Spool Gun DP 3035-10 And DP 3035-20
Contents
1. een een een 9 SECTIONS INSTALLATION zu copias mu ote dew beers sinen bow coince dual 11 Sly SD CIICAIOAS SAS EE al A a oe ae AI ce revus 11 3 2 Removing MIG Gun From Handler 210 11 3 3 Connecting Spool Gun To Handler 210 12 3 4 Installing Wire Spool And Threading Welding Wire 13 SECTION 4 OPERATION u ua weende eis konnen reren 14 Aal ORTO Star ir Dre mas ee Patna era 14 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 15 5 1 Routine Maintenance xix ceo erde Te meee eee A 15 5 2 Changing Dive ROS als a a ia 16 5 3 GChanging LINGE sedrsa aik ne UE das ules wd ead RAS saw ae vee se Bees 17 5 4 ThOUDIESNOOUNG igre en ee Peed be eee teeta ieee eres slenterde as een eae Del 17 5 5 GMAW MIG Aluminum Welding Hints naer 18 SECTION 6 ELECTRICAL DIAGRAMS wc cies ctw ind ee chat desta deter tse un et 20 SECTION 7 PARTS LIST ur 222 22er I Soe eee a eas we a a ete sede 22 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2010 03 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 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 hazardous2. e Ne pas utiliser le poste de soudage pour d geler des conduites ge lees e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil a la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES eae SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures ell
3. 1 scr 0 si dues 1945627 er LOCKING SCREW wa ns mm ee nee ade 1 O eect REN 187 239 2 COVER drive roll ass ae a 1 B AA 231 107 STRAIN RELIEF cable 1 A 231 108 SPRING CADIE es ein en ae tasa 1 sph ee 226 615 NUT handle plastic 1 me MO er dy sas ie tee 193 999 SPRING CPRSN 310 OD x 040 wire x 1 380 1 fe Io ara 186 415 PRESS ARM W SHAFT C clip washer 1 Ok A terete 187 238 BEARING sua cats Dil eae dace heed ak ha eee bees 1 Se lose des 186 414 PUSH ROLL 030 035 0 8 0 9 MM 1 vee beendet 209 079 SCREW M4 x 0 7 x 16 1 a O A ce 209 080 SCREWM4x0 7XB 1 PERS AA 186 413 DRIVE ROLL 030 035 0 8 0 9 MM 1 sin Ot sheet Sad tee 199 732 PUSH ROLEUK 023 nn aaneen ese Beem ermee nid a es 1 Ei EEN 199 731 DRIVE ROLE UK 0297 resia a a ara nia te ehh 1 RERE Eeten ede ase feted 186 488 KEY drive roll 2 MMX7MM 1 1 at ao Le 186410 INLET GUIDE cours an ee ten net Gv estan et acess 1 hacia PR ed E 046 6343 2 CLAMP CIE East ee anne dant Dome ne 1 EIER ETE weeny AE 079 878 CONNECTOR W SOCKETS 1 A es 194 631 NUT DASS ado de do ti eo ee oies 1 TN 236
4. 1 877 413 5184 site Internet www global ins 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 telephone 1 877 413 5184 site internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 telephone 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 Chan tilly VA 20151 t l phone 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 t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m
5. 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 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pres que possible de la soudure 6 Ne pas travailler a proximit 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 d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 230 261 Page 9 OM 230 261 Page 10 SECTION 3 INSTALLATION 3 1 Specifications Approximate z PRE Wire Diameter Cooling Maximum Weld Circuit B B r Range Hs Feed Method Spool Size Rating Overall Dimensions Weight ange 030 Thru 035 in En Be 0 8 Thru 0 9 mm Length 7 E Aluminum Wire 445 10 745 iom ee sa gt 11 1 2 in 291 mm Or Flux Cored Wire 44 To er Air 4in 102 mm SR ce Width mpm Cooled Diameter res u n 2 1 4 in 57 mm 5 0 lb 2 3 kg 7 5 Ib 3 4 kg 023 Thru 035
6. cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement a la meuleuse dot e de protecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P 4 SS on LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 230 261 Page 7 GIO Les PI CES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PI CES MOBILES peuvent causer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d e
7. pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders 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 e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload buil
8. 2 1 Symboles utilis s l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont monir s par les symboles joints ou sont expliqu s dans le texte A DANGER Indique une situation dangereuse qui si on Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des
9. Manual or door chart for appropriate setting 6 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual or door chart for appropriate setting 7 To purge shielding gas line set gun selection switch item 3 to the MIG Gun position Press spool gun trigger to energize gas valve Shielding gas will flow but spool gun will not feed wire Hold trigger in for several seconds to purge gas line Return gun selection switch to the Spool Gun position before welding sb5 1 6 92 S 0621 C Ref 804 695 A 804 696 A SECTION 5 MAINTENANCE amp TROUBLESHOOTING Routine Maintenance PN ea Disconnect power before maintaining 3 Maintain more often during severe conditions Y Check Change Y Clean To be done by Factory Authorized Service Agent Replace Reference Afi er Every x Unreadable Labels Weld Terminals zx Damaged Gas Hose Mix Weld Cables 3 Months AS Mix Cords Every 6 IN Months AM N Drive Rolls Inside Unit OM 230 261 Page 15 5 2 Changing Drive Rolls e A 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 se cure with washer and
10. de Parc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des brdlure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI 249 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours a des crans protecteurs ou a des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 230 261 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauff
11. gaz de soudage e Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur a alimentation d air Demander toujours a un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s a proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium a moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement
12. in A Gee Height Gun With Gun With 0 6 Thru 0 9 mm g 8 in 203 mm Cable Cable Solid Wire 3 2 Removing MIG Gun From Handler 210 Cut Off End Of Wire Hold wire tightly to keep it from unraveling Rewind Wire Onto Spool Fasten End Of Wire To Spool Loosen Thumbscrew Disconnect Gun Trigger Plug And Pull Gun From Unit Ref 804 686 A OM 230 261 Page 11 3 3 Connecting Spool Gun To Handler 210 MIG Gun Incorrect Gun Not Seated OM 230 261 Page 12 Exposed O rings will cause shielding gas leakage Correct Gun Fully Seated 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position 7 Polarity Changeover Terminal Block To make proper polarity connection see welding power source Owner s Manual Close door 804 695 A 3 4 Installing Wire Spool And Threading Welding Wire e 1 Thumb Screw D SA gt 2 Spool Cover Remove thumb screw and spool Tools Needed 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 P
13. la borne de terre du sectionneur ou que la fiche du cordon est raccord e a une prise correctement mise a la terre e Eneffectuant les raccordements d entr e fixer d abord le conduc teur de mise a la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidite d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil a nu peut entrainer la mort L equipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles
14. lower the oxygen level causing injury or death Be sure the breath ing air is safe e 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 e 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 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 e 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 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection PRIE 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 a
15. screw Changing Lower Drive Roll To remove drive roll It may be necessary to remove drive roll side of gun case to change lower drive roll Washer Lower Drive Roll Screw Lower Drive Roll Drive Roll Key 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 Tools Needed Reinstall drive roll cover ES 804 698 A OM 230 261 Page 16 5 3 Changing Liner Turn off and disconnect input power Nozzle Contact Tip 3 Liner Remove and replace liner Reinstall parts as shown Tools Needed Ref 804 687 A 5 4 Troubleshooting Trouble Remedy Gun tube assembly loose Tighten nut at base of gun tube assembly No weld output gun feeder does not Place Power switch on welding power source in the On position See welding power source Owner s work Manual Check Spool Gun MIG Gun switch for correct position Erratic weld output Tighten and clean all connections Check for proper weld output polarity connections see Section 3 3 Pressing gun feeder trigger does not Secure plug from gun feeder trigger cord into 4 socket receptacle on welding power source See Section energize
16. welding power source welding 3 3 wire is not energized shielding gas does not flow Place Spool Gun MIG Gun switch in Spool Gun position see Section 3 3 Wire feeds shielding gas flows but Secure spool gun cable connector to wire drive assembly inside welding power source See Section 3 3 welding wire is not energized _ See Troubleshooting section in welding power source Owner s Manual Wire feeds erratically Check and correct drive roll pressure see Section 3 4 Clean or replace drive roll clean or replace liner see Sections 5 2 and 5 3 OM 230 261 Page 17 5 5 GMAW MIG Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system MIG welding aluminum requires different techniques than MIG welding mild steel A Before You Start Welding Material thickness that can be welded with MIG process or aluminum are 14 ga 0 074 in 1 9 mm or heavier How heavy depends on the output capacity of the welder being used To MIG weld aluminum thinner than 14 ga either specialized pulsed MIG or AC TIG welding equipment may be necessary The removal of lubricants from the aluminum base material may be necessary Consult with your local welding distributor for their recommendation on aluminum cleaners Oxide removal should be done after degreasing This should be done with a stainless steel wire brush This can be done with a hand
17. wire brush or with a cup wire brush If a power wire brush is used keep the RPM s and pressures low to reduce smearing the surface of the material which could entrap oxides and impurities under the surface Always use a wire brush that is used only on aluminum to keep from contaminating the base material Contact you local welding distributor or aluminum filler metal representative for recommendations on wire alloys that fit your application Know the alloy of your base aluminum and what conditions the finished part will be subjected to The two most readily available aluminum filler wires are ER4043 and ER5356 Welding Techniques Make sure the welding power source is set up to weld DCEP DC Electrode Positive For MIG welding aluminum you need to use a 10 to 15 degree push travel angle tip and nozzle pointing in the direction of travel See Figure 5 1 Side View Of Gun Tip Angle 10 15 Direction Of Welding Forehand Push Backhand Drag Technique Technique Figure 5 1 Gun Tip Angle Pulling or using a drag angle will produce porous dirty welds due to a lack of gas coverage Spray transfer is the desired mode of metal transfer for welding aluminum The spray transfer is a very smooth transfer of molten metal droplets from the end of the electrode to the molten pool The droplets crossing the arc are smaller in diameter than the electrode There is no short circuiting in spray transfer With spray transfer the depositio
18. 677 CONNECTOR plug dp spool gun 1 han Altered boat 236 921 CABLE ASSEMBLY 10ft w connector plug 3035 10 1 EAN car eee tate oe 230 674 CABLE ASSEMBLY 20ft w connector plug 3035 20 1 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 230 261 Page 23 Notes Notes Notes 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 HOBART JEN WARRANTY 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 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 below Hobart Miller Electri
19. 923 GEARBOX ASSEMBLY 8035 10 arseen soon an 1 Ds loue A 186 412 GEARBOX ASSEMBLY 3035 20 1 LH PLO cries date Se 236922 MOTOR 3035 10 suster Eu 1 Jee POIs RIES ara 186417 ix MOTOR 3035 20 um ar nn A nee Aime noie 1 ER EN 196 398 BUSS BAR interconnecting 1 Shen then edn 197570 24 ANTEROTATION PIN esse th Geese eed ed 1 RS eben ud ee 196 848 CONTACT ADAPTER 3035 20 1 hb EEN 234 348 HEAD TUBE ASSY 3035 10 in nar en a a BOGEN Bee ee 1 nes eee ee A 196 849 HEAD TUBE ASSY 3035220 sus fase ne mines ni dt 1 EE 206 509 EINER KIT on ci data ip bale eenander des 1 ER gt 1 VENEN 196 847 LOCKING NUT 3035 20 1 ID Aben ee ee 194639 BARREL erstes ae Se een dhe eee oe Braet ed dere 1 BEN BON Se ion 209 080 SCREW M4 x 0 7 xX6 mm 1 RE whine Rie Bae TE 186 408 GAS NIPPLE ass ns sea ee neer i ae oe ee 1 ENE 186409 x GAS DIFFUSER 1500 ES Bet asis 1 O e ra 186 419 CONTACT TIP 030 oes neen a I eats 1 RN gt RAR 186 406 4 CONTACT TAP 035 Saas Besser idee Ba al 1 D A 4199 730 CONTACT TIP 023 Warn ee ae 1 AN ae 186405 NOZZLE sen reren men er an Ale oda Seen de 1 A ee de 111 400 HOSE SAE 187 ID X 410 OD X 8 000 1 Sl een 197 123 O RING 312 ID X 062 70 duro buna n 2 cos enh die 230
20. D EXPLOSION e Ne pas placer l appareil sur au dessus ou a proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger I installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service AY LA CHUTE DE L QUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement cables et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste bh LES TINCELLES PROJET ES peuvent provoquer des blessures e Porter un
21. L 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 WELDERS warranted separately by the manufacturer 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 City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Cont
22. OM 230 261C 2010 04 Processes MIG GMAW Welding Description Wire Feeder Spool Gun WELDERS Spool Gun DP 3035 10 And DP 3035 20 an a Weld SHAT Online Forum OWNER S MANUAL File Wire Feeder E www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years NI 0001 of reliable service with proper maintenance And if for some reason the unit needs repair REGISTERED E there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered to the you may need to fix the problem Warranty and from Hobart is backed by FR Quality System Service information for your particular model the best warranty in the business are also provided Protect Your Investment Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart product
23. 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 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 operat
24. act your Distributor for Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks 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 ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Hobart Welding Products 2010 01 Protect Your Investment Register your product at HobartWelders com 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 HOBART 0 WELDERS
25. as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire Lj MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place ua D e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e 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 e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference
26. as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input Capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns mili OM 230 261 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and
27. br lures graves Le circuit de l lectrode et de la piece est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues en contact avec le fil sont sous tension electrique Un equipement install ou mis a la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la piece a couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique a courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l utilisation d une source lectrique a courant lectrique s avere n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des stru
28. c 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 80 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
29. ctures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants 7 Indique des instructions sp cifiques 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 aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante a fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller Palimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre a la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord a
30. dicaux doivent tre prises par exemple des restrictions d acces pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des cables de soudage Disposer les cables d un c t et a distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 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 t l phone 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 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 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 t l phone 301 504 7923 site inter net
31. ding wiring be sure power supply system is properly sized rated and protected to handle this unit HE FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards Uy SS MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such
32. dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU
33. e hazards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable
34. e and have less chance of cold lapping burn through and other weld defects e It will be necessary to increase torch travel speed as the base material becomes heated during the welding process e The skill level of the operator joint types fit up and positions as well as the welding power supply will all have a great influence on the weldability of the aluminum and your success C Common Problems Troubleshooting e Burn through melt through caused by over heating the base material 1 Increase travel speed Make shorter welds 2 Move around on part spreading out the heat 3 Use thicker material change joint design or welding process to AC TIG 4 Eliminate or reduce gaps e Dirty welds 1 Use push angle instead of drag technique 2 Increase voltage to get into spray transfer 3 Use proper base metal cleaning techniques stainless steel brush 4 Check for proper shielding gas and wire alloy type e Wire burns back to contact tip during or at the end of the weld 1 Maintain a 3 4 in 19 mm tip to work distance 2 Check to make sure the contact tip size drive rolls and gun liner match the wire diameter that you are using Sometimes an oversized tip can be used The ID should only be one size larger than the wire diameter e Wire bird nests piles up in front of inlet guide on gun 1 Check and adjust drive roll tension 2 Check to make sure drive rolls match wire diameter 3 Replace contact tip if fou
35. e harm Wash hands after handling This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 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 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 703 788 2700 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 Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magn
36. eavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them 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 e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e 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 e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high
37. ement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur a proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment a AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie
38. es risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologue Les CHAMPS ELECTROMAGNETIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester a distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des
39. etic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere 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 assess ment 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 OM 230 261 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive 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 212 642 4900 web site 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 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Par
40. ion 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 LEGA
41. l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE A L ARC risque de provoquer des interf rences e nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interference maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder a une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements gt gt OM Les quipements de soudage et de coupage produisent des fum es et des gaz qui contie
42. led or plugged Sometimes an oversized tip can be used The ID should only be one size larger than the wire diameter OM 230 261 Page 19 SECTION 6 ELECTRICAL DIAGRAMS 4 WARNING e Do not touch live electrical parts 0 e Disconnect input power or sto N put p p engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit LUN ASSEMBLY TRIGGER WELL CABLE 186 451 Figure 6 1 Circuit Diagram OM 230 261 Page 20 Notes OM 230 261 Page 21 SECTION 7 PARTS LIST 3 Hardware is common and not available unless listed 38 39 40 804 699 A Figure 7 1 Complete Assembly OM 230 261 Page 22 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Complete Assembly 1 PB tes 186 416 TRIGGER SWITCH iss tende nd ae ee ad 1 De dad 226 855 4 PLASTIC HANDLE sis an boot nile ie nbr ende Mace he 1 a dues 226 853 SPOOL COVER ASSY consisting of 1 a eect iste Pte te dentin ee 226 854 SPOOL DEFENCE SHELL eee 1 Du piliers 194629 sere SPOOL SHARF wasmiddelen an 1 Ori Bg 194 624 BUSHING RESISTANCE RUBBER 1 Peer tie 194 625 tas LOCATION BUSHING Hansen Air mie inc inc 1 HO pre dites 194 626 ADJUSTING NUT rset semester eee ons 1 a an RING ring C clip 140 shaft x 015 thick
43. n rate and efficiency is relatively high The arc is very smooth stable and stiff and the weld bead has a nice appearance and a good wash into the sides In the spray transfer a large amount of heat is involved which creates a large pool with good penetration that can be difficult to control and cannot be used on materials thinner than 14 ga This transfer will produce a hissing sound and no spatter The short arc transfer on aluminum produces poor cleaning action poor tie in at the edges of the weld and large amounts of spatter and smoke The reflective heat and weld puddle that is present when MIG welding aluminum is very hot Holding the tip closer than 3 4 in could lead to the wire burning back to the contact tip and other feeding problems The most common shielding gas for MIG welding aluminum is 100 argon Flow rates of 20 to 30 CFH cubic feet per hour 0 57 to 0 85 m hr are acceptable C25 or argon CO shielding gases are not acceptable OM 230 261 Page 18 e Maintain a 3 4 in 19 mm tip to work distance and have the contact tip recessed approximately 1 8 in inside the nozzle if possible See Figure 5 2 Gas Nozzle gt Contact Tip To Work Contact Tube Recessed 1 8 Distance 3 4 in 19 mm in 3 2 mm Inside The Nozzle Figure 5 2 Contact Tube Position And Tip To Work Distance e Avoid large weave beads on aluminum If larger fillet welds are needed multiple pass straight beads will provide better appearanc
44. nnent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconna t qu ils provoquent 230 261 Page 8 des cancers des malformations cong nitales ou d autres problemes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone
45. ntretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher Palimentation lectrique LIRE LES INSTRUCTIONS Al e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pieces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de
46. rc The flying sparks hot 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e 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 e Do not use welder to thaw frozen pipes OM 230 261 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves h
47. rk and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e 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 unavoid able 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 volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e 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 7 Indicates special instructions 0 a I A This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid th
48. s contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 Hobartl or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 VOR pe Hob_Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad SYMDOl USAC Ceca prana ete o ae eee ten eee ed ae eben aa tae eee 1 162 Arc Welding Hazards ketenen ers ah a ie eae Ae aan Ban rd ae Us 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 155 P ncipal Satety Standarda etste ne Pee ee ee ete bee random nen 4 16 EME MTOR NEV ON as dd O 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 Zels RVI OLS S USES aman a eae ride das ne tite TOR nee aa 5 2 2 Dangers relatifs au soudage l arc 80 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes d S curit arne aime dun done a ace ta een ri 9 2 6 Informations relatives aux CEM
49. situation which if not avoided DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained 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 e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from wo
50. sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la piece pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 230 261 Page 5 Il reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur UNE FOIS Palimentation coup e e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher a mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des
51. stop using the equipmentat once Have the installation regularly checked and maintained 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf 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 230 261 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 amp 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 reproductiv
52. t 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 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 301 504 7923 website WWW Cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 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 recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2010 03 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes
53. ush 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 Remove nozzle and contact tip Push Release red lever and hold red lever Thread wire through inlet quide past push roll drive roll and out end of gun 2 inches 50 mm Install contact tip and nozzle Reinstall Turn On welding spool cover and thumb screw power source power Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure Press gun trigger to feed wire to check drive roll Cut off wire pressure Turn screw enough to prevent slipping 804 697 A OM 230 261 Page 13 4 1 Controls Spool Gun MIG Gun SECTION 4 OPERATION OM 230 261 Page 14 7 Spool Gun MIG Gun switch on Handler 210 must be in Spool Gun position for spool gun to operate 1 Shielding Gas Cylinder For shielding gas connections see welding power source Owner s Manual 2 Valve Open valve on cylinder just before welding Close valve on cylinder when finished welding 3 Spool Gun MIG Gun Switch Switch must be set in Spool Gun position for spool gun to operate 4 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed 5 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s
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