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Hobart Welding Products 3545-20 manual

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Table of contents for the manual

  • Page 1

    OM-226 857B 2010 − 04 Processes Description MIG (GMA W) W elding Wire Feeder Spool Gun Spool Guns 3035-20 And 3545-20 File: Wire Feeder[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-226 857 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010 − 03 7 Protect yourself and others from injury — read and follow these precautions. 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[...]

  • Page 6

    OM-226 857 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-226 857 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-226 857 Page 4 1-4. California Proposition 65 W arnings W elding 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.) Battery posts, terminals and related accessories contain lead and l[...]

  • Page 9

    OM-226 857 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2010 − 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

  • Page 10

    OM-226 857 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHA[...]

  • Page 11

    OM-226 857 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter l[...]

  • Page 12

    OM-226 857 Page 8 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. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistol[...]

  • Page 13

    OM-226 857 Page 9 2-5. P ri nc ipa le s no rm es d e sé cu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Societ[...]

  • Page 14

    OM-226 857 Page 10[...]

  • Page 15

    OM-226 857 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications For Spool Gun 3035-20 Wire Diameter Range Approximate Wire Feed Range Cooling Method Maximum Spool Size W eld Circuit Rating Overall Dimensions W eight .030 Thru .035 in. (0.8 Thru 0.9 mm) Aluminum Wire .023 Thru 035 in. (0.6 Thru 0.9 mm) Hard Or Cored Wire 1 15 T o 715 ipm (4.1 T[...]

  • Page 16

    OM-226 857 Page 12 3-4. Installing Optional Spool Gun Switch In W elding Power Source 802 936-A T ools Needed: 1/4 in. 9/16 in. ! T urn off and disconnect in- put power . 1 W elding Power Source Center Baf fle 2 Switch Location 3 Switch Mounting Plate Remove 2 screws securing switch mounting plate to center baf fle. Pull switch mounting plate to pu[...]

  • Page 17

    OM-226 857 Page 13 3-5. Connecting Spool Gun T o W elding Power Source Ref. 802 582-A T ools Needed: ! T urn off and disconnect input power . Disconnect and remove MIG (GMAW) welding gun, if applicable. 1 Front Panel Opening 2 Spool Gun Weld Cable Route weld cable through front panel open- ing. 3 Positive (+) Output T erminal Connect spool gun weld[...]

  • Page 18

    OM-226 857 Page 14 3-6. Installing Wire Spool And Threading W elding Wire Ref. 801 891-A T ools Needed: 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover . 3 Hub T ension 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[...]

  • Page 19

    OM-226 857 Page 15 3-7. Removing Existing Barrel And Installing Contact Adapter 802 379-A 1 Base Nut Location Remove base nut from handle. 2 Handle Section Remove handle section from gun. 3 Drive Roll Assemblies Remove drive roll assemblies. 4 Nut Remove nut from barrel. 5 Barrel Remove barrel from gun. Disconnect gas hose from gas nipple. 6 Antiro[...]

  • Page 20

    OM-226 857 Page 16 SECTION 4 − OPERA TION 4-1. Controls sb5.1* 6/92 − S-0621-C / 801 889-A . Spool Gun On/Off switch in Millermatic 185 Hobart IronMan 210 or IronMan 250 must be in On position for spool gun operation (see Field Kit 207 642 instructions). 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner ’ [...]

  • Page 21

    OM-226 857 Page 17 5-2. Changing Drive Rolls 801 893-A T ools Needed: ! T urn off and disconnect input power . 1 Drive Roll Cover Remove cover . Changing Push Roll: T o remove push roll: 2 Push Roll Screw 3 W asher 4 Push Roll Remove screw and washer , and lift out drive roll. T o install drive roll: Slide drive roll onto shaft and se- cure with wa[...]

  • Page 22

    OM-226 857 Page 18 5-3. Changing Liner Ref. 801 891-A T ools Needed: ! T urn off and disconnect input power . 1 Nozzle 2 Contact T i p 3 Liner Remove and replace liner . Reinstall parts as shown. 1 2 3 5-4. T roubleshooting T rouble Remedy Gun tube assembly loose. Tighten nut at base of gun tube assembly . No weld output; gun/feeder does not work. [...]

  • Page 23

    OM-226 857 Page 19 5-5. GMA W (MIG) Aluminum W elding 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 Y ou Start Welding S Material thickness that can be welded with MIG process or aluminum are 14 ga. [0.074 in. [...]

  • Page 24

    OM-226 857 Page 20 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 Tu be R ecessed 1/8 in. (3.2 mm) Inside The Nozzle Contact Tip T o W ork Distance 3/4 in. (19 mm) Figure 5-2. Contact T ube Position And Tip-T o-Work Distance[...]

  • Page 25

    OM-226 857 Page 21 SECTION 6 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram 186 451[...]

  • Page 26

    OM-226 857 Page 22 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. 801 900-D 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 38 39 40 41 37 36 34 35 33 32 19 22 21 20 12 14 Figure 7-1. Complete Assembly For Spool Gun 3035-20[...]

  • Page 27

    OM-226 857 Page 23 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly for Spool Gun 3035-20 1 PB1 186 416 TRIGGER SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 226 855 PLASTIC HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-226 857 Page 24 . Hardware is common and not available unless listed. 802 577-A 3 2 30 34 26 29 31 35 32 39 40 41 27 15 33 36 37 38 28 22 21 25 24 23 18 17 16 13 11 10 4 9 8 7 6 5 4 2 1 12 14 19 20 Figure 7-2. Complete Assembly For Spool Gun 3545-20[...]

  • Page 29

    OM-226 857 Page 25 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Complete Assembly For Spool Gun 3545-20 1 PB1 186 416 TRIGGER SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 226 855 PLASTIC HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    Notes[...]

  • Page 31

    Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 2010 − 01 Service Y o u 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 Hoba[...]

  • Page 32

    ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Hobart Welding Products. 2010 − 01 Hoba rt W elding Pr oducts An Illinois T oo l W orks Co mpany 600 W est Main Street Tr oy, OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Lite ratu re Or Nea rest Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date whi[...]