Spool Gun DP 3035-10 And DP 3035-20
Contents
1. OM 230 261 Page 15 5 2 Changing Drive Rolls N 2 A Turn Off power at welding AN power source first 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 screw Changing Lower Drive Roll To remove drive roll lt 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 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 Tools Needed Reinstall drive roll cover E Pr 804 698 A OM 230 261 Page 16 5 3 Changing Liner Tools Needed 5 4 Troubleshooting Turn Off power at welding power source first Nozzle Contact Tip 3 Liner Remove and replace liner Reinstall parts as shown Ref 804 687 A 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 powe2. e RES 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 u
3. SION 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 l installation lectrique s assurer que Palimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser Tanneau 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 L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re specter 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 LES TINCELLES VOLANTES ris quent de provoquer des blessures B e Porter un cran facial pour prot ger le visage el les yeux e Affuter l electrode au tungst ne uniquement la meuleuse dotee de protecteurs Cette manceuv re 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 in
4. D autres consignes de s curit sont necessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si Ton porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque leve de contact in vitable ou accidentel avec la piece a souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC a tension constante 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 afferant pour les actions n cessaires afin d viter le danger a fil 2 un poste a souder DC manuel lectrode ou 3 un poste a souder AC a tension a vide r duite Dans la plupart des situations Putilisation d un poste a souder DC a fil a 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 Deverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationale
5. 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 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 alimentation d air Demander toujours 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 Tair de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s 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 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
6. 197 123 O RING 312 ID X 062 70 duro buna n annee 2 a e aal t Soa teas 230 677 CONNECTOR plug dp spool gun 1 a AN 236 921 CABLE ASSEMBLY 10ft w connector plug 3035 10 1 as a aaa 230 674 CABLE ASSEMBLY 20ft w connector plug 3035 20 1 OPTIONAL To maintain the factory original performance of your eguipment 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 6 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 WELDERS HOBART 531 WARRANTY Effective January 1 2008 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of LJ 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 LI
7. d gager des fum es toxiques en cas de soudage LES RAYONS DE LARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des brulure 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 pendant le soudage voir ANSI Z49 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 des crans protecteurs ou 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 in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d etincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectro
8. di 194 626 ADJUSTING NUT 1 P hd Ma nae ihe eid EEE te Bote E RING ring C clip 140 shaft x 015 thick 2 222 nenenennenn 1 lee meurtre 194627 se LOCKING SCREW sans ea ea 1 a E 187239 COVER drive roll aan a done 1 er WZ Boots ave noobs aa 231 107 lt 2 STRAIN RELIER Cable Lire cals eue aaa 1 ie ods r sie daia aaa da a bl 231 108 24 SPRING Cable sisas NS diri do ae t il ten riada 1 E ei ta AAA 226 615 NUT handle plastic ca 1 eae etes 193 999 SPRING CPRSN 310 OD x 040 wire x 1 380 1 DAs AAN 186 415 PRESS ARM W SHAFT C clip washer 1 na MP oh co athe te ate atte he 187238 BEARING moss careia we mad an ce ma Senne heads Aue Ana ents 1 Peg AM 186 414 PUSH ROLL 030 035 0 8 0 9 MM 1 el Om ine 209979 SCREVW MA XOZ X TO ites ee nn ee 1 tie OO Ae aise ANGER 209 080 SCREW M45 0 7 X Do ain ma 1 cated A 186 413 DRIVE ROLL 030 035 0 8 0 9 MM 1 a gt OBEREN 199 732 2 PUSH ROLL UK 1023 a en ee ma 1 etek PTR 199731 DRIVE ROLL UK 023 erkenne 1 SS taani eth igs 186 488 KEY drive roll 2 mm x 7 mm ea 1 45000 A 186 410 INLET GUIDE saamatu ms man N RT ee 1 kaod vaata a 048 834 22 CLAMP CIC raie Matis lanti aid 1 ite A 079 878 CONNECTOR W SOCKE US aa 4 2 2 20 0 0 ea dea 1 Lec lt FREE 19468112 NUT c e ama a bn tiu ss 1 Ol wk Sa
9. 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 building wiring be sure power supply system is properly sized rated and protected to handle this unit IX FALLING UNIT can cause injury 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 en
10. 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 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 Bi 109 159 Direction Of Welding Forehand Push Backhand Drag Technique Technique Figure 5 1 Gun Tip Angle Pulling or using a drag angle will pr
11. A 3 4 Installing Wire Spool And Threading Welding Wire A ee 1 Thumb Screw D SA 2 Spool Cover Remove thumb screw and spool Tools Needed cover 3 Hub Tension Nut 4 Wire Spool Install soool 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 Wire Inlet Guide 9 Contact Tip 10 Nozzle WCA Remove nozzle and contact tip Push Release red lever and hold red lever Thread wire through inlet guide 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 7 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
12. ARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province y y p p hobart_warr 2008 01 YA 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
13. MITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Sys
14. Number To locate a Distributor retail or service location Contact 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 PRINTED IN USA 2008 Hobart Welding Products 2008 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 ZG WELDERS
15. OM 230 261B 2008 05 Processes MIG GMAW Welding Description Wire Feeder Spool Gun WELDERS Spool Gun DP 3035 10 And DP 3035 20 al aa Well SHAT Online Forum OWNER S MANUAL File Wire Feeder oo 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 of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered tothe you may need to fix the problem Warranty and from Hobart is backed by ISO 9001 2000 Quality service information for your particular model the best warranty in the System Standard business are also provided 150 9001 2000 QUALITY SYSTEM Protect Your Investment Hobart Welders manufactures a full line of welders and welding related equipment For informa
16. Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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 If notified by the FCC about interference 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 Ifinterference still occurs the user must take extra measures such as moving the welding
17. 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 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 gt 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 8 TROUBLESHOOTING 5 1 Routine Maintenance A PA si y A Disconnect power gt Maintain more often ef before maintaining during severe conditions L Check O Change Q Clean x Replace Reference To be done by Factory Authorized Service Agent X 6 Fy 4 d i 8 2 y og 9 Y YX Gy Every x Unreadable Labels Weld Terminals x Damaged Gas Hose r x Weld Cables 3 Months AS Max Cords Every 6 lp Months Am L Drive Rolls Inside Unit
18. cendie loigner toute sub stance inflammable gt Q S a LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprimes e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pieces e Utiliser des pochettes et des bo tes antistati ques pour stocker deplacer ou expedier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels gue des rouleaux de commande LC a OM 230 261 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures ate e S abstenirde toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termine et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions ava
19. d 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 Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion z Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot 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 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover th
20. d Method Spool Size Rating Overall Dimensions Weight ange 030 Thru 035 in 0 8 Thru 0 9 mm Length 3035 10 3035 20 Aluminum Wire 100 Volts 150 11 1 2 in 291 mm Or Flux Cored Wire RZ PSN Air 4in 102 mm m l R Sa Cooled Diameter l 5 0 Ib 2 3 kg 7 5 lb 3 4 kg mpm Using Argon 023 Thru 035 in Shielding Gas Height Gun With Gun With 0 6 Thru 0 9 mm 8 in 203 mm Cable Cable Solid Wire 3 2 Removing MIG Gun From Handler 210 Cut Off End Of Wire 7 Hold wire tightly to keep it from unraveling Rewind Wire Onto Spool Fasten Loosen Thumbscrew Disconnect Gun End Of Wire To Spool 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
21. de avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier 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 soigneusement avec 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 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 AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charge de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le c ble 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 inc
22. duits chimiques dont l tat 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 securite Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping 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 P O Box 9101 Quincy MA 02269 9101 telephone 617 770 3000 site Internet www nfpa 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 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et d
23. e 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 une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis a la terre conform ment a ce mode d emploi e En cas d interf rences apres avoir pris les mesures preceden tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c 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 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent 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 OM 230 261 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro
24. ecessed approximately 1 8 in inside the nozzle if possible See Figure 5 2 Gas Nozzle 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 appearance 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
25. em 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 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 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 Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 OM 230 261 Page 2 Do not use welder to thaw frozen pipes 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 heavy 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 r
26. equirements 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 MAGNETIC FIELDS can affect Implanted Medical 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 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
27. es champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apres avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques a haute fr quence repr sente un risque a la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent a tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L4W 5NS telephone 800 463 6727 ou a Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 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 Nationa
28. from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 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 Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Ed
29. g MIG Gun From Handler 210 ss ii Mei dia A rd een we 11 3 3 Connecting Spool Gun To Handler 210 zn ee A ns paves 12 3 4 Installing Wire Spool And Threading Welding Wire 13 SEGHON4 OPERATION osa AAA AAN 14 dali CONTOS ots aan desborda Aa o ae L Baar dd 14 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING 15 S Routine Maintenance 5144 2 a kr N ats DE a Ne de 15 9 2 Changing Dive Bolsa sa Hr 16 a A tone shoe Beno kae ee Bas Gee hey een 17 2 4 NN am eee Laa eho ne nase maa kids pa Ride sun hee 17 5 5 GMAW MIG Aluminum Welding Hints eee enne nene 18 SECTION 6 ELECTRICAL DIAGRAMS sss sss s m ala maa aema 20 SECIION 7 PARTS EST ores Ted a ala ia a ba Yea ee Ve ala a dh 22 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A
30. l Fire Protection Association P O Box 9101 Quincy MA 02269 9101 telephone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 telephone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles dun c t et a distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs dimplants doivent d abord consulter leur m decin avant de s approcher des operations de soudage larc 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 Wire Diameter Cooling Maximum Weld Circuit i A 2 Range vee Fee
31. 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 reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 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 Code for Safety in Welding and Cutting CSA Standard W117 2
32. nt l utilisation ou la maintenance de l appareil e Nutiliser que les pieces de rechange recom mand es par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e 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 RAYONNEMENT HAUTE FRE QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs 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 LE SOUDAGE L ARC risque de provoquer des interferences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique 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 duir
33. oduce 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 deposition 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 r
34. onnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil 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 Cate SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la piece a la brosse en fil de fer et le meulage g n rent des tincelles et des pa
35. ough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can cause injury 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 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 A lt lt UN MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury 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 43 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place ua N e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read
36. pareil 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 sont correctement en place e Fixer le cable 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 possible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable 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 quand on a coupe l alimentation 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 DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher 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 brulures 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
37. properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks 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 Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 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 as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power miil T
38. r a distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la piece est sous tension lorsque le courant est d livr a la sortie Le circuit d alimentation et les circuits internes 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 talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis a la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pieces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la piece a 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 Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou la ou on risque de tomber Se servir d une source lectrique a courant lectrique UNIQUE MENT si le proc d de soudage le demande Si Putilisation 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
39. r source in the On position see welding power source Owner s 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 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 3 Place Spool Gun MIG Gun switch in Spool Gun position see Section 3 3 Wire feeds shielding gas flows but welding wire is not energized Secure spool gun cable connector to wire drive assembly inside welding power source see Section 3 3 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 outout capacity of the welder being used To MIG
40. recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas Les dangers possibles sont montr s par les symboles 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 gt gt si Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer Pattention et identifier les dangers possibles En presence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en matiere de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus completes 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 a installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement mainteni
41. rticules metalligues volantes Pendant la p riode de refroidissement des soudures elles 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 meme la mort e Fermerlalimentation 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 MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester a distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage 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 leve LES BOUTEILLES peuvent exploser si elles sont endommagees Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Proteger les bouteilles de gaz comprime d une chaleur excessive des chocs m caniques des dommages phy
42. ry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED W
43. s 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 la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e Verifier 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 nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des cables us s endommag s de grosseur insuffi sante ou mal piss s e 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 ap
44. se remote output control if present on unit 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 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 7 Indicates special instructions de FA xf 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 the hazards 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
45. siques 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 e Ne jamais placer une torche de soudage sur une bouteille a gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e 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 procedures 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 D EXPLO
46. 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 fouled 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 LUN ASSEMBLY TRIGGER WELD LADLE 186 451 Figure 6 1 Circuit Diagram OM 230 261 Page 20 Notes OM 230 261 Page 21 SECTION 7 PARTS LIST 7 Hardware is common and not available unless listed I gt P I m x ver es 00 mM 39 40 804 699 A Figure 7 1 Complete Assembly OM 230 261 Page 22 Item Dia Part No Mkgs No Description Guantity Figure 7 1 Complete Assembly 1 PBI e 186 416 TRIGGER SWITCH 3 22 au cere mara at iaa 1 ae es 226 855 PLASTIC HANDLE 5e in dees ai maa ae 1 CRE re ER 226 853 SPOOL COVER ASSY consisting Qh anaana nananana 1 RAR tee ke 220 894 SPOOL DEFENCE SHELL ociosos 1 Datos 194 623 4 SPOOL SHAPY a eds 1 Dan ta 194 624 BUSHING RESISTANCE RUBBER 0 1 Vean td 194 625 2x22 LOCATION BUSHING ea pace See bP ota died aint ees ama 1 TPE AO sin dia tnt
47. teen ta deine 236 923 GEARBOX ASSEMBLY 3035 10 1 ee JONES aliat 186 412 GEARBOX ASSEMBLY 3035 20 1 30 00 rise Be ae 236 922 24 MOTOR 3039 10 2er 1 242100 Aia B2 aa ne 186417 s MOTOR 3035 20 samen iia 1 eo VER er 196 398 BUSS BAR interconnecting 1 EES REEE 1975702 ANTFROTATION PIN see zeci fra fara ai mitt ema per hmm add de 1 kae lt Niiet aed 196 848 CONTACT ADAPTER 3035 20 22220 cenen seen neen nenn 1 E kus 234 348 HEAD TUBE ASSY 3035 10 1 O Ait de 196 849 HEAD TUBE ASSY 3035 20 ana ann a ra sd 1 OO ape ti ge liane 20600082 EINER KIT vastake te dra do ee nai ae ae gi at a 1 225 eee eee 196 847 LOCKING NUT 3035 20 1 i dn DO a ded depen ib dle 19416033 44 BARREL sons da cia loan ie dia ded elder 1 Ode sens 209 080 SCREW M4x0 7xXBMMD ea 1 eo ee Dita 16604086 GAS NIPPL nee ami mene ne FE 1 AO doit Saat A 186409 GAS DIFFUSER zur ee een 1 aa O Orei fate Aneta suite 1504192 CONTACT TI OSO ni ocean arata a aims aasa 1 e EEE 18040642 CONTACT TP 2035 atraido iaa weeded iks 1 RER taia tea 8199 73025 CONTACT TIP 2023 ir een Aare 1 AO aie a i ts ee a 18604052 NOZZLE 2 ses a air HEN s ees ees 1 Al netten 111 400 HOSE SAE 187 ID X 410 OD X 8 000 1 soap AAA
48. tems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HE Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories 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 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 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 indust
49. tion on other quality Hobart products 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 Hobart1 or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 ORARI AS Hob Thank 2005 06 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ths SYINDOL USAGE cados 1 1 22 Are Weding Haza aserne nea st matma a ae a 1 1 3 Additional Symbols For Installation Operation And Maintenance anasan nnnnan 3 1 4 California Proposition GS Warnings rn en uss eae owe nina a ewe Ra ee tas 4 194 Principal SAS Standards aial aa in dac inoata e a ae dadu un e abad 4 1 02 EME NATO A OI rd ai Ar ac soso Rte elo e il dedos au nn wey els 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 221z OYIMDOISS UNISES aaa dn 5 2 2 Dangers relatifs au soudage larc east 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 222222 neeeeneenenen rennen een een 8 2 5 Principales normes de S curit sn ohne nt aka rene a ala 9 2 6 MO malo EME o a 2 ans tan E 9 SECTION 3 INSTALLATION 232 a er 11 14 OPINE gt NN pian JA rem reden 11 3 2 Removin
50. ucational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 48rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble 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 cuiting or induction heating operations If cleared by your doctor then following the above procedures is
51. urn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 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 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 lower the oxygen level causing injury or death Be sure the breath ing air is safe 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 Do not weld on coated metals such as galvanized lea
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