TM-9-3431-258-14-and-P

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T M 9 - 3 4 3 1 - 2 5 8 - 1 4 & P

T E C H N I C A L M A N U A L

O P E R A T O R ’ S , O R G A N I Z A T I O N A L , D I R E C T S U P P O R T

A N D G E N E R A L S U P P O R T M A I N T E N A N C E

M A N U A L I N C L U D I N G R E P A I R P A R T S L I S T

F O R

T O R C H O U T F I T , W E L D I N G , G A S

M O D E L 1 3 7

( N S N 3 4 3 1 - 0 0 - 6 9 1 - 1 4 1 5 )

T h i s c o p y i s a r e p r i n t w h i c h i n c l u d e s c u r r e n t p a g e s f r o m C h a n g e 1

.

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

31 JULY 1981

Change

No. 1

Changes in force: C1

O P E R A T O R ’ S , O R G A N I Z A T I O N A L , D I R E C T S U P P O R T

A N D G E N E R A L S U P P O R T M A I N T E N A N C E M A N U A L

I N C L U D I N G R E P A I R P A R T S L I S T

F O R

T O R C H O U T F I T , W E L D I N G , G A S

M O D E L 1 3 7

( N S N 3 4 3 1 - 0 0 - 6 9 1 - 1 4 1 5 )

T M 9 - 3 4 3 1 - 2 5 8 - 1 4 & P

C 1

H E A D Q U A R T E R S

D E P A R T M E N T O F T H E A R M Y

Washington, DC, 20 March 1985

TM 9-3431-258-14&P, 31 July 1981, is changed as follows:

Page i.

U n d e r “ R E P O R T I N G O F E R R O R S ” , c h a n g e m a i l i n g a d d r e s s t o : C o m m a n d e r , U S A r m y A r m a ment, Munitions and Chemical Command, ATTN: AMSMC-MAS, Rock Island, IL

61299-6000.

Page 3. The part number chart is rescinded. Add new part number charts as follows:

Wire Wire

T ype Size

(In.)

Front Guide Bushing

Part No.

N S N

Rear Guide Bushing

Part No.

N S N

Aluminum 0.020

2220A338H04

0.030 220A338H04

3/64

1/16

220A338H06

220A338H05 3431-00-126-8947

Mild &

Stainless

Steel

0.020 220A338H04

0.030 220A338H04

0.035 220A338H04

488A441H02

488A441H02

488A441H01

488A441H01

488A441H02

488A441H02

488A441H02

5365-00-166-8500

5365-00-166-8500

1

TM 9-3431-258-14&P

Wire

Type

Wire

Size

(In.)

Part No.

Drive Roll

NSN

Aluminum 0.020 419A009G3 3431-00-160-7879

0.030 419A009G03 3431-00-160-7879

3/64

1/16

419A009G01

419A009G01

3431-00-875-7633

3431-00-875-7633

Mild &

Stainless

Steel

0.020

0.030

0.035

419A009G03

419A009G03

419A009G01

3431-00-160-7879

3431-00-160-7879

3431-00-875-7633

Part No.

Guide Tube

NSN

306B172H01

306B172H01

306B172H09

306B172H10

306B172H01

306B172H03

306B172H04

3431-00446-2644

Nozzle

Wire

Type

Aluminum

Mild &

Stainless

Steel

Wire

Size

(In.)

0.020

0.030

3/64

1/16

0.020

0.030

0.035

Part No.

311B703H03

311B703H03

311B703H02

311B703H02

311B703H03

311B703H03

311B703H02

Page 14. Add the following NSNs to the parts list:

Ref. No.

1

3

9

10

Add NSN

5355-00-246-3925

3431-00-164-2666

5905-00-161-3447

3431-00-446-2643

NSN

3431-00-446-2642

3431-00-446-2642

3431-00-446-2642

2

Ref. No.

14

34

35

22

23

27

29

15

19

20

Page 15. Add the following NSNs to the parts list:

Ref. No.

37

47

48

57

58

59

60

Page 29. Add the following NSNs to the parts list:

Ref. No.

1

10

22

Add NSN

3431-00-875-7638

3431-00-875-3977

3431-00-875-3977

5315-00-175-7467

5360-00-175-2907

3110-00-409-3279

5365-00-166-8500

3431-00-875-7646

3431-00-875-7635

3431-00-163-0180

Add NSN

3431-00-446-2637

3431-00-875-7641

5365-00-173-0055

3431-00-446-2642

3431-00-446-2644

3431-00-875-7633

6105-00-169-6189

Add NSN

5930-00-132-2672

6150-01-045-1260

5945-00-875-7889

TM 9-3431-258-14&P

3

By Order of the Secretary of the Army:

JOHN A. WICKHAM, JR.

General, United States Army

Chief of Staff

Official:

DONALD J. DELANDRO

Brigadier General, United States Army

The Adjutant General

D I S T R I B U T I O N :

To be distributed in accordance with DA Form 12–21 requirements for FSC

Group 3431-IL.

Technical Manual

No. 9-3431-258-14&P

TM 9-3431-258-14&P

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington, DC, 31 July 1981

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT

AND GENERAL SUPPORT MAINTENANCE

MANUAL INCLUDING REPAIR PARTS LIST

FOR

TORCH OUTFIT, WELDING, GAS

MODEL 137

(NSN 3431-00-691-1415)

I

REPORTING OF ERRORS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028

(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2, located in the back of this manual direct to: Commander, US Army Armament

Materiel Readiness Command, ATTN: DRSAR-MAS, Rock Island, IL 61299.

A reply will be furnished directly to you.

NOTE

This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to whom this welding set is issued.

Manufactured by: Westinghouse Electric Corp.

Industrial Electric Div.

P.O Box 300

Sykesville, MD 21784

Procured under Contract No. DAAA09-79-C-2019

L

This technical manual is an authentication of the manufacturers’ commercial literature and does not conform with the format and content specified in AR 310-3,

Military Publications. This technical manual does, however, contain available information that is essential to the operation and maintenance of the equipment.

i/(ii blank)

INSTRUCTIONS FOR REQUISITIONING PARTS

NOT IDENTIFIED BY NSN ldhe~ requisitioning parts mandatory that the follow net identified by National Stock Number, it is ng information be furnished the supPly officer.

1Manufacturer’s Federal Supply Cod6 Number - 0$452

2Manufacturer’s Part Number exactly as listed herein.

3Nomenclature exactly as listed herein, including dimensions, if necessary.

4Manufacturer’s Model Number Model 137

5Manufacturer’s Serial Number (End Item)

6Any other information such as Type, Frame Number, and Electrical

Characteristics, if applicable.

7[f DO Form 1348 is used, fill in all blocks except 4, 5, 6, and

Remarks field in accordance with AR 725-50.

Ccmplete Form as Follows:

(a) In blocks 4. S, 6, list manufacturer’s Federal Supply Code

Number - 08452 followed by a colon and manufacturer’s

Part Number for the repair part.

(b) Complete Remarks field as follows:

Noun: (nomenclature of repair part)

For: NSN: 3431-00-691-1415

Manufacturer: Westinghouse Electric Corp.

Model:

Serial:

137

(of end item)

Any other pertinent information such as Frame Number,

Type, Dimensions, etc.

TABLE OF CONTENTS

INTRODUCTION

DESCRIPTION .

The SP WELDING GUN

INSTALLATION . . . . . . .

GAS CONNECTIONS .

LOCATIONS . . . .

WELDING CURRENT CONNECTIONS

GUN CONTROL CONNECTIONS . . .

OPTIONAL PARTS REQUIRED FOR VARIOUS WIRE SIZES

OPERATION . . . . . . . . .

SAFETY PRECAUTIONS

GUIDE TUBE POSITION

WIRE THREADING . .

BRAKE ADJUSTMENT .

WELDING SETUP . .

WELDING TECHNIQUES

NOZZLE SPACING .

GUN ANGLE . . . .

CLEANNESS OF MATERIAL

WIRE CLEANERS

MAINTENANCE . . . . . . . . .

OPERATING MAINTENANCE

REPLACEMENT PARTS .

ILLUSTRATIONS

SP-9 and SP-10 OUTLINE

WIRING DIAGRAM . . . .

SCHEMATIC . . . . . . .

DRAWING

TYPE CCD-4 CONTROL

ILLUSTRATIONS

Outline

Schematic

Wiring Diagram

483A756

655C951

483A767

16

2214A57

720B096

221C688

PAGE

1

1-2

1-2

2-3

2

2

3

3

3

6

6

6

6

6-7

7

7

3-6

5

6

4

4

3-4

4

INTRODUCTION

The SP-9 and SP-10 Welding Gun is intended for use as part of a complete package for control of gas shielded consumable metal arc welding.

The package includes the SP-9 or SP-10 Gun and the CV-2 Control when used with a constant potential welder.

When arc spot welding is to be performed with a constant voltage welder, the CVS-2 Control and the CVAS-2 Timer is used.

The guns may be used with a constant current DC Welder when the CC-2 Control is used.

The WCP-1 Welder, a constant potential welder with a built-in gun control, may also be used with these guns.

DESCRIPTION

The SP Welding Gun

Type SP-9 Welding Gun is designed for use with 1/16-inch to 3/64-inch diameter aluminum welding wire on one-pound spools, 0.035-inch to 3/64-inch diameter Type MS

21 mild steel welding wire on 1-1/2 pound spools, and 0.035-inch to 3/64-inch diameter stainless steel welding wire on one-pound Spools.

It can also be used with

10-pound spools of 3/64-inch diameter aluminum wire.

The SP-10 Welding Gun is designed for use with 0.020-inch and 0.030-inch diameter aluminum welding wire on one-pound spools, 0.020-inch to 0.030-inch diameter Type

MS-21 mild steel welding wire on 1-1/2 pound spools, and 0.020-inch to 0.030-inch diameter stainless steel welding wire on one pound spools.

The Welding Gun SP-9 and SP-10 are compact, light-weight units designed to give dependable service over an extended period.

All exposed parts of the gun are fully insulated from welding voltage for operator safety and prevention of accidental shorts.

The distribution of weight and the cable and hose arrangement give excellent balance which make the welding guns easy to handle in all positions. The total weight of either welding gun (including a one-pound wire spool) is less than four pounds.

Each welding gun consists primarily of a gun barrel housing with a removable tapered nozzle, a mounting bracket with a shielding gas valve operated by the trigger, a handle of high impact plastic which contains the wire drive motor, a protective shield with electrode speed control, a plastic reel cover, a control cable, a welding current cable, and a gas hose.

The tapered nozzle (Part 1 on Drawing 483A756) is held by a nozzle holder (2) which is threaded to the gun barrel housing (3). A copper guide tube (4) passes thru the gun barrel and is secured by a thumbscrew (5). Mounted within the mounting bracket are a front guide bushing (6) and a rear guide bushing (7).

The mounting bracket also includes a ball type shielding gas valve operated by the trigger (8) through a plunger. The trigger also actuates the weld switch (9). Pivoted on the side of the mounting bracket is a swing arm (10) on which is mounted an idler roll (11).

DESCRIPTION

The SP Weldinq Gun - Continued

The swing arm is secured in the closed position by a pressure screw (12) and a pressure spring (13). A, 50-foot control cable (14) extends from the base of the handle, and has a plug for connection to the control.

A protective shield (15) is secured to the mounting bracket and includes the electrode speed control (16).

A four-inch diameter spool of welding electrode (17) is mounted on the spool shaft supported by the shield.

A plastic cover (18) is secured to the spool shaft supported by the shield.

A plastic cover” (18) Is secured to the spool shaft by a knurled thumbscrew.

The combination of protective shield and plastic cover completely enclose the welding wire spool and provide protection against spatter or other foreign matter.

The plastic cover also enables the operator to see the quantity of welding wire remaining the spool.

An adjustable spool brake (19) is secured to the protective shield, and bears against the wire spool to prevent uncoiling of the weldlng wire.

In operation, the welding electrode from the spool passes thru the rear guide bushing, between the drive and idler roll, thru the front guide bushing, and thru the guide tube.

The wfre then passes thru the nozzle to the arc.

Welding current is transmitted thru the current cable to the gun barrel and to the guide bar, which in turn, ing current to the welding wire.

When the weld trigger is squeezed, the motor is energized to feed the welding wire to the arc and the gas valve shielding gas to the arc area.

transmits weldwlre drive opens to supply

NOTE : Inching circuit not included in CV-2 Control.

Inch button will operate when this gun is used with CVS-2 or CC-2 Control.

INSTALLATION

Immediately after opening the carton, make a careful examination of the contents to ensure that no damage has occurred during shipment.

Do not discard any packing without first accounting for all small parts such as guide tubes. If any shortage or damage is discovered or suspected, promptly file a claim with the carrier and notify the nearest

Sales Office.

Gas Connections

Gas is supplied to the welding gun thru the gas hose which must be connected thru a regulator and flowmeter to the shielding gas supply.

Location

The ideal location for this welding equipment is a clean, dry place where the temperature does not exceed 40°C. (104°F.).

Under these conditions, the system can be expected to give excellent performance with a minimum of maintenance.

- 2 -

Wires &

Sizes

Aluminum

Mild &

Stainless

Steel

0.020

0.030

3/64

1/16

0.020

0.030

0.035

Front Guide

Bushing

220A338H04

220A338H04

220A338H06

220A338H05

220A338H04

220A338H04

220A338H04

INSTALLATION

Welding Current Connections

Welding current is supplied from the welder to the welding gun through the gun current cable (21 of Drawing 483A756).

This cable should be connected to the Electrode

(Positive) terminal on the welder.

Also, connect a #2 or larger welding cable from the Work (Negative) terminal to the work ground.

Gun Control Connections

Plug the control cable (14 of Drawing 483A756) into the gun control receptacle on the control, making sure that the plug is fully engaged.

Optional Parts Required for Various Wire Sizes

Depending upon the size of the welding wire used, optional parts for the welding gun may be required.

These parts are listed below with the corresponding welding wire sizes.

Insure that the welding gun is equipped with the correct part.

Rear Guide

Bushing

488A441H02

488A441H02

488A441H01

488A441H01

488A441H02

488A441H02

488A441H02

Drive Roll

419AO09G03

419AO09G03

419AO09G01

419AO09G01

419AO09G03

419AO09G03

Guide Tube

306B172H01

306B172H03

306B172H09

306B172H1O

306B172H01

306B172H03

306B172H04

Nozzle

311B703H03

311B703H03

311B703H02

311B703H02

311B703H03

311B703H03

311B703H02

NOTES: The SP-9 Gun as shipped is equipped for 3/64-inch wire.

The SP-10 Gun as shipped is equipped for 0.030-inch wire.

OPERATION

Safety Precautions

Inert-gas, metal-arc weldinq processes Produce intense ultra-violet radiation which can be harmful to the eyes and skin.

Therefore, certain precautions must be observed to protect the operator from injury.

Eye and face protection should be accomplished with a welding helmet which has a #10 or

#12 shade welding plate.

In addition, the operator should wear #2 shade flash goggles beneath the helmet.

Skin must be completely covered.

Leather gloves are recommended

3

Safety Precautions - Continued for hand protection.

Heavy, dark-colored clothing should be worn to prevent the radiation penetrating to the skin or reflecting onto the neck under the helmet. Light weight leather clothing Is recommended because of its durability and resistance to deterioration from radiation.

Cotton clothing will deteriorate rapidly when subjected to ultra-violet radiation.

Adequate ventilation should be provided to remove fumes which are produced by this welding process.

American Standard Z-49.1 on welding safety covers such ventilation procedures.

Highly toxic gases are formed when the vapors from halogenated solvents are subjected to ultra-violet radiation.

Therefore, It is recommended that degreasers and other sources of these vapors should be located so that the vapors cannot reach the welding operation.

Detailed safety precautions are given In the American Welding Society’s publication

A6.1-55T, “Recommended Safe Practices for Inert-Gas Metal-Arc Welding”.

GuideTube Position

Loosen the thumbscrew (5), and adjust the position of the guide tube until the end of the guide tube is 1/8-inch behind the edge of the nozzle.

When using 0.020 and

0.030-inch wires, the rear end of the guide tube must be back against the front guide tube bushing to prevent the wire from buckling. With the rear end of an .020

or .030 guide tube (in the SP-10 Gun) positioned against the guide bushing, the front end will be just even or slightly in front of the nozzle.

Wire Threading

Unscrew the knurled spool cover bolt, and remove the plastic cover. Pull back the adjustable brake (19), and place the desired spool of welding wire on the spool shaft so that the free end of the wire will pay off from the top of the spool into the rear guide bushing (7).

Loosen the wire pressure screw (12) and open the swing arm (10).

Thread the free end of the wire Into the rear guide bushing, thru the front guide bushing (6), and Into the wire guide tube (4).

Close the swing arm (10) and adjust the pressure screw until there is just sufficient pressure to prevent the wire from slipping.

Excessive pressure will overload the motor and cause erratic welding action.

Too little pressure will allow slippage and cause burn backs . Switcn the welder on and pull the gun trigger (8).

Since welding power still will be on when the trigger is pulled, make sure the electrode does not touch the work ground as an arc will result.

If the wire has been threaded properly and the pressure screw is adjusted for the correct pressure, the wire will feed freely from the guide tube. -

Brake Adjustment

Loosen the two screws support by moving the wire spool to prevent which hold the brake support.

Adjust the position of the brake screw in the slotted hole. Just enough pressure is applied to the the wire from uncoiling.

4

OPERATION

Welding Setup

The following data is intended as a starting point in arriving at the proper adjustment of the system for welding an aluminum joint.

It is important to understand that the final adjustment for a particular joint may vary considerably from this data depending on weld position, fit up material thickness, fillet size, etc.

1.

Set the voltage control on the welder at the applicable voltage setting:

GUN WIRE SIZE VOLTAGE SETTING

SP-9

SP-9

SP-10

3/64 Inch

1/16-Inch

0.030-Inch

23 Volts

28 Volts

20 volts

NOTE : The open circuit voltage is usually about one to two volts higher per 100 amperes of welding current than the arc voltage.

2. Loosen the pressure screw (12) and release the swing arm (10) to move the idler roll out of position.

Taking care not to touch the work piece with wire, squeeze and hold the weld trigger; at the same time, adjust the gas regulator to give the required gas flow.

As a starting point, adjust the gas flow to 35 cubic feet/hr.

An increase or decrease may be required after welding conditions have been established.

Reclose the swing arm and readjust the pressure screw.

3.

Adjust the position of wire so that the free end protrudes 1/2-inch to 3/4-inch beyond the end of the nozzle.

4.

Turn the electrode feed speed control to the maximum setting.

5. With the electrode near the work, but not touching, lower the head shield, squeeze the trigger, and bring the electrode into contact.with the work piece to strike an arc.

6.

Reduce the electrode feed speed control setting until the stubbing ceases and the crackling sound of the arc just disappears.

When the setting of the electrode feed speed control is increased, the weld current is increased.

7.

To stop the weld, release the trigger and draw the welding gun away from the work.

Do NOT whip the gun away from the work without first releasing the trigger to

TO BREAK the arc.

Failure to observe this precaution may result in: a.

Loss of the gas shield before the weld pool freezes, causing porosity.

b. Too much wire will extend from the nozzle at the end of the weld requiring a clipping operation before the next weld.

c.

Extremely high transient voltages can develop which may damage the motor.

5

OPERATION

Welding Techniques

After the operator has found the desired current, voltage, and electrode feed speed settings for a particular application, it is still necessary to observe some elementtary principles of technique.

1.

2.

3.

4.

Nozzle Spacing -

In general, the gas nozzle should be held as close to the work as is practical.

In most cases, a distance of 3/8-inch to 5/8-inch is satisfactory.

Gun Angle -

The best cleaning action is obtained, and excellent porosity-free welds are made by using a forehand technique. For example, a horizontal fillet is best made by the welding gun at an angle of 40° to 50° to the horizontal and using a forehand angle of 20° to 25°.

A right-handed operator would then weld from right to left on a horizontal weld.

Cleanness of Material -

It is essential that aluminum be absolutely clean when it is welded. To ensure porosity-free welds, a cleaning operation should immediately precede the welding operation.

Several organic solvents are now available for this purpose.

Wire Cleanness -

Wire should be clean and free from oxide, grease, and other foreign material. Do not try to use wire that is not clean.

Wire which is not in use should be kept in a container which will protect it from all forms of contamination.

MAINTENANCE

Operating Maintenance -

As the gun is used, a small amount of spatter will collect on the end of the guide tube and on the nozzle.

This spatter can be removed easily with a knife or similar implement.

Periodically, remove the nozzle by pulling it from the nozzle holder and inspect the nozzle and gun barrel for spatter which may have collected inside.

Excessive spatter can cause a short between the nozzle and the guide tube. Such a short will create an arc between the nozzle and the workpiece if accidental contact is made.

If the guide tube becomes bent, replace it with a new guide tube.

If a burn back occurs, do not inch the wire.

Attempts to inch the wire under these circumstances will blow the fuses in the control circuit.

When a burn back occurs, loosen the thumbscrew which secures the guide tube, and inch both the wire and the guide tube out of the gun.

Cut the wire about 1/16” from the rear of the guide tube.

Hold the guide tube perpendicular to a hard, flat surface, and strike the end of the wire against the flat surface.

If this does not free the wire, cut or grind off the melted portion of the guide tube and remove the wire.

The burr caused by cutting should be removed from the guide tube hole with a small drill.

Failure to remove the burr can result in another burn back. Reinstall the guide tube in the gun, ensuring that the end of the guide tube is the correct

6

MAINTENANCE

Operating Maintenance - Continued distance from the nozzle.

The 1/16 to 0.035-inch tubes may be trimmed a maximum of

3/8-inch, and the 0.020 to 0.030-inch tubes may be trimmed a maximum of l/8-inch before discarding.

The gas holes in the gun barrel may become clogged with a residue of white powder which will obstruct the flow of gas.

The gun should be dismantled every 100 hours, and the gas holes blown out with high pressure air.

REPLACEMENT PARTS

Reference should be made to the Renewal Parts List for identification of replacement parts.

7

Renewal Parts Data

RENEWAL PARTS DATA

TYPE SP-10 GUN

STYLE #483B128G02

11

RENEWAL PARTS DATA

26

27

28

29

30

21

22

23

24

25

31

32

33

34

35

11

12

13

14

15

6

7

8

9

10

16

17

18

19

20

THE FOLLOWING PARTS ARE MOST SUBJECT TO WEAR IN

ORDINARY OPERATION:

COMMON PARTS

REF. NO.

DESCRIPTION OR NAME OF PART

1

2

3

4

5

KNOB FOR RHEOSTAT

SHIELD

REEL SHAFT

REEL COVER

REEL COVER BOLT

O RING

RUBBER BUSHING

POT. SHIELD

DUAL POT. ASSY

BRAKE

BRAKE SUPPORT

INSULATOR *

ADAPTER

INSULATING WASHER

INSULATING WASHER

GUN BARREL HOUSING

GUN BARREL INSULATION

GUN BARREL ASSEMBLY

FRONT GUIDE BUSHING 1/16 & 3/64

PIN

PIPE PLUG

SPRING

BALL BEARING

MTG. BRACKET

FITTING ASSEMBLY

FITTING

REAR GUIDE (.035 TO 1/16)

INSULATING WASHER

NYLON SCREW

INSULATED IDLER ROLL

BEARING ARM

SPRING

BEARING ARM BOLT

INSULATED GUIDE TUBE LOCK SCREW

HANDLE ASSEMBLY (INCLUDES BOTH LEFT AND

RIGHT HANDLE HALVES)

IDENTIFICATION NUMBER

451A240H01

867D652G01

448A024H01

637C247H01

419A029H01

576D964H07

363A421H90

483A753H01

483A752H01

419A011H01

419A008H01

222A550H01

419A003H01

419A006H02

419A006H01

453A483H01

419A005H02

419A002G02

2209A70H01

452A107H01

2209A69H01

452A106H01

452A108H01

427C605G08

427C605G04

419A043H01

488A441H01

310B141H04

442A169H01

557D415H39

419A026H02

419A027H01

419A025H01

422A505G01

827D099G03

1

1

1

1

1

1

1

1

1

2

3

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

NUMBER

PER UNIT

1

1

1

1

1

14

RENEWAL PARTS DATA

46

47

48

49

50

41

42

43

44

45

51

52

53

54

55

56

57

58

59

60

36

37

38

39

40

THE FOLLOWING PARTS ARE MOST SUBJECT TO WEAR IN

ORDINARY OPERATION.

COMMON PARTS

REF. NO.

DESCRIPTION OR NAME OF PART

NUMBER

IDENTIFICATION NUMBER PER UNIT

SWITCH TRIGGER

SPRING FLAT

SPRING

TRIGGER ASSEMBLY

CAPACITOR

301B663H05

205A091H01

453A464H01

451A241G01

422A518H04

1

1

1

1

1

KNIFE DISCONNECT

SWITCH

GAS HOSE ASSEMBLY

CURRENT CABLE ASSEMBLY

POWER SUPPLY CABLE ASSEMBLY

PLUG

BOOT

RETAINING RING *

BUSHING, CORD PROTECTOR

COPPER STRAP *

INSULATION

TUBING

TUBING

PLUG BUTTON *

PLUG BUTTON *

INSULATION

NOZZLE

GUIDE TUBE

DRIVE ROLL

MOTOR

429C550H10

301B663H09

1474B90G01

1474B91G01

1112C77G07

483A890H01

419A046H01

52D9290H01

2214A61H01

576D964H64

419A010H02

422A484H01

422A484H02

451A237H02

451A237H03

453A434H01

311B703H02

306B172H09

419A009G01

429C550G05

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

2

2

1

1

WIRING DIAGRAM

* NOT SHOWN

655C951

15

DESCRIPTION INSTALLATION OPERATION MAINTENANCE

Instruction Book

16

TYPE CCD-4 CONTROL

The CCD-4 Control is designed for consumable electrode inert-gas shielding welding with the SP-9 or SI?-10 gun.

It incorporates a well-balanced hand-gun and a control with a built in contactor. The system is designed for semi-automatic welding of aluminum with aluminum wire sizes from .030 to 1/16 inch diameters , and for steel wire siz’es of

.030 to 3/64 inch diameters.

DESCRIPTION

The Control as shown on Outline Drawing 2214A57 is lightweight, properly insulated, and compact. (Numbers in parentheses indicate item numbers on referenced drawings.)

The_Control operates from a 115 volt A.C.

or D.C. power supply required for tile operation of the co~trol and inching circuits.

The power for the gear-head drive motor during the welding operation is supplied by the welding machine.

The motor armature is said to be across the arc , This is accomplished by attaching the terminal of the ground cord (4) to the negative lug of the welder and the terminal of’ the current cable (12) to the positive lug of the welder.

The control cable for the welding gun is coxmected to the Gun Control Receptacle (1) and the welding current cable of the gun inserts into the Receptacle (5).

A rheostat in the welding gun is adjusted to control the wire feed speed and the arc length.

The rheostat setting will vary with the t-ype of shielding gas used and with different welding machines, and is primarily dependent on the current setting of the welder. The fact that the wire feed drive opera,tes from the arc voltage is important, because it insures good steady feeding consistent with constant arc length.

It is based on the following principle of operation: If the arc length increases, the voltage across the arc becomes higher and increases the motor speed, thereby feeding more wire and shortening the arc length.

shortens,

If the arc length the voltage across it is lower and the motor speed decreases, thereby i~creasing the arc l-ength.

approximately a 6 to 1 speed range.

The rheostat type control works through

An On-Off switch (2) energizes the control monitor while replaceable fuzes (6) protect the line.

The power supply cord (3) is a 16 foot cable terminated in a three-prong plug with a three to two wire plug adapter.

A replaceable fuze (7) in series with the wire drive motor protects the armature from damage due to high current.

should not be replaced with a larger fUZe.

This is a one ampere fUZe and

The line fUZeS (6) shoul.dbe 2 atnperefuzes.

The Control Monitor has a current relay which permits touch starts. The normal minimum current required to operate the relay is approximately 45 amperes. A 200 amp D.C.

contactor (9) is mounted in the control enclosure and is controlled from the control panel (8).

1 7

INSTALLATION

Receivinq

Immediately upon receipt of the equipment, make a careful examination for evidence of damage encountered in transit.

If any damage is found or suspected, file a claim promptly with the transportation company and notify the nearest sales office.

Do not discard any packing materiel without first checking it for small accessory items.

Location

The control should be installed so that all parts of the workpiece to be welded can be reached with a minimum of effort.

Approximately 50 feet of cable and hose. are normally supplied with the gun. The control unit should be located so no sharp kinks or bends are made in the gas hose. Care should be taken to avoid dragging the cable or hose over hot work or sharp projections.

The distance from the welding machine to the control is not critical and is limited only if the voltage drop due to the length and size of the cable prevents stable welding conditions.

The 115 volt suppuly cable maybe extended as required, within reasonable limits.

It is usually best if the control is placed as close to the workpiece as is practical, therefore making it easy for the operator to make adjustments or reenergize the equipment as required.

Connections

1 .

Attach the Regulator and Flowmeter to a cylinder of pure argon by threading nut on regulator-flowmeter to matching threads on cylinder.

Tighten the nut to prevent gas leaks.

The gas cylinder is not part of.

welding set.

2.

Attach nut on gas hose from welding gun to the matching threads on the outlet side of regulator-flowmeter and tighten to prevent gas leakage.

3.

As shipped, the SP-9 or SP-10 welding gun has a terminal on the end of the welding cable.

Remove this terminal and add the camlock plug ineluded with the CCD-4 Control. Insert the plug into the matching receptacle on the control. ‘this plug is keyed and must be rotated to the proper position before inserting.

After inserting plug, turn plug 1/4 turn clockwise to lock in place.

4

0

Insert plug on end of control cable from welding gun in matching receptacle on the control monitor.

This plug is also keyed and must be rotated to the proper position before inserting.

After the plug is lined up properly with receptacle, gently work plug into socket and tighten retaining ring.

18

5* Attach current cable from control monitor to the positive (+) output

~ermina,l of the welding power SUpply.

This cable includes a large terminal for connection to the positive (+) output terminal. Since this weliiing set may be used tith various types of welding power supplies, some adaptation to make this connection may be required. HOW ever, a tight connection is required.

include a polarity stitch,

On welding power supplies which this cable should be attached to the terminal marked electrode and the polarity switch should be placed in the Reverse Polarity position.

Be certain that any high voltage or high frequency arc starters are kept deactivated.

6.

Attach one end of a ground cable and the ground cord from the control monitor to the negative terminal of the welding power supply.

must be a ti&t connection.

This

On welding power supplies with a polarity switch, these leads are connected to the Work terminal.

should be tight amd electrically conducting.

Connections

7* Connect the other end of the ground cable to the workpiece or material to be welded.

This must be a tight connection with good electrical conductiv~ty.

8, Connect the line cord to a 110 to 125 volt AC or DC supply. This cord is equipped with a standard 3-prong plug.

supply, an adapter is provided.

For connection to a 2-prong

Where used, the screw on the side of the adapter should be conneeted to the frame of the welding machine with a short piece of wire.

OPERATION

Welding

1.

Adjust the current control on the welder to the required output current.

2* To adjust the gas flow, first turn on the gas supply by turning on the main valve at the top of the gas cylinder.

Being careful not to touch the wire to the workpiece, pull the weld trigger and hold; at the same time adjust the gas regulator by turning the flow adjustment to the required gas flow. As a starting point adjust the flow to 35 cubic feet/ hour.

This is indicated when the top of the ball in the flow reaches the calibration marked 35.

An increase or decrease may be required after welding conditions are established.

3* Adjust the position of the wire to protrude 1/2 to 3/4 of an inch beyond the end of the nozzle by pressing the inch button.

4. Turn the rheostat knob (16) on the welding gun to maximum.

1 9

Welding+ (cent)

5.

With the wire near the work, but not touching, lower the head shield, pull the veld trigger and bring the wire into contact with the workpiece. M arc will form and the wire will begin to feed.

6.

With the wire feed speed knob on the control monitor adjusted near maximum as described in paragraph 4, the arc will probably be too short and the wire will stub, causing considerable spatter.

Decrease the setting of the wire feed control until the proper arc length is accomplished.

This is usually the point where the crackling sound of the arc just disappears.

With this welding control system, the dial setting affects axc length by changing electrode wire feed speed at a given welding power supply current setting.

Increasing the setting of the dial will. shorten the arc.

7* To stop the weld, release the trigger.

Do not whip the gun aw ay from the work before releasing the trigger to break the arc as this will cause excessive wire stick-out.

High Frequency Precautions

The control monitor should never be connected to a welder at the same time the welder is being used on high frequency as the motor will burn-out instantly.

Neither the ground clamp nor the electrode lead should ever connect to a welder which is supplying welding current and high frequency to a tungsten arc torch or any other prccess requiring high frequency.

SAFETY PRECAUTIONS

Inert-gas metal-arc welding processes produce intense visible and ultraviolet radiation smd require certain precautions to protect the operator from injury.

For eye protection, welding helmets should have a #10 or #12 shade welding plate.

In addition, the operator should wear #2 shade flash goggles with wide side shields under the helmet.

The skin should be completely covered.

Leather gloves are recommended for hand protection. Heavy, dark-colored clothing should be worn to prevent radiation from penetrating to the skin or from reflecting onto the neck under the hood.

Lightweight leather protective clothing is also recommended because of its durability and resistance to deterioration from the radiation and sparks. It shouldbe noted that cotton clothing is subject to rather rapid deterioration.

Adequate ventilation should be provided to remove fumes produced by the process, as set forth in American Standard Z-49.1 on safety in welding.

Inas much as vapors from halogenated solvents such as trichloroethylene are decompose3by ultra-violet light to form highly toxic gases, it is recommended that degreasers or other sources of such vapors be so located that the vapors will not reach the welding operation.

2 0

Safety Precautions (cont)

Detailed safety practices are given in the publication A6.1-55T on

“Recommended Safe Practices for Inert-Gas Metal-Arc Welding”, published by the American Welding Society.

2 1

Renewal Parts Data

Type CCD-4 Control

Style 483B126G05

Renewal Parts

25

26

28

RENEWAL PARTS

21

22

23

24

25

16

17

18

19

20

11

12

13

14

15

6

7

8

9

10

26

27

28

29

COMMON PARTS

REF. NO.

DESCRIPTION OR NAME OF PART

1

2

3

4

5

ON-OFF SWITCH

NAMEPLATE

HANDLE

GUN CONTROL RECEPTACLE

FUSES (2 AMP)

FUSE (1 AMP)

RECEPTACLE

CABLE ASSY (GROUND)

CABLE ASSY

CABLE ASSY (CURRENT)

TERMINAL BOARD

RESISTOR (5R) 10 OHM, 25W

RESISTOR (1R) 100 OHM, 100W

RESISTOR (2R) 25 OHM, 25W

RESISTOR (4R) 1K, 20W

CONTACTOR

STRAIN RELIEF

STRAIN RELIEF

STRAIN RELIEF

RELAY (2CR) 3PDT

CAPACITOR (3C, 4C) .047 MFD

RELAY (3CR)

CAPACITOR (2C)

RECTIFIER ASSY (1RX)

CAPACITOR MOUNTING CLAMP

CAPACITOR (5C) 4 MFD

RESISTOR (3R)

RELAY (4CR) DPDT

FUSE HOLDERS

SCHEMATIC DIAGRAM

WIRING DIAGRAM

IDENTIFICATION NUMBER

429A051H02

228P758H01

1129648

483A891H01

363A018H16

363A018H15

419A012H01

432C524G12

2222A01G01

1474B91G02

32B1029H15

363A014H46

422A473H02

422A473H06

363A114H88

2224A77H01

582D430H06

576D916H73

427C613H04

480B096H27

363A104H86

320B224G01

2224A78H01

2224A79H01

474A830H01

2224A78H02

474A023H01

480B096H26

2218A11H01

720B096

221C688

2

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

NUMBER

PER UNIT

1

1

1

1

2

29

30

31

3 2

33 (34 blank)

By Order of the Secretary of the Army:

Official:

B. G. JOYCE

Brigadier General, United States Army

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with Special List.

E. C. MEYER

General. United States Army

Chief of Staff

* U.S. GOVERNMENT PRINTING OFFICE: 1995 -388-421/00349

THE METRIC SYSTEM AND EQUIVALENTS

P I N : N 0 4 9 3 3 2 - 0 0 1 2 - 0 0 0

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