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Hobart Welding Products DP 3035-20 manual

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Table of contents for the manual

  • Page 1

    OM-230 261C 2010 − 04 Processes Description MIG (GMA W) W elding Wire Feeder Spool Gun Spool Gun DP 3035-10 And DP 3035-20 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 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-230 261 Page 10[...]

  • Page 15

    OM-230 261 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications 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 Or Flux Cored Wire .023 Thru 035 in. (0.6 Thru 0.9 mm) Solid Wire 1 15 T o 715 ipm (4.1 T o 20.4 mpm[...]

  • Page 16

    OM-230 261 Page 12 3-3. Connecting Spool Gun T o Handler 210 804 695-A 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 plu[...]

  • Page 17

    OM-230 261 Page 13 3-4. Installing Wire Spool And Threading W elding Wire 804 697-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 Pres[...]

  • Page 18

    OM-230 261 Page 14 SECTION 4 − OPERA TION 4-1. Controls sb5.1* 6/92 − S-0621-C / Ref. 804 695-A / 804 696-A . 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 V alve Open valve on cylinder just be[...]

  • Page 19

    OM-230 261 Page 15 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 * T o be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels ~ W eld T erminals l Damaged Gas [...]

  • Page 20

    OM-230 261 Page 16 5-2. Changing Drive Rolls 804 698-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 21

    OM-230 261 Page 17 5-3. Changing Liner Ref. 804 687-A T ools Needed: ! T urn 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. 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. Pl[...]

  • Page 22

    OM-230 261 Page 18 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 23

    OM-230 261 Page 19 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 T o W ork Distance 3/4 in. (19 mm) Figure 5-2. Contact T ube Position And Tip-T o-Work Distance [...]

  • Page 24

    OM-230 261 Page 20 SECTION 6 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram 186 451[...]

  • Page 25

    OM-230 261 Page 21 Notes[...]

  • Page 26

    OM-230 261 Page 22 SECTION 7 − P ARTS 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[...]

  • Page 27

    OM-230 261 Page 23 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    Notes[...]

  • Page 29

    Notes[...]

  • 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[...]