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OM-230 261A 2006 −10
Processes
MIG (GMAW) Welding
Description
Wire Feeder Spool Gun
Spool Gun DP 3035
File: Wire Feeder
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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
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation,
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. 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 HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − INSTALLATION 3-1. Specifications Approximate Cooling Maximum Spool Weld Circuit Overall Wire Feed Wire Diameter Range Weight Method Size Rating Dimensions Range .030 Thru .035 in Length: (0.8 Thru 0.9 mm) 11-1/2 in (291 mm) 100 Volts, 150 Aluminum Wire 115 To 715 ipm Amperes, 60% Width: 4 in (102 mm) 7.5 lb (3.4 kg) Or Flux Cored Wire (4.1 To 20.4 Air Cooled Duty Cycle 2-1/4 in (57 mm) Diameter Gun With Cable mpm) Using Argon .023 Thru 035 in Shielding Gas Height: (0.6 Thru 0.9 mm)
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3-3. Connecting Spool Gun To Handler 210 1 Drive Assembly 2 Spool Gun 7 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew. Insert end Spool Gun through opening until it bottoms against drive assembly. Tighten thumbscrew. 5 Spool gun must be inserted ÇÇ completely to prevent leakage of ÇÇ shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 6 Spool Gun/MIG Gun Switch 6 Place switch in Spool Gun position. MIG Gun 7 Polarity Changeover Terminal Block 2 To
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3-4. Installing Wire Spool And Threading Welding Wire 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool Tools Needed: cover. 7 8 6 3 Hub Tension Nut 4 Wire Spool 5 Install spool so wire feeds from top. Turn hub tension nut just so a slight 4 drag is felt on the wire spool. 5 Push Roll/Lower Drive Roll 2 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever 1 (Red) 3 8 Wire Inlet Guide 9 9 Contact Tip 10 10 Nozzle Remove nozzle and contact tip. Push Release red lever. and hol
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SECTION 4 − OPERATION 4-1. Controls Spool Gun/MIG Gun switch on Handler 210 must be in Spool Gun position for spool gun to operate. 1 Shielding Gas Cylinder 2 For shielding gas connections, see welding power source Owner’s 1 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 Spool Gun power source conta
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SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. = Check = Change = Clean = Replace Reference * To be done by Factory Authorized Service Agent Every Unreadable Labels Weld Terminals Damaged Gas Hose Weld Cables 3 3 Months Cords Gun Cables Every 6 OR Months Drive Rolls Inside Unit OM-230 261 Page 13
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5-2. Changing Drive Rolls Turn Off power at welding 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- 4 cure with washer and screw. 3 Changing Lower Drive Roll: 2 1 To remove drive roll: It may be necessary to remove 5 Lower Drive Roll Screw drive roll side of gun case to 6 Washer change lower drive roll.
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5-3. Changing Liner Turn Off power at welding power source first. 1 Nozzle 2 Contact Tip 3 Liner Remove and replace liner. Reinstall parts as shown. 3 2 1 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 wel
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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 TI
