Milweld | Auto Arc XLT 165, XLT 135 | Specifications | Milweld Auto Arc XLT 165, XLT 135 Specifications

OM-218 696B
September 2004
Processes
Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder
Auto Arc XLT 222
And M-10 Gun
R
Includes Installation Instructions For
Optional Spoolmate Spoolgun Switch
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Welding Power Source Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Welding Gun Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing Work Clamp Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Changing Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Installing Optional Spoolmate Spoolgun Switch In Welding Power Source . . . . . . . . . . . . . . . . . . . . . .
3-15. Connecting Spoolgun To Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Replacing Drive Roll And Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Removing Knob From Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Welding Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Wire Drive/Gun Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 6 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17. Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y 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 Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-218 696 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-218 696 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y 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.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-218 696 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-218 696 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-218 696 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-218 696 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
D
D
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-218 696 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-218 696 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − INTRODUCTION
3-1. Specifications
Amps Input at Rated Output, 60 Hz, Single-Phase
Rated Output
Max. Open
Circuit
Voltage
200 V
230 V
KVA
KW
150 A at 23 VDC,
40% Duty Cycle
33
29
2.3*
25
2*
5.8
0.4*
4.9
0.1*
No Load Wire Feed
Speed
Wire Type and Diameter
Solid Steel/
Stainless Steel
Aluminum
Flux Cored
.023 − .045 in
(0.6 − 1.2 mm)
.030 − .035 in
(0.8 − 0.9 mm)
.030 − .045 in
(0.8 − 1.2 mm)
90−750 IPM
(2.3−19 m/min)
Dimensions
Weight
H: 31-1/4 in (794
mm)
W: 18
18-7/8
7/8 in (479
mm)
D: 36-1/2 in (927
mm)
146 lb
(66 kg)
* While idling
3-2. Welding Power Source Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
40%dutycycle
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − 199 211
OM-218 696 Page 9
3-3. Welding Gun Duty Cycle And Overheating
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.
•
•
Do not weld at rated load longer than shown below.
Using gasless flux cored wire reduces gun duty cycle.
Definition
warn7.1 8/93
.023 To .045 in (0.6 To 1.1 mm)
Hard Or Flux Cored Wires
0
.023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires
60% Duty Cycle At 100 Amperes
Using Mixed Gases
100% Duty Cycle At 100 Amperes
Using CO2
10
Minutes
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
Continuous Welding
6 Minutes Welding
4 Minutes Resting
SB1.1 8/93
3-4. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
35
DC VOLTS
30
25
20
15
10
5
0
0
50
100
150
200
250
DC AMPERES
va_curve1 4/95 − 199 212
OM-218 696 Page 10
3-5. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Loosen knob. Insert gun end
through opening until it bottoms
against drive assembly. Tighten
knob.
4
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
1
3
4
2
Ref. 802 601-A
3-6. Installing Work Clamp Cable
1
Work Cable
Route cable through opening in
front panel.
2
2
Negative (−/Black) Output
Terminal
Connect cable to terminal.
Close door.
1
Tools Needed:
3/4 in
Ref. 802 601-A / Ref. 801 566-B
OM-218 696 Page 11
3-7. Setting Gun Polarity For Wire Type
1
2
3
Polarity Changeover Label
Positive (+/Red) Output
Terminal
Negative (−/Black) Output
Terminal
Always read and follow wire
manufacturer’s
recommended
polarity.
Close door.
1
Ref. ST-192 432
2
3
Tools Needed:
3/4 in
OM-218 696 Page 12
Ref. 802 601-A
3-8. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
. DO
NOT use Argon/Mixed gas
regulator/flowmeter with CO2
shielding gas. See Parts List for
optional CO2 gas regulator/flowmeter.
1
Cap
2
Cylinder Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
1
4
2
Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
7
3
5
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s
recommended
flow rate.
7
Argon Gas Or
Mixed Gas
6
Rear Panel
Tools Needed:
1-1/8, 5/8 in
Ref. 220 747-A / 802 028-A / Ref. 802 286-E
OM-218 696 Page 13
3-9. Installing Wire Spool And Adjusting Hub Tension
Use compression spring
with 8 in (200 mm) spools.
When a slight force is needed
to turn spool, tension is set.
Installing 1 Or 2 lb Wire Spool
Spindle
Spindle
Install these
components
onto spindle.
To install either a 1 lb or 2 lb wire
spool, follow the procedure as
shown in the illustration.
Order extra spring
Part No. 186 437
Remove these
components
from spindle.
Tools Needed:
15/16 in
072573-B / 802 922
3-10. Changing Input Voltage
Y Turn Off unit, and disconnect
input power.
Unit was shipped from factory set
for 230 volts.
2
1
2
3
3
Transformer T1
Rear Of Power Switch S1
Lead Marked 230 Volt And
Fan Motor Lead
Disconnect 230 volt lead and fan
motor lead from rear of S1. Leave
fan motor lead connected to 230
volt lead.
1
4
Lead Marked 200 Volt
Remove cable tie, and slide short
piece of sleeving off 200 volt lead,
and slide sleeving over end of 230
volt and fan motor leads. Fold
sleeving over and secure in place.
Connect 200 volt lead to S1 where
230 volt lead was removed.
Reinstall wrapper.
4
Tools Needed:
3/8, 7/16 in
OM-218 696 Page 14
801 580-A
3-11. Electrical Service Guide
Input Voltage
200
230
Input Amperes At Rated Output
29
25
Circuit Breaker 1, Time-Delay 2
35
30
Normal Operating 3
45
35
12
12
60
(18)
79
(24)
12
12
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
3-12. Selecting A Location And Connecting Input Power
1
Rating Label
Supply correct input power.
2
3
Y Do not move or operate
unit where it could tip.
Plug
Receptacle
Connect plug to receptacle.
18 in (457 mm) of
space for airflow
4
Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5
Line Disconnect Device
See Section 3-11.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Y Always connect grounding
conductor first.
= GND/PE
5
L1
L2
1
2
4
3
L1
L2
230 VAC, 1
Ref. 802 286-E
OM-218 696 Page 15
3-13. Threading Welding Wire
1
2
3
4
5
6
7
4
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
7
Tools Needed:
1
2
3
5
Ref. 802 601-A
6
. Hold wire tightly to keep it
from unraveling.
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator
Tighten
scale to set a desired
drive roll pressure.
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
4 in
(102 mm)
Pressure
Indicator
Scale
Remove gun nozzle and contact tip.
Turn On.
Tighten
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
OM-218 696 Page 16
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
1
2
3
4
Cut off wire.
Close door.
3-14. Installing Optional Spoolmate Spoolgun Switch In Welding Power Source
Y Turn Off unit, and disconnect
input power.
1
2
2
3
1
Welding Power Source Center
Baffle
Switch Location
Switch Mounting Plate
Remove 2 screws securing switch
mounting plate to center baffle. Pull
switch mounting plate to pull wiring
harness through center baffle hole.
4
Plastic Plug
Remove and discard plastic plug
from center hole in switch mounting
plate panel.
5
Nylon Cable Tie
Cut and discard nylon cable tie.
6
7
Jumper Plug
Wiring Harness Switch Plug
Remove jumper plug from wiring
harness switch plug. Retain jumper
plug by placing looped lead over
unit wiring harness.
8
3
Switch Plug
Connect switch plug to wiring harness switch plug.
9
Jam Nut
Remove top jam nut from switch
(switch is equipped with two nuts, a
jam nut and a backing nut).
8
Insert switch shaft through switch
mounting plate. Switch should be
positioned so lead with resistor is
facing down.
5
3
Secure switch to plate with jam nut.
Tighten jam nut enough to keep
switch from rotating.
4
Operation:
9
7
Push wiring harness back through
hole, and reinstall switch mounting
plate to center baffle.
Tools Needed:
1/4 in
9/16 in
6
Place switch in On position for
spoolgun operation. Place switch in
Off position for wire feeder/MIG
(GMAW) gun operation.
When spoolgun switch is in On
position, spoolgun wire feed speed
is controlled by welding power
source Wire Speed control.
802 936-A
OM-218 696 Page 17
3-15. Connecting Spoolgun To Welding Power Source
5
2
3
5
4
7
1
6
6
Tools Needed:
8
Ref. 802 582-A
3/4 in
Y Turn Off unit.
negative (−) output terminal.
Disconnect and remove MIG (GMAW)
welding gun, if applicable.
5
Existing Gas Hose
1
Front Panel Opening
6
Spoolgun Gas Hose
2
Spoolgun Weld Cable
7
Gas Diverter Valve
Route weld cable through front panel opening.
3
Positive (+) Output Terminal
Connect spoolgun weld cable to positive
(+) output terminal.
4
Work Clamp Lead
Work clamp lead should be connected to
OM-218 696 Page 18
To install diverter valve, cut existing gas
hose above barbed fitting at wire drive
housing.
Install supplied hose clamp onto end of
hose at wire drive housing, and insert either
of the two output barbed ends of diverter
valve into hose. Secure with hose clamp.
Install another supplied hose clamp onto
end of hose from gas supply, and insert in-
put barbed end of diverter valve into hose.
Secure with hose clamp.
Slide hose clamp down gas hose from gun,
and cut barbed fitting off hose. Route gas
hose through front panel opening, and
insert remaining output barbed end of
diverter valve into hose. Secure with hose
clamp.
8
Trigger Control Plug
Insert plug into receptacle, and tighten
threaded collar.
Close welding power source door.
SECTION 4 − OPERATION
4-1. Controls
1
Wire Speed Control
The scale around the control is percent, not wire feed speed.
2
Voltage Control
The higher the selected number,
the thicker the material that can be
welded (see welding guide and
Section 4-2).
3
Power Switch
1
2
3
Ref. 199 206
OM-218 696 Page 19
4-2. Weld Parameters
Selecting Wire, Gas and Control Settings*
What Material are
You Welding?
Suggested
Wire Types
Suggested Shielding Wire Sizes
Gases and Flow Rate (Diameter)
Steel
Solid (or hard)
ER70S−6
100% CO2, 20 cfh
.023” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
75% Ar/25% CO2, 20
cfh (Ar/CO2 produces
less spatter−better
overall appearance)
.023” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
Steel − for outdoor,
windy applications or
when weld appearance
is not critical.
Flux core
E71T−GS
No shielding gas required
.030” (0.8 mm)
.035” (0.9 mm)
.045” (1.1 mm)
Stainless steel
Stainless steel
ER 308
Tri−Mix, 20 cfh
(90% He/7.5%
Ar/2.5% CO2)
.023” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
Aluminum with
Optional Spoolmatet
185 or Spoolmatet
3035 spoolgun
Aluminum
4043 AL
100% Ar, 20 cfh
.030” (0.8 mm)
.035” (0.9 mm)
Aluminum
5356 AL
100% Ar, 20 cfh
.030” (0.8 mm)
.035” (0.9 mm)
*Do not change Voltage switch position while welding. Wire Speed is a starting value only, and can be adjusted while welding.
Weld conditions also depend on other variables such as stickout, travel speed, weld angle, cleanliness of metal, etc.
Input Line
Voltage
OM-218 696 Page 20
Parameter
Chart Settings
Higher
e.g. 240
Volts AC
Weld Will Be
Hotter
Lower Settings
230 Volts AC
Use Parameter
Chart Inside
Door
Lower
e.g. 218
Volts AC
Weld Will Be
Colder
Raise Settings
Select Voltage and Wire
Speed Based on Thickness
of Metal Being Welded
Example: 2 / 4 0 =
To read settings:
Number on left of slash
is voltage, number on
right of slash is wire
speed. “—“ Means not
recommended.
20 ga.
22 ga.
16 ga.
18 ga.
1/8”
14 ga.
1/4”
3/16”
3/8”
(9.5 mm) (6.4 mm) (4.8 mm) (3.2 mm) (2.0 mm) (1.6 mm) (1.2 mm) (0.9 mm) (0.8 mm)
—
5/58
5/52
—
4/48
4/34
4/74
4/44
4/34
3/46
3/34
3/20
3/46
3/32
3/18
2/18
2/14
2/12
2/18
2/12
2/12
2/18
2/10
—
2/16
—
—
5/100
5/72
5/60
5/100
4/62
4/52
4/80
4/62
4/50
4/80
3/42
3/40
3/68
3/40
3/36
2/36
2/24
2/20
2/36
2/24
2/16
1/16
1/16
2/14
1/16
1/16
—
5/66
5/44
5/30
4/52
4/36
5/30
3/46
3/20
4/20
2/20
2/10
3/10
2/14
2/4
—
1/12
1/0
—
1/12
—
—
—
—
—
6/90
6/76
6/70
5/86
5/68
5/66
5/82
5/64
5/66
4/70
4/56
4/40
3/50
3/46
3/32
3/46
3/46
3/28
—
—
6/78
6/72
5/72
5/66
4/68
4/60
2/68
2/58
1/56
—
—
—
—
—
—
—
—
—
6/100
6/84
5/88
5/84
4/88
4/84
2/80
2/70
1/70
—
—
—
—
—
—
—
—
—
—
3/42
3/40
2/24
—
—
—
3/42
2/32
—
Ref. 199 208
OM-218 696 Page 21
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace unreadable labels.
Repair or replace
cracked weld cable.
Clean and tighten weld terminals.
6 Months
Blow out or vacuum inside. During
heavy service, clean monthly.
OR
Remove drive roll
and apply light coat
of oil or grease to
drive motor shaft.
5-2. Circuit Breakers
Y Turn Off unit.
1
2
1
Circuit Breaker CB1
CB1 protects main circuit board PC1
if drive motor shorts or fails. If CB1
opens, wire feeding stops. Check for
gun liner blockage or kinks, and check
for jammed wire, or binding drive rolls.
2
Circuit Breaker CB2
CB2 protects the trigger circuit from
overload. If CB2 opens, weld output
stops. Check gun switch, and trigger
leads.
Correct problem. Press button to reset
circuit breaker. Close door.
Ref. 802 601-A
OM-218 696 Page 22
5-3. Replacing Drive Roll And Wire Inlet Guide
1
2
Inlet Wire Guide Securing
Screw
Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
3
Drive Roll
Install correct drive roll for wire size
and type.
4
2
Drive Roll Securing Screw
Secure drive roll with screw as
shown.
3
4
1
Tools Needed:
Ref. 802 601-A
5-4. Removing Knob From Front Panel
Y Turn Off power.
1
2
3
4
3
Front Panel
Knob
Slot
Control Shaft
Rotate knob to allow access to slot.
Insert tip of screwdriver into slot,
and while pushing on spring clip,
pull knob off control shaft.
To reinstall, push knob fully onto
control shaft.
4
2
1
Ref. 803 346 / 802 280-E
OM-218 696 Page 23
5-5. Replacing Gun Contact Tip
Y Turn Off power before
replacing contact tip.
1
2
Nozzle
Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
2
1
Tools Needed:
Ref. 802 399-A
OM-218 696 Page 24
5-6. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit.
3/8 in
Head Tube
Remove nozzle, contact tip,
adapter, gas diffuser, and wire
outlet guide.
1/2 in
Remove liner.
Lay gun cable out straight
before installing new liner.
To Reassemble Gun:
Install and tighten new liner.
Blow out gun casing.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
Ref. 802 399-A
OM-218 696 Page 25
5-7. Replacing Switch And/Or Head Tube
Y Disconnect gun first.
1
Remove handle
locking nut.
3
2
4
Slide handle.
Remove switch housing. Note: If installing new
switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.
Secure head
tube in vice.
5
6
Loosen jam nut. Remove
from vice and turn head
tube out by hand.
Install existing shock washer onto
new head tube. Hand-tighten head
tube into connector cable.
8
7
Place head tube in vice and tighten
until nuts are tight.
Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
Tools Needed:
3/4 in
Ref. 800 795-C
OM-218 696 Page 26
5-8. Welding Troubleshooting Table
Welding Trouble
No weld output; wire does not feed.
Remedy
Secure power cord plug in receptacle (see Section 3-12).
Check and replace power switch if necessary.
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 5-2).
Replace building line fuse or reset circuit breaker if open (see Section 3-12).
Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Sections 3-5 and/or
Parts List).
Thermostat open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (see
Section 3-2).
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 5-5).
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 3-12).
Low, high, or erratic wire speed.
Readjust front panel settings (see Section 4-1).
Change to correct size drive roll (see Section 5-3).
Readjust drive roll pressure (see Section 3-13).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-3, 5-5 and/or 5-6).
5-9. Wire Drive/Gun Troubleshooting Table
Wire Drive/Gun Trouble
Remedy
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section 5-6).
welding.
Adjust drive roll pressure (see Section 3-13).
Readjust hub tension (see Section 3-9).
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 5-2).
Replace contact tip if blocked (see Section 5-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Sections 5-3 and/or 5-6).
Replace drive roll if worn or slipping (see Section 5-3).
Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 3-5 and/or
see Parts List).
Check and clear any restrictions at drive assembly and liner (see Section 5-6).
Have nearest Factory Authorized Service Agent check drive motor.
OM-218 696 Page 27
SECTION 6 − MIG WELDING (GMAW) GUIDELINES
6-1. Typical MIG Process Connections
Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Shielding
Gas
Supply
Gas
Hose
Wire Feeder/
Power Source
Gun
Work Clamp
Workpiece
light mig 5/967 / Ref. 802 601-A
OM-218 696 Page 28
6-2.
Typical MIG Process Control Settings
NOTE
These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
Material thickness determines weld
parameters.
1/8 or 0.125 in
Convert Material
Thickness to
Amperage (A)
(0.001 in = 1 ampere)
0.125 in = 125 A
.035 in
Wire
Size
Wire Size
Amperage Range
0.023 in
30 − 90 A
0.030 in
40 − 145 A
0.035 in
50 − 180 A
Recommendation
Wire Speed
(Approx.)
Select Wire Size
Select Wire Speed
(Amperage)
0.023 in
3.5 in per ampere
3.5 x 125 A = 437 ipm
0.030 in
2 in per ampere
2 x 125 A = 250 ipm
0.035 in
1.6 in per ampere
1.6 x 125 A = 200 ipm
125 A based on 1/8 in
material thickness
ipm = inches per minute
Low voltage: wire stubs into work
Select Voltage
High voltage: arc is unstable (spatter)
Set voltage midway between high/low voltage
Wire speed (amperage)
controls weld penetration
(wire speed = burn-off rate)
Voltage controls height and
width of weld bead.
802 600-C
OM-218 696 Page 29
6-3.
Holding And Positioning Welding Gun
NOTE
Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
1
1
3
2
2
3
4
5
5
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
1/4 to 1/2 in (6 To 13 mm)
Cradle Gun and Rest Hand on
Workpiece
4
0°-15°
90°
90°
End View of Work Angle
Side View of Gun Angle
GROOVE WELDS
0°-15°
45°
45°
End View of Work Angle
Side View of Gun Angle
FILLET WELDS
OM-218 696 Page 30
S-0421-A
6-4.
Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
10°
Push
10°
Drag
Perpendicular
GUN ANGLES AND WELD BEAD PROFILES
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTODE EXTENSIONS (STICKOUT)
Slow
Normal
GUN TRAVEL SPEED
Fast
S-0634
OM-218 696 Page 31
6-5.
Gun Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
1
1
2
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
3
S-0054-A
6-6.
Poor Weld Bead Characteristics
1
2
3
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
5
S-0053-A
6-7.
Good Weld Bead Characteristics
1
2
3
1
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4
5
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-218 696 Page 32
6-8.
Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
6-9.
Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
6-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Excessive heat input.
S-0639
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-218 696 Page 33
6-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
6-12. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
6-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-218 696 Page 34
6-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
6-15. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Excessive heat input.
S-0642
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-218 696 Page 35
6-16. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas
Spray Arc Steel
Short Circuiting Steel
Short Circuiting
Stainless Steel
Aluminum
X
Argon
X
Argon + 25% CO2
80% or greater Argon +
balance CO2 or Oxygen
X
X1
X
100% CO2
Tri-Mix2
X
1
Limited short circuiting use
2
90% HE + 7-1/2% AR + 2-1/2% CO2
6-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Probable Cause
Wire feed motor operates, but Too little pressure on wire feed rolls.
wire does not feed
feed.
Incorrect wire feed rolls.
Wire curling up in front of the
wire feed rolls (bird nesting)
nesting).
Wire feeds, but no gas flows.
Remedy
Increase pressure setting on wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high.
Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly.
Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Too much pressure on wire feed rolls.
Decrease pressure setting on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner.
Replace liner.
Gas cylinder empty.
Replace empty gas cylinder.
Gas nozzle plugged.
Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted.
Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid.
Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source.
for correct voltage.
OM-218 696 Page 36
Problem
Probable Cause
Remedy
Welding arc not stable.
Wire slipping in drive rolls.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-218 696 Page 37
Notes
OM-218 696 Page 38
SECTION 7 − ELECTRICAL DIAGRAM
204 205
Figure 7-1. Circuit Diagram For Welding Power Source
OM-218 696 Page 39
SECTION 8 − PARTS LIST
. Hardware is common and
13
18
21
22 − Fig 8-5
1
20
2
3
19
4
17 − Fig 8-4
5
6
23
7
24
16
9 − Fig 8-2
12
14
15
8
10 − Fig 8-3
11
not available unless listed.
802 602-C
Figure 8-1. Main Assembly
OM-218 696 Page 40
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . . . . . . 203 481
. . . 2 . . . . . . . . . . 151 187
. . . 3 . . . . . . . . . . 134 464
. . . 4 . . . . . . . . . +205 868
. . . 5 . . . . . . . . . . 205 867
. . . 6 . . . . T1 . . 202 077
. . . 7 . . . . Z . . . 199 220
. . . . . . . . . TP2 . . 213 414
. . . 8 . . . SR1 . . 199 188
. . . . . . . . . TP1 . . 604 515
. . . 9 . . . . . . . . . . . Fig 8-2
. . . 10 . . . . . . . . . . . Fig 8-3
. . . 11 . . PLG1 . 199 192
. . . 12 . . . . . . . . . . 146 161
. . . 13 . . . . . . . . . . 135 390
. . . 14 . . . . . . . . . . 186 758
. . . 15 . . . . . . . . . . 121 614
. . . 16 . . . . . . . . . . 209 870
. . . 17 . . . . . . . . . . . Fig 8-4
. . . 18 . . . . . . . . . . 196 328
. . . 19 . . . . . . . . . . 196 318
. . . 20 . . . . . . . . . . 146 149
. . . 21 . . . . . . . . . . 130 750
. . . 22 . . . . . . . . . . 195 605
. . . 23 . . . . . . . . . . 199 187
. . . 24 . . . . . . . . . . 022 160
. . . . . . . . . . . . . . . . 220 747
. . . . . . . . . . . . . . . . 183 581
. . . . . . . . . . . . . . ♦212 492
. . PANEL, side lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LATCH, side flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 200/230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC, open 211F, close 186F . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CENTER BAFFLE w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD SET, 250V 6-50p 12ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CASTER, swvl 4.00 in X 1.250 in poly−olefin . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, work 10’ no. 3 w/clamp & boot (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CABLE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP, work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUN, M-10 (8-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 120000uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR/FLOWMETER, 10−50 CFH ARGON/CO2 . . . . . . . . . . . . . . . . .
. . HOSE, gas 5 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR/FLOWMETER, 10-50 CFH CO2 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦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.
OM-218 696 Page 41
10
. Hardware is common and
31
19
23
24
25
22
26
21
20
27
28
1
2
3
4
5
6
29
7
17
8
16
15
9
30
14
13
12
11
not available unless listed.
802 603-B
Figure 8-2. Center Baffle w/Components
OM-218 696 Page 42
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9)
. . . 1 . . . . . . . . . . . . . 058 427
. . . 2 . . . . . . . . . . . . . 085 980
. . . 3 . . . . . . . . . . . . . 605 941
. . . 4 . . . . . . . . . . . . . 186 437
. . . 5 . . . . . . . . . . . . . 057 971
. . . 6 . . . . . . . . . . . . . 057 745
. . . 7 . . . . . . . . . . . . . 186 435
. . . 8 . . . . . . . . . . . . . 186 436
. . . 9 . . . . . . . . . . . . . 197 521
. . . . . . . . . . . . . . . . . . . . 198425
. . . . . . . . . . . . . . . . . . . . 198426
. . . 10 . . . . . R2 . . . . 091 685
. . . 11 . . . . . W . . . . 189 486
. . . . . . . . . . . . . . . . . . . 034 260
. . . 12 . . . . CR1 . . . 072 817
. . . 13 . . . . CB2 . . . 180 912
. . . 14 . . . . CB1 . . . 183 492
. . . 15 . . . . . . . . . . . . . 039 047
. . . 16 . . . . . . . . . . . . . 039 046
. . . 17 . . . . C7-10 . . 136 735
. . . 19 . . . . . . . . . . . . . 199 191
. . . 20 . . . . . . . . . . . . . 199 215
. . . 21 . . . . . . . . . . . . . 203 081
. . . 22 . . . . . . . . . . . . . 079 633
. . . 23 . . . . . . . . . . . . . 126 652
. . . 24 . . . . . . . . . . . . . 193 681
. . . 25 . . . . . . . . . . . . . 184 735
. . . 26 . . . . . . . . . . . . . 184 741
. . . 27 . . . . . . . . . . . . . 197 309
. . . 28 . . . . . . . . . . . . . 202 925
. . . 28 . . . . . . . . ♦407 230-004
. . . 28 . . . . . . . . . . . . ♦193 330
. . . 28 . . . . . . . . . . . . ♦193 331
. . . 29 . . . . . . . . . . . . . 134 201
. . . 30 . . . . PC1 . . . 171 986
. . . . . . . . . . . . . . . . . . . 165 745
. . . 31 . . . . . . . . . . . . . 184 965
. . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 625-11 .94 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, cprsn .84500 x .110W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .632 ID x 1.500 OD x .12 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, cprsn 2.430 OD x .90 wire x 2.500 . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, brake plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, finishing 1.19 X .37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, DEF PRP, (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LINKS, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, man reset 1P 5A 250V . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output red w/nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output black w/nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, .1 uf 500 v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DRIVE ASSEMBLY, wire, (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . MOTOR, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, feedroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, hose brs barbed nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB, T 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, connector gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . GUIDE, wire adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAD, feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . GUIDE, inlet 1.2−1.6 mm wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ROLL, feed .024”, .030”/.035” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROLL, feed .024” and .045” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROLL, drive VK groove .030-.035 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROLL, drive VK groove .039-.045/.052-1/16 wire . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
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.
OM-218 696 Page 43
. Hardware is common and
not available unless listed.
7
6
8
5
9
10
4
3
2
1
802 283
Figure 8-3. Rear Panel w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Rear Panel w/Components (Fig 8-1 Item 10)
. . . 1 . . . . . . . . . . . . . 049 399
. . . 2 . . . . . . . . . . . . . 148 809
. . . 3 . . . . . M . . . . 188 706
. . . 4 . . . . . . . . . . . . . . 203 711
. . . 5 . . . . . . . . . . . . . 216 396
. . . 6 . . . . . . . . . . . . . 203 478
. . . 7 . . . . . . . . . . . . +200 179
. . . . . . . . . . . . . . . . . . . 137 653
. . . 8 . . . . . . . . . . . . . 188 441
. . . 9 . . . . . . . . . . . . . 137 761
. . . 10 . . . . . . . . . . . . . 604 102
..
..
..
..
..
..
..
..
..
..
..
NUT, 312−18 push-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN, 9 in 5wg 34 deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, fan 230V 50/60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, 9in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, 24 VAC 2 way custom port 1/8 orf w/frict . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, support tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAIN, safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, 750 NPT 1.31 hex .27 H nyl blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, clamp cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
1
1
1
1
1
1
1
1
1
1
1
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.
OM-218 696 Page 44
. Hardware is common and
not available unless listed.
2
1
3
4
5
11
10
6
9
8
7
802 604-C
Figure 8-4. Front Panel w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-4. Front Panel w/Components (Fig 8-1 Item 17)
. . . 1 . . . . . . . . . . . . . 143 974
. . . 2 . . . . . . . . . . . . . 206 589
. . . 3 . . . . . . . . . . . . . 207 074
. . . 4 . . . . . . . . . . . . . 207 077
. . . 5 . . . . . . . . . . . . . 208 207
. . . 6 . . . . . S2 . . . . 153 197
. . . . . . . . . . . . . . . . . . . 136 343
. . . 7 . . . . . S1 . . . . . 124 511
. . . 8 . . . . . . . . . . . . . 170 647
. . . 9 . . . . . . . . . . . . . 204 413
. . . 10 . . . . . . . . . . . . . 048 282
. . . 11 . . . . . . . . . . . . . 218 718
..
..
..
..
..
..
..
..
..
..
..
..
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POTENTIOMETER, CP flat 1/T 2W 1K linear (wire feed speed) . . . . . . .
SWITCH, selector 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, K50X 20 pan hd−phl stl pld pt thread forming . . . . . . . . . . . . . . .
SWITCH, tgl DPST 40A 600 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
4
1
1
1
1
1
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.
OM-218 696 Page 45
1
3
2
4
5
6
7
11
12
13
8
10
9
802 388-A / Ref. 800 792-C
Figure 8-5. M-10 Gun
Item
No.
Part
No.
Description
Quantity
Figure 8-5. M-10 Gun (Fig 8-1 Item 20 )
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
2
2
3
4
5
6
7
8
9
10
11
11
11
12
13
. . . . . 169 715
. . . ♦087 299
. . . ♦000 067
. . . ♦000 068
. . . ♦000 069
. . . . . 169 716
. . . . . 170 470
. . . . . 169 718
. . . . . 169 738
. . . . . 169 719
. . . . . 180 433
. . . . . 209 495
. . . . . 079 974
. . . ♦194 010
. . . ♦194 011
. . . ♦194 012
. . . . . 079 975
. . . . . 196 255
♦OPTIONAL
. . NOZZLE, slip type .500 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TIP, contact scr .023 wire x 1.125
. . TIP, contact scr .030 wire x 1.125
. . TIP, contact scr .035 wire x 1.125
. . TIP, contact scr .045 wire x 1.125
. . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD, trigger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O-RING, .500 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .023/.025 wire x 15ft (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .030/.035 wire x 15ft (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINER, monocoil .035/.045 wire x 15ft (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
1
1
1
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.
OM-218 696 Page 46
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Optional Spoolmate Spoolgun Switch
...................
...................
...................
...................
...................
186 420
202 449
605 510
604 804
202 910
..
..
..
..
..
SWITCH ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 008-15x.37 hexwhd-pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, spoolgun/mig gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
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.
OM-218 696 Page 47
Notes
Notes
Notes
Warranty
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, warrants to its original retail purchaser that new
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped from factory. 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, manufacturer will
repair or replace any warranted parts or components that fail
due to such defects in material or workmanship.
Manufacturer must be notified in writing within thirty (30) days
of such defect or failure, at which time manufacturer will
provide instructions on the warranty claim procedures to be
followed.
Manufacturer 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
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
distributor.
1.
5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, relays, brushes, slip
rings, or parts that fail due to normal wear.
2.
Items furnished by manufacturer, 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 manufacturer, 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.
MANUFACTURER’S 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 manufacturers option: (1)
repair; or (2) replacement; or, where authorized in writing by
manufacturer in appropriate cases, (3) the reasonable cost of
repair or replacement at an authorized 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. manufacturer’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at an authorized service facility as
determined by manufacturer. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
*
Flowgauge and Flowmeter Regulators (No Labor)
*
*
*
*
*
*
HF Units
Grids
Spot Welders
Load Banks
Running Gear/Trailers
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.)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER 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 MANUFACTURER IS
EXCLUDED AND DISCLAIMED BY MANUFACTURER.
*
MIG Guns/TIG Torches
*
Induction Heating Coils and Blankets
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.
*
*
*
*
*
*
Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts
Spoolmate Spoolguns
Canvas Covers
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.
4.
6 Months — Batteries
5.
90 Days — Parts and Labor
brand_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Owner’s Manuals
Circuit Diagrams
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
1/04
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