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Secure with hose clamp. 8 Trigger Control Plug Insert plug into receptacle, and tighten threaded collar. Close welding power source door. 3/4 in. 7 6 5 23 4 8 1 5 6 OM-226 857 Page 13 OM-226 857 Page 14 3-6. Installing Wire Spool And Threading Welding Wire Ref. 801 891-A Tools Needed: 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover. 3 Hub Tension Nut 4 Wire Spool Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool. 5 Push Roll/Lower Drive Roll 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever (Red) 8 Wire Inlet Guide 9 Contact Tip 10 Nozzle 4 1 5 6 7 8 10 9 3 Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm). Release red lever. Turn On welding power source power. Install contact tip and nozzle. Reinstall spool cover and thumb screw. Wood Press gun trigger to feed wire to check drive roll Cut off wire. pressure. Turn screw enough to prevent slipping. 2 Screw rotation clockwise decreases drive roll pressure and counterclockwise rotation increases pressure. OM-226 857 Page 15 3-7. Removing Existing Barrel And Installing Contact Adapter 802 379-A 1 Base Nut Location Remove base nut from handle. 2 Handle Section Remove handle section from gun. 3 Drive Roll Assemblies Remove drive roll assemblies. 4 Nut Remove nut from barrel. 5 Barrel Remove barrel from gun. Disconnect gas hose from gas nipple. 6 Antirotation Pin 7 Contact Adapter Remove antirotation pin from contact adapter. Install contact adapter into gun, and secure with nut. Reinstall drive roll assemblies. Reinstall handle section onto gun. Reinstall base nut onto handle. Tools Needed: 1 2 4 5 6 7 4 12 mm 3 2 3 OM-226 857 Page 16 SECTION 4 . OPERATION 4-1. Controls sb5.1* 6/92 . S-0621-C / 801 889-A Spool Gun On/Off switch in Millermatic 185 Hobart IronMan 210 or IronMan 250 must be in On position for spool gun operation (see Field Kit 207 642 instructions). 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 Valve Open valve on cylinder just before welding. 3 Trigger Press trigger to energize welding power source contactor, start shielding gas flow, and begin wire feed. Wire feed speed is controlled by welding power source Wire Speed control (see appropriate welding power source Owner’s Manual). Close valve on cylinder when finished welding. 1 2 3 SECTION 5 . MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance ! Disconnect power before maintaining. Maintain more often during severe conditions. = Check = Change = Clean = Replace * To be done by Factory Authorized Service Agent Reference Every 3 Months Unreadable Labels Weld Terminals Damaged Gas Hose Weld Cables Cords Gun Cables Every 6 Months OR Drive Rolls Inside Unit OM-226 857 Page 17 5-2. Changing Drive Rolls 801 893-A Tools Needed: ! Turn off and disconnect input power. 1 Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer, and lift out drive roll. To install drive roll: Slide drive roll onto shaft and secure with washer and screw. Changing Lower Drive Roll: To remove drive roll: 5 Lower Drive Roll Screw 6 Washer 7 Lower Drive Roll 8 Drive Roll Key 9 Drive Roll Shaft Remove screw and washer, and lift out drive roll. Note: drive roll key will come out with drive roll. To install drive roll: Place drive roll key in slot in drive roll shaft. Line slot in drive roll up with drive roll key, and slide drive roll onto shaft. Secure drive roll with washer and screw. Reinstall gun case, if applicable. Reinstall drive roll cover. 1 2 3 4 5 6 7 8 9 It may be necessary to remove drive roll side of gun case to change lower drive roll. 5-3. Changing Liner Ref. 801 891-A Tools Needed: Turn off and disconnect input power. 1 Nozzle 2 Contact Tip 3 Liner Remove and replace liner. Reinstall parts as shown. 1 2 3 5-4. Troubleshooting Trouble Remedy Gun tube assembly loose. Tighten nut at base of gun tube assembly. No weld output; gun/feeder does not work. Place Power switch on welding power source in the On position (see welding power source Owner’s Manual). Erratic weld output. Tighten and clean all connections. Pressing gun/feeder trigger does not energize welding power source; welding wire is not energized; shielding gas does not flow. Secure plug from gun/feeder trigger cord into 4-socket receptacle on welding power source (see Section 3-5, field kit instructions F207 643, or appropriate welding power source Owner’s Manual). Wire feeds, shielding gas flows, but welding wire is not energized. Secure control cable leads in welding power source (see field kit instructions F207 643 or appropriate welding power source Owner’s Manual). See Troubleshooting section in welding power source Owner’s Manual. Wire feeds erratically. Check and correct drive roll pressure (see Section 3-6). Clean or...
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