Hobart DP 3545-20 Le manuel du propriétaire
- Catégorie
- Système de soudage
- Taper
- Le manuel du propriétaire
Spool Gun DP 3545-20
www.HobartWelders.com
Description
OM-241 877D 2012−05
Processes
MIG (GMAW) Welding
Wire Feeder Spool Gun
File: Wire Feeder
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1......
1-1. Symbol Usage 1.................................................................
1-2. Arc Welding Hazards 1............................................................
1-3. Proposition 65 Warnings 2.........................................................
1-4. Principal Safety Standards 2.......................................................
1-5. EMF Information 2................................................................
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION 3.................................................................
2-1. Signification des symboles 3.......................................................
2-2. Dangers relatifs au soudage à l’arc 3................................................
2-3. Proposition californienne 65 Avertissements 4.........................................
2-4. Principales normes de sécurité 4....................................................
2-5. Informations relatives aux CEM 4...................................................
SECTION 3 − INSTALLATION 5................................................................
3-1. Specifications 5..................................................................
3-2. Installing Optional DP 3545 Spool Gun To Welding Power Source 5.......................
3-3. Installing Wire Spool And Threading Welding Wire 6....................................
SECTION 4 − OPERATION 7..................................................................
4-1. Controls 7.......................................................................
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 8.........................................
5-1. Routine Maintenance 8............................................................
5-2. Changing Drive Rolls 9............................................................
5-3. Changing Liner 10.................................................................
5-4. Troubleshooting 10................................................................
5-5. GMAW (MIG) Aluminum Welding Hints 11.............................................
SECTION 6 − ELECTRICAL DIAGRAMS 13......................................................
SECTION 7 − PARTS LIST 14...................................................................
WARRANTY
Hobart is registered to
the ISO 9001 Quality
System Standard.
OM-241 877 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2011-10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. 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.
. Indicates special instructions.
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.
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 welding power source Owner’s Manual. 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.
D Always wear dry insulating gloves.
D Insulate yourself from work and ground.
D Do not touch live electrode or electrical parts.
D Repair or replace worn, damaged, or cracked gun or cable insula-
tion.
D Turn off welding power source before changing contact tip or gun
parts.
D Keep all covers and handle securely in place.
D Keep your head out of the fumes.
D Ventilate area, or use breathing device.
D Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for material
used.
FUMES AND GASES can be hazardous.
D Do not weld near flammable material.
D Do not weld on containers that have held com-
bustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly prepared ac-
cording to AWS F4.1 and AWS A6.0 (see Safety Standards).
D Watch for fire; keep extinguisher nearby.
WELDING can cause fire or explosion.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in
use.
D Always ventilate confined spaces or use ap-
proved air-supplied respirator.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D Wear welding helmet with correct shade of fil-
ter.
D Wear correct eye and body protection.
D Cover exposed skin with spatter-resistant
clothing.
ARC RAYS can burn eyes and skin.
HOT PARTS can burn.
D Allow gun to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Check for noise level limits exceeding those
specified by OSHA.
D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.
WELDING WIRE can injure.
D Keep hands and body away from gun tip when
trigger is pressed.
READ INSTRUCTIONS.
D 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.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OM-241 877 Page 2
1-3. 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 & Safety Code Section 25249.5 et seq.)
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.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
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.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
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, 14501 George Carter Way, Suite
103, 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,
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), 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 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic 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 meas-
ures for persons wearing medical implants have to be taken. For ex-
ample, restrict access for passers−by or conduct individual risk assess-
ment for welders. All welders should use the following procedures in or-
der 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.
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.
OM-241 877 Page 3
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2011−10fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
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
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez vigi-
lant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées dans le manuel d’utilisation du poste de
soudage. Veuillez lire et respecter toutes ces normes de sé-
curité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
D Porter toujours des gants secs et isolants.
D S’isoler de la pièce et de la terre.
D Ne jamais toucher une électrode ou des pièces
électriques sous tension.
D Réparer ou remplacer un pistolet ou la gaine d’isolement d’un
câble usée, endommagée ou fissurée.
D Mettre la soudeuse hors tension avant de remplacer un bec con-
tact ou des pièces de pistolet.
D S’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
D Éloigner sa tête des endroits renfermant des
vapeurs.
D Aérer la zone de travail ou porter un appareil re-
spiratoire.
D Consulter les fiches toxicologiques (MSDS) et les notices du fab-
ricant de chaque matériel utilisé.
LE SOUDAGE peut causer un incen-
die ou une explosion.
D Ne pas souder à proximité de matériaux inflam-
mables.
D Ne pas effectuer le soudage sur des conte-
neurs fermés tels que des réservoirs,
tambours, ou conduites, à moins qu’ils n’aient
été préparés correctement conformément à
AWS F4.1 et AWS A6.0 (voir les Normes de
Sécurité).
D Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
D Quand on n’utilise pas le gaz comprimé de
protection, fermer le robinet de la bouteille.
D Assurer toujours la ventilation des zones fer-
mées ou utiliser un appareil respiratoire avec
alimentation en air.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LE RAYONNEMENT DE L’ARC peut
brûler les yeux et la peau.
D Porter un casque de soudage muni d’un filtre
de protection oculaire approprié.
D Porter une protection oculaire et des vête-
ments de protection appropriés.
D Protéger la peau nue en portant des vêtements anti-éclabous-
sures.
OM-241 877 Page 4
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Laisser refroidir le pistolet avant de le toucher.
D Ne pas toucher d’objets métalliques chauds.
D Abriter les objets métalliques contre tout con-
tact par les personnes à proximité.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Vérifier si les niveaux de bruit excèdent les lim-
ites spécifiées par l’OSHA.
D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés
si le niveau de bruit est élevé.
D Avertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Éloigner les mains et le corps de la buse du pis-
tolet après avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-3. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des
malformations congénitales et, dans certains cas, des
cancers. (Code de santé et de sécurité de Californie, chapitre
25249.5 et suivants)
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver
les mains après toute manipulation.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
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.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
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, 14501 George Carter Way, Suite
103, 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,
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), 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 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3 Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4 Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5 Connecter la pince sur la pièce aussi près que possible de la
soudure.
6 Ne pas travailler à proximité 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
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les procédu-
res précédentes.
OM-241 877 Page 5
SECTION 3 − INSTALLATION
3-1. Specifications
Wire Diameter Range
Approximate
Wire Feed
Range
Cooling
Method
Maximum
Spool Size
Weld Circuit
Rating
Overall Dimensions Weight
.030 Thru .047 in.
(0.8 Thru 1.2 mm)
Aluminum Wire
.030 Thru 047 in.
(0.8 Thru 1.2 mm) Hard
Wire Or Cored Wire
0 To 1200 ipm
(0 To 30.5 mpm)
Air Cooled
4 in. (102 mm)
Diameter
100 Volts, 200
Amperes, 60%
Duty Cycle Using
Argon Shielding
Gas
Length:
11-1/2 in. (291 mm)
Width:
2-1/4 in. (57 mm)
Height:
8 in. (203 mm)
8 lb (3.6 kg)
Gun With Cable
SPOOL GUN
MIG GUN
3-2. Installing Optional DP 3545 Spool Gun To Welding Power Source
242 143-A / 242 154-A
! Turn off and disconnect
input power.
1 Drive Assembly
2 Spool Gun
3 Gun Securing Thumbscrew
4 Gun End
Loosen thumbscrew. Insert gun
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 Change Over
Terminal Block
To make proper polarity connection
see welding power source Owner’s
Manual.
Close door.
8 Wire Feed Speed Control
Wire feed speed is controlled by
welding power source Wire Feed
Speed control (see welding power
source Owner’s Manual or door
chart for appropriate setting).
9 Voltage Control
Arc voltage is controlled by welding
power source Voltage control (see
welding power source Owner’s
Manual or door chart for appropri-
ate setting).
10 Trigger
Press trigger to energize welding
power source contactor, start
shielding gas flow, and begin wire
feed.
7
9
8
CB2
CB1
SPOOL GUN
MIG GUN
6
1 3 5
4
10
2
OM-241 877 Page 6
3-3. Installing Wire Spool And Threading Welding Wire
804 697-A
Tools Needed:
1 Thumb Screw
2 Spool Cover
Remove thumb screw and spool
cover.
3 Hub Tension Nut
4 Wire Spool
Install spool so wire feeds from top.
Turn hub tension nut just so a slight
drag is felt on the wire spool.
5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure
Adjustment Opening
7 Drive Roll Release Lever
(Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle
Remove nozzle and contact tip. Push
and hold red lever. Thread wire through
inlet guide, past push roll/drive roll, and
out end of gun 2 inches (50 mm).
Release red lever.
Turn On welding
power source power.
Install contact tip and nozzle. Reinstall
spool cover and thumb screw.
Wood
Cut off wire.
Press gun trigger to feed wire to check drive roll
pressure. Turn screw enough to prevent slipping.
. Rotating screw clockwise decreases
drive roll pressure and counterclockwise
increases pressure.
4
1
5
6
7
8
10
9
3
2
OM-241 877 Page 7
SECTION 4 − OPERATION
6
5
4
4-1. Controls
S-621-C / 242 154-A / 242 143-A
. Spool Gun/MIG Gun switch
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 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).
. 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.
1
2
SPOOL GUN
MIG GUN
CB2
CB1
SPOOL GUN
MIG GUN
3
OM-241 877 Page 8
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
! Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent
Reference
Every
3
Months
l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose nl Weld Cables
nl Cords nl Gun Cables
Every
6
Months
OR
~ Drive Rolls ~ Inside Unit
OM-241 877 Page 9
5-2. Changing Drive Rolls
804 698-A
Tools Needed:
! Turn off and disconnect
input power.
1 Drive Roll Cover
Remove cover.
Changing Push Roll:
To remove push roll:
2 Push Roll Screw
3 Washer
4 Push Roll
Remove screw and washer, and lift
out drive roll.
To install drive roll:
Slide drive roll onto shaft and se-
cure with washer and screw.
Changing Lower Drive Roll:
To remove drive roll:
5 Lower Drive Roll Screw
6 Washer
7 Lower Drive Roll
8 Drive Roll Key
9 Drive Roll Shaft
Remove screw and washer, and lift
out drive roll. Note: drive roll key will
come out with drive roll.
To install drive roll:
Place drive roll key in slot in drive
roll shaft.
Line slot in drive roll up with drive
roll key, and slide drive roll onto
shaft.
Secure drive roll with washer and
screw.
Reinstall gun case, if applicable.
Reinstall drive roll cover.
It may be necessary to remove
drive roll side of gun case to
change lower drive roll.
5
6
7
8
9
1
2
3
4
OM-241 877 Page 10
5-3. Changing Liner
Ref. 804 687-A
Tools Needed:
! Turn off and disconnect
input power.
1 Nozzle
2 Contact Tip
3 Liner
Remove and replace liner.
Reinstall parts as shown.
1
2
3
5-4. Troubleshooting
Trouble Remedy
Gun tube assembly loose. Tighten nut at base of gun tube assembly.
No weld output; gun/feeder does not
work.
Place Power switch on welding power source in the On position (see welding power source Owner’s
Manual).
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 3-2).
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 3-2).
Place Spool Gun/MIG Gun switch in Spool Gun position (see Section 3-2).
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 3-2).
See Troubleshooting section in welding power source Owner’s Manual.
Wire feeds erratically. Check and correct drive roll pressure (see Section 3-3).
Clean or replace drive roll; clean or replace liner (see Sections 5-2 and 5-3).
OM-241 877 Page 11
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
S 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.
S The removal of lubricants from the aluminum base material may be necessary. Consult with your local welding
distributor for their recommendation on aluminum cleaners.
S 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.
S 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.
B. Welding Techniques
S Make sure the welding power source is set up to weld DCEP (DC Electrode Positive).
S 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.
10-15
Side View Of Gun Tip Angle
10-15
Direction Of Welding
Forehand (Push)
Technique
Backhand (Drag)
Technique
Figure 5-1. Gun Tip Angle
S Pulling or using a drag angle will produce porous, dirty welds due to a lack of gas coverage.
S 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.
S 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.
S 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.
S 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
3
/hr)] are acceptable. C25 or argon CO
2
shielding gases are not acceptable.
OM-241 877 Page 12
S 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
Contact Tube Recessed 1/8
in. (3.2 mm) Inside The Nozzle
Contact Tip To Work
Distance 3/4 in. (19 mm)
Figure 5-2. Contact Tube Position And Tip-To-Work Distance
S 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.
S It will be necessary to increase torch travel speed as the base material becomes heated during the welding
process.
S 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
S 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.
S 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.
S 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.)
S 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-241 877 Page 13
SECTION 6 − ELECTRICAL DIAGRAMS
Figure 6-1. Circuit Diagram
186 451
OM-241 877 Page 14
SECTION 7 − PARTS LIST
. Hardware is common and not
available unless listed.
804 699-A
3
2
30
26
29
31
27
15
28
25
24
23
18
17
16
13
11
10
4
9
8
7
6
5
4
2
1
42
39
40
41
38
37
34
35
33
32
19
22
21
20
12
14
36
43
44
Figure 7-1. Complete Assembly
OM-241 877 Page 15
Quantity
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 7-1. Complete Assembly
1 PB1 186 416 Trigger Switch 1... ... ..... .. ..................................................
2 226 855 Plastic Handle 1... ............. .. ..................................................
3 226 853 Spool Cover Assy (Consisting Of) 1... ............. .. .................................
4 226 854 Spool Defence Shell 1... ............. .... ...........................................
5 194 623 Spool Shaft 1... ............. .... ...................................................
6 194 624 Bushing Resistance Rubber 1... ............. .... .....................................
7 194 625 Location Bushing 1... ............. .... ..............................................
8 194 626 Adjusting Nut 1... ............. .... .................................................
9 Ring, Rtng C-Clip .140 Shaft X .015 Thick 1... .......................... .........................
10 194 627 Locking Screw 1... ............. .... ................................................
11 187 239 Cover, Drive Roll 1... ............. .. ................................................
12 231 107 Strain Relief, Cable 1... ............. .. ..............................................
13 231 108 Spring, Cable 1... ............. .. ...................................................
14 226 615 Nut, Handle Plastic 1... ............. .. ..............................................
15 193 999 Spring, Cprsn .310 Od X .040 Wire X 1.380 1... ............. .. .........................
16 186 415 Press Arm W/Shaft, C-Clip Washer 1... ............. .. ................................
17 187 238 Bearing 1... ............. .. ........................................................
18 186 414 Push Roll .030/.035 (0.8/0.9 mm) 1... ............. .. ..................................
19 209 079 Screw M4 X 0.7 X 16 1... ............. .. ............................................
20 209 080 Screw M4 X 0.7 X 6 1... ............. .. .............................................
21 186 413 Drive Roll .030/.035 (0.8/0.9 mm) 1... ............. .. ..................................
18 199 397 Push Roll .047 (1.2 mm) 1... ............ .. ..........................................
21 199 396 Drive Roll .047 (1.2 mm) 1... ............ .. .........................................
22 186 488 Key, Drive Roll 2 mm x 7 mm 1... ............. .. .....................................
23 186 410 Inlet Guide 1... ............. .. .....................................................
24 048 834 Clamp, Circ 1... ............. .. .....................................................
25 079 878 Connector W/Sockets 1... ............. .. ............................................
26 194 631 Nut, Brass 1... ............. .. ......................................................
27 199 395 Gearbox Assembly 1... ............. .. ..............................................
28 B2 186 417 Motor 1... .... ..... .. ..........................................................
29 199 384 Buss Bar, Interconnecting 1... ............. .. ........................................
30 197 570 Anti-Rotation Pin 1... ............. .. ................................................
31 196 848 Contact Adapter 1... ............. .. .................................................
32 199 394 Head Tube Assy 1... ............. .. ................................................
33 206 363 Liner Kit 1... ............. .. ........................................................
34 196 847 Locking Nut 1... ............. .. .....................................................
35 199 393 Barrel 1... ............. .. ..........................................................
36 209 080 Screw, M4 x 0.7 x 6 mm 1... ............. .. ..........................................
37 199 391 Gas Nipple 1... ............. .. .....................................................
38 199 390 Gas Diffuser 1... ............. .. ....................................................
39 199 387 Contact Tip .030 1... ............. .. ................................................
39 199 388 Contact Tip .035 1... ............. .. ................................................
39 199 389 Contact Tip .047 1... ............ .. ................................................
40 199 386 Nozzle 1... ............. .. .........................................................
41 111 400 Hose, Sae .187 Id X .410 Od X 8.000 1... .............. .. .............................
42 079 974 O−Ring, .500 ID X .103 cs rbr 2... ............. .. ....................................
43 234 236 Connector, Plug Dp Spool Gun 1... ............. .. ....................................
44 241 879 Cable Assembly 20Ft W/Connector Plug 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.
Notes
Warranty Questions?
Call
1-800-332-3281
7 AM − 5 PM EST
hobart_warr 2012-03
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
Effective January 1, 2012
5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a
serial number preface of MC 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 Brothers Co., Troy, Ohio, and 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
* Reactors
* Stabilizers
* Transformers
2. 3 Years — Parts and Labor
* Drive Systems
* Idle Module
* PC Boards
* Rotors, Stators and Brushes
* Solenoid Valves
* Spot 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
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, 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 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 WARRANTY, 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.
Resources Available
Always provide Model Name and Serial/Style Number.
To locate a Service Center:
Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy
For Technical Assistance:
Call 1-800-332-3281
7 AM to 5 PM EST − Monday through Friday
ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Hobart Brothers Co.. 2012-03
Hobart Brothers Co.
An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA
For Assistance:
Call1-800-332-3281
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Owner’s Record
Thank you for purchasing Hobart. Our trained technical support team is
dedicated to your satisfaction. For questions regarding performance, op-
eration, or service, contact us!
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Hobart DP 3545-20 Le manuel du propriétaire
- Catégorie
- Système de soudage
- Taper
- Le manuel du propriétaire
dans d''autres langues
- English: Hobart DP 3545-20 Owner's manual
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