AMPS
30.0
25.0
20.0 Range 4
OUTPUT VOLTS
Range 3
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
LOAD AMPS
OM-944 Page 11
SECTION 3 – INSTALLATION
3-1. Installing Welding Gun
1 Drive Assembly
2 Gun Securing Thumbscrew
3 Gun End
4 Loosen thumbscrew. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
thumbscrew.
4 Gun Trigger Leads
2 3 Insert leads, one at a time, through
gun opening on front panel.
Connect female friction terminals to
matching male terminals in unit.
Polarity is not important.
Close door.
Tools Needed:
5 4
OM-944 Page 12
3-3. 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-944 Page 13
3-5. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other station-
Tools Needed: ary support so cylinder cannot fall
5/8, 1-1/8 in and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
1 blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
2 Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
6 Welding Power Source Gas
Hose Connection
3 Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
4
7 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur-
Argon Gas er’s recommended flow rate.
Or 1 8 CO2 Adapter (Customer Sup-
Argon/CO2 Gas Mix
plied)
9 O-Ring (Customer Supplied)
OR
Install adapter with O-ring between
2 regulator/flowmeter and CO2
cylinder.
7
5
8 9
CO2 Gas
6
OM-944 Page 14
3-6. Selecting A Location And Connecting Input Power For 115 VAC Model
1 Rating Label
2 Grounded Receptacle
18 in
(460 mm)
802 442-A
OM-944 Page 15
3-7. Selecting A Location And Connecting Input Power For 230 VAC Model
1 Rating Label
Supply correct input power.
2 Plug
3 Receptacle
Connect plug to receptacle.
18 in (457 mm) of 4 Line Disconnect Device
space for airflow See Section 3-8.
Y Special installation may be
required where gasoline or
volatile liquids are present –
4 see NEC Article 511 or CEC
Section 20.
L1
Y Always connect
grounding
conductor first.
= GND/PE L2
3
1 2
L2 L1
230 VAC, 1
OM-944 Page 16
3-8. Electrical Service Guide For 230 VAC Model
Tools Needed:
1/2 in
802 971 / 803 012 / 803 013 -A
OM-944 Page 17
3-10. 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. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
1 Pressure
2 Indicator
3 Scale
4
INPUT
POWER
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-944 Page 18
SECTION 4 – OPERATION
4-1. Controls
1 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see weld setting label in
welding power source or Sections
4-2 and 4-3, as applicable). Do not
switch under load.
OM-944 Page 19
4-2. Weld Parameter Chart For 115 VAC Model
Welding Guide
Settings are approximate. Adjust as required. Thicker materials can be welded
using proper technique, joint preparation, and multiple passes.
**Aluminum wire is relatively soft so feedability is not as good. Make sure that hub tension is not too tight and
OM-944 Page 20
for 115 Volt Wire Welding Package
Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded. CHANGING
Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. POLARITY
DCEN
22 gauge 18 gauge 16 gauge 1/8 inch 3/16 inch Electrode Negative
(.8 mm) (1.2 mm) (1.6 mm) (3.2 mm) (4.8 mm) For Flux Core Wire
––– 1/10 1/20 3/30 4/40
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.
keep torch as straight as possible. A ”push angle” for the torch is normally recommended.
209 228
OM-944 Page 21
4-3. Weld Parameter Chart For 230 VAC Model
Welding Guide
Settings are approximate. Adjust as required. Thicker materials can be welded
using proper technique, joint preparation, and multiple passes.
**Aluminum wire is relatively soft so feedability is not as good. Make sure that hub tension is not too tight and
OM-944 Page 22
for 230 Volt Wire Welding Package
Recommended V oltage and Wire Speed Settings for Thickness of Metal Being Welded. CHANGING
Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. POLARITY
DCEN
22 gauge 18 gauge 16 gauge 1/8 inch 3/16 inch 1/4 inch Electrode Negative
(.8 mm) (1.2 mm) (1.6 mm) (3.2 mm) (4.8 mm) (6.4 mm) For Flux Core Wire
––– 1/10 1/30 3/50 3/60 4/80
––– ––– 1/20 3/40 3/50 4/60
––– ––– ––– 2/20 3/40 4/50
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.
keep torch as straight as possible. A ”push angle” for the torch is normally recommended.
209 229
OM-944 Page 23
SECTION 5 – MAINTENANCE &TROUBLESHOOTING
5-1. 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-944 Page 24
5-4. Changing Drive Roll Or Wire Inlet Guide
1 Inlet Wire Guide Securing
Screw
2 Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
1 3 Drive Roll
3 The drive roll consists of two differ-
ent sized grooves. The stamped
markings on the end surface of the
2 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 3-10).
4 Retaining Pin
To secure drive roll, locate open slot
4 and push drive roll completely over
Tools Needed:
retaining pin, then rotate drive roll
(1/4 turn) to closed slot.
Tools Needed:
OM-944 Page 25
5-6. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit.
8 mm / 10mm
8 mm
10 mm
Remove liner.
OM-944 Page 26
5-7. Replacing Switch And/Or Head Tube
1 Remove handle
locking nut.
3 Slide handle.
4 Secure head
tube in vice.
Tools Needed:
OM-944 Page 27
5-8. Troubleshooting Table
Trouble Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-6).
does not 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 2-2).
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.
Adjust drive roll pressure (see Section 3-10).
Change to proper drive roll groove (see Section 5-4).
Readjust hub tension (see Section 3-9).
Replace contact tip if blocked (see Section 5-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-4 or Section 5-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 5-4).
Secure gun trigger leads or repair leads (see Section 3-1).
Check and clear any restrictions at drive assembly and liner (see Section 3-10 or Section 5-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Have nearest Factory Authorized Service Agent check drive motor.
OM-944 Page 28
SECTION 6 – ELECTRICAL DIAGRAM
194 324-C
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gas Hose
Shielding Gas
Gun
OM-944 Page 31
7-2. 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-944 Page 32
7-3. 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-944 Page 33
7-4. 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-944 Page 34
7-5. 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-944 Page 35
7-8. 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.
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-944 Page 36
7-11. 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.
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-944 Page 37
7-14. 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-944 Page 38
7-16. 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).
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-944 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-944 Page 40
Notes
OM-944 Page 41
SECTION 8 – PARTS LIST
32
35
8
9
49
43
39
3
40
42
4
37
38
13
10
5
12
11
21 22 23 24
1
25
16
18
15
17
50
47
20
44
26
19 52
14
51
36
28
41
29
30
31
27
45
33
46
34
48
802 449-D
OM-944 Page 42
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-944 Page 43
Item Dia. Part
No. Mkgs. No. Description Quantity
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.
NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.
OM-944 Page 45
Notes
Effective January 1, 2002
Warranty Questions? 5/3/1 WARRANTY applies to all Handler 135 and 175 models, Airforce 250, 250A, and 375 models,
and Champion 10,000 models.This warranty also applies to the Beta-Mig 1800, Champ 1435, 2060,
Call 8500 models, Ironman 250, Stickmate models, Tigmate models, and HSW-15 and HSW-25 spot
1-877-HOBART1 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.
Service LIMITED WARRANTY – Subject to the terms and conditions Hobart’s 5/3/1 Limited Warranty shall not apply to:
You always get the fast, below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin,
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
need. Most replacement free of defects in material and workmanship at the time it is torch tips and electrodes, weld cables, and tongs and
parts can be in your shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU tips, or parts that fail due to normal wear.
hands in 24 hours. OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND 2. Items furnished by Hobart/Miller, but manufactured by
Support FITNESS. others, such as engines or trade accessories. These items
Need fast answers to the
Within the warranty periods listed below, Hobart/Miller will repair are covered by the manufacturer’s warranty, if any.
tough welding questions?
Contact your distributor or or replace any warranted parts or components that fail due to
such defects in material or workmanship. Hobart/Miller must be 3. Equipment that has been modified by any party other than
call 1-800-332-3281. The notified in writing within thirty (30) days of such defect or failure, at Hobart/Miller, or equipment that has been improperly
expertise of the distributor which time Hobart/Miller will provide instructions on the warranty installed, improperly operated or misused based upon
and Hobart is there to claim procedures to be followed. industry standards, or equipment which has not had
help you, every step of reasonable and necessary maintenance, or equipment
Hobart/Miller shall honor warranty claims on warranted which has been used for operation outside of the
the way. equipment listed below in the event of such a failure within the specifications for the equipment.
warranty time periods. All warranty time periods start on the date
that the equipment was delivered to the original retail purchaser, HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND
or one year after the equipment is sent to a North American USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
distributor or eighteen months after the equipment is sent to an TRAINED AND EXPERIENCED IN THE USE AND
International distributor. MAINTENANCE OF WELDING EQUIPMENT.
1. 5 Years — Parts and Labor In the event of a warranty claim covered by this warranty, the
* Original Main Power Rectifiers exclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair;
or (2) replacement; or, where authorized in writing by
* Transformers Hobart/Miller in appropriate cases, (3) the reasonable cost of
* Stabilizers repair or replacement at an authorized Hobart/Miller service
station; or (4) payment of or credit for the purchase price (less
* Reactors reasonable depreciation based upon actual use) upon return of
* Rotors, Stators and Brushes the goods at customer’s risk and expense. Hobart’s/Miller’s
option of repair or replacement will be F.O.B., Factory at
2. 3 Years — Parts and Labor Appleton, Wisconsin, or F.O.B. at a Hobart/Miller authorized
* Drive Systems service facility as determined by Hobart/Miller. Therefore no
compensation or reimbursement for transportation costs of any
* PC Boards kind will be allowed.
* Idle Module
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Solenoid Valves PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Switches and Controls REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* Spot Welder Transformer 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
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Relays REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Contactors OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
* Regulators CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
* Water Coolant Systems ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
* Flowgauge and Flowmeter Regulators (No Labor) ANY AND ALL EQUIPMENT FURNISHED BY
* HF Units HOBART/MILLER IS EXCLUDED AND DISCLAIMED BY
Hobart/Miller.
* Running Gear/Trailers
* Plasma Cutting Torches Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
* Remote Controls
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 6/02
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 for: 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.