Miller Electric SPW-1 Technical data

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Miller Electric SPW-1 Technical data | Manualzz

IMPORTANT

_____________

Contents of this

Read and understand the entire manual, with special emphasis on the safety material throughout the manual, before installing, operating, or

maintaining

this eqUip ment.

This unit and these instructions are for use only by persons trained and experienced in the safe operation of welding equipment.

Do not allow un trained unit.

persons to

Contact install, operate, or maintain this your distributor if you do not fully understand these instructions.

1.

May1988

FORM: 113 336A

Effective With Serial

No.

JJ377166

MODEL

AUTO ARC MW 4150

SPW1

OWN

ERS

MANUAL

ill

IT?

LiI~F~L_____

RJ

I ~J ~

MILLER ELECTRIC MFG.

718 S. BOUNDS SI, P.O.

Box 1079

APPLETON, WI 54912 USA

Co.

ADDITIONAL COPY PRICE 85 CENTS

NWSA CODE NO. 4579

PRINTED IN U.S.A.

ONEYEARLIMITEDWARRANTY

~

~

~

COVERAGE

-

Miller Electric Mfg.

Co.

warrants to the buyer who purchases this Auto Arc Welder (Welder) for personal, family or household purposes (Consumer) will be free from defects in material and that this Welder workmanship for a period of one year from the date of purchase.

This warranty covers only the original purchaser of this Welder. Miller Electric does not authorize any party, including its authorized distributors, to offer any other warranty on behalf of Miller

EXPRESS WARRANTY; AND, EXCEPT TO THE EXTENT

PROHIBITED BY APPLICABLE LAW, THE DURATION OF

ALL IMPLIED WARRANTIES, INCLUDING BUT NOT

REMEDY FOR DEFECTIVE WELDER

defective

Upon

Welder, Miller Electric will, at its receipt of option, repair any or replace the defective Welder at its expense, refund or credit the tual purchase price (less reasonable depreciation based on ac use), or reimburse the Consumer for the cost of repair or replacement at an approved Miller Electric warranty station, provided that the purchaser of that Welder has followed the procedure for obtaining warranty performance set forth below.

~ Electric.

The Welder so repaired or used as a replacement will be ship Upon expiration of the warranty period, Miller Electric

~ shall have no further liability related to the Welder, except on ped to the purchaser of the defective Welder, with transporta warranty claims made during the warranty period.

tion charges prepaid to any destination in the continental

(transportation charges on shipments to Alaska United States

THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER paid only to the nearest port of exportl.

or

Hawaii will be

THE PURCHASERS REMEDIES FOR A DEFECTIVE

WELDER, TO THE EXTENT PERMITTED BY APPLICABLE

LIMITED TO THE IMPLIED WARRANTIES OF MERCHAN-

LAW, ARE LIMITED TO THE REMEDY PROVIDED BY THIS

TABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IS

LIMITED TO THE DURATION OF THIS WARRANTY.

WARRANTY: AND, TO THE EXTENT ENFORCEABLE

UNDER APPLICABLE LAW, MILLER ELECTRIC SHALL IN

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

NO EVENT BE LIABLE FOR CONSEQUENTIAL, INCIDENTAL

OR SPEcIAL DAMAGES ARISING OUT OF THE USE OF, OR

INABILITY TO USE, THE WELDER, WHETHER BASED ON

BREACH OF THIS WARRANTY, MILLER ELECTRICS

NEGLIGENCE OR OTHER TORT, OR ON ANY THEORY OF

STRICT LIABILITY.

~ to

Except as specified below, Millers warranty does not apply components having normal useful life of less than one

)1) year, such as spot welder tips, relay parts that come in contact with the and contactor welding wire points, including nozzles and nozzle insulators where failure does not result from defect in workmanship or material.

Some states do not allow the exclusion or limitation of con sequential or incidental damages, so the above limitations may not apply to you.

PROCEDURE FOR OBTAINING WARRANTY PERFORMANCE

Miller shall be ranted required to honor warranty claims on war

Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equipment to the original user:

1.

2.

Arc welders, power sources, and components

Original main power rectifiers

(labor

-

1 year only)

...

.

1 year

3 years

3.

All welding guns, feeder/guns and plasma torches...

90 days

4.

Replacement or repair parts, exclusive of labor

..

60 days

As soon as any defect in a

Welder becomes known, the pur chaser of the Welder must, within thirty (30) days, notify an approved Warranty Station or

Miller Electric in writing of the defect. The purchaser must then, within the one year warranty period, return the Welder to Miller Electric at the following address:

Miller Electric Mfg Co

718 South Bounds Street

P.O.

Box 1079

Appleton, Wisconsin 54912 to

WHAT IS NOT COVERED

-

This warranty does not extend any

Welder subjected to misuse, neglect, accident, or inwarranty repair by anyone except Miller Electric..

Further, this warranty only extends to those purchasing the Welder for personal, family or household purposes.

Commercial and in dustrial users are given a different warranty.

All transportation charges to Warranty Station or

Miller Electric must be prepaid.

c3~

ERRATA

SHEET

After this manual was printed, refinements in

equipment design

occurred. This sheet lists

exceptions

to data

appearing

later In this manual.

**

4-25

5-10

5-23

Part

No.

004988

056081

044954

Replaced

With

121 015

058 549

000 366

120 370

Description

DRIVE ASSEMBLY, wire (Eff w/JJ389988)

GUIDE, wire-inlet

(Eff w/JJ389988)

RING, retainer E

(used

on

guide)

HOUSING, drive

(Eff

WI

JJ389988)

**First

digit

represents page no

digits following

dash represent item no.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Quantity

1

1

1

1

I~E1u1~ c~r)i3y

L-D~

July 12, 1988 FORM: 113336A

ERRATA

SHEET

After this manual was printed, refinements in

equipment

design occurred. This sheet lists

exceptions

to data

appearing

later in this manual.

IMPORTANT: Replace all references to wire feed motor M with wire feed motor

MOT.

AMENDMENT TO SECTION 6- MAINTENANCE & TROUBLESHOOTING

Delete Section 6-9.

RECTIFIER PROTECTION

(Thermal Shutdown)

Amend

Figure

6-4.

Circuit

Diagram

For

Welding

Power Source

B AC

RC3

GUN

TRIGGER

2

3

4

<

SI

PLGI

230V.

PLG2

POSITIVE

NEGATIVE

Circuit

Diagram

No.

B-121 827

Figure

6-4. CIrcuit

Diagram

For

Welding

Power Source Effective With Serial No. JJ421 795

**

2-4

2-17

4-21

4-23

4-25

4-25

4-25

4-28

5-10

5-13

5-22

8-8

8-23

9-

Dia.

Mkgs

PLG2

VR2

SR2

Part

No.

008 073

057 511

082 722

035 914

044 988

120 663

121 014

010 014

056 081

M

RC3

CR3

093153

044 954

083 917

023 083

112 770

112 772

112768

Replaced

With

Deleted

034 260

082 722

035 914

120 663

121 014

122 192

010 145

058 549

000 366

119040

120 370

119 191

600 318

Description

(Eff w/JJ421795)

LINK, connector-contactor

VARISTOR (qty

RECTIFIER

chg) (Eff w/JJ421795)

(qty chg) (Eff w/JJ421795)

DRIVE ASSEMBLY, wire

(Elf w/JJ377166)

DRIVE ASSEMBLY, wire

(Eff

w/JJ377167 thru

JJ421794)

DRIVE ASSEMBLY, wire

(Eff

w/JJ421795 & on)

CLAMP,

1/2 dia

GUIDE, wire-inlet

(Eff w/JJ389988)

RING, E retainer

(used

on

guide)

MOTOR,gear(Effw/JJ421795)

HOUSING, drive roll

(Elf w/JJ389988)

PANEL, front

(Effw/JJ377166)

CABLE, weld-stranded No.

3

(order by It)

(Elf

w/JJ389988)

Quantity

4 ft

I

2

1

1

2

1

1

1

1

1

1

1

Deleted

Deleted

Deleted

073 383

006 393

058 553

RECEPTACLE, 3 socket MS-3102A-14S-1S

(Elf w/JJ421795)

RELAY, enclosed 24 volts ac

DPDT

GEAR, drive roll

(Eff w/JJ377166)

1

1

1

**First

digit

represents page no

-

digits following

dash represent item no.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113 336 Page 2

TABLE OF CONTENTS

Section No.

Page No.

SECTION 1

-

SAFETY RULES FOR OPERATION OF ARC WELDING

POWER SOURCE

1 -1.

Introduction

1

-

2.

General Precautions

1 -3.

Arc Welding

1

-

4.

Standards Booklet Index

1

1

4

6

SECTION 2

-

INTRODUCTION

2

-

1.

2-2.

2

-

3.

2

-

4.

2

-

5.

2

-

6.

2

-

7.

2

-

8.

2-9.

Volt-Ampere Curves

DutyCycle

General Information And Safety

Receiving-Handling

Description

Supplied Equipment

Additional Required Equipment

Optional Equipment

Consumable Parts

8

8

8

9

10

7

7

7

10

SECTION 3

-

INSTALLATION

3-1.

3

-

2.

3

-

3.

3

-

4.

Running Gear Installation

Optional SPW-1 Panel Installation

Shielding Gas Installation

3 -5.

Work Cable Assembly

3

-

6.

Weld

3 -7.

Polarity Selection

GA-20C Welding Gun Installation

3

-

8.

Installation Of Optional Spool Gun

3-9.

3-10.

3 -11.

3-12.

Location

WeldingWireSpoollnstallation

HubTensionAdjustment

Electrical Input Connections

ThreadingWeldingWire

SECTION 4

-

OPERATOR CONTROLS

10

10

11

12

12

13

14

15

16

16

16

17

4

-

1.

4

-

2.

4

-

3.

4-4.

4

-

5.

4-6.

4

-

7.

Power Switch

Pilot Light

Thickness/Volts

Fineluning/Wire Speed Control

Fan-On-Demand

Circuit Breakers

Optional Spot Pulse Panel Controls

SECTION 5

-

SEQUENCE OF OPERATION

5

-

1.

Gas Metal Arc

5

-

3.

Welding (GMAW)

-

Continuous And Gas Metal

Arc Welding-Pulsed Arc (GMAW-P)

5

-

2.

Gas Metal Arc Welding (GMAW)

-

Spot

Shutting Down

18

18

18

19

19

19

19

20

21

22

SECTION 6

-

MAINTENANCE & TROUBLESHOOTING

6-1.

6

-

2.

6

-

3.

6

-

4.

6

-

5.

6

-

6.

6

-

7.

6

-

8.

6

-

9.

6-10.

6-11.

6-12.

6-13.

FanMotor

Inspection And Upkeep

Internal Cleaning

Cleaning Drive Rolls

Replacing Drive Roll And Wire Inlet Guide

Realigning Drive Housing

Replacing Hub Assembly

Resetting Circuit Breakers CB1 And CB2

Rectifier Protection

Inspecting And Replacing Motor Brushes

Replacing SPW-1 Panel Circuit Board

Replacing SPW-1 Panel

Troubleshooting Chart

SECTION 7

-

WELDING TECHNIQUES & TROUBLESHOOTING

7

-

1.

7

-

2.

7 -3.

7 -4.

7-5.

7

-

6.

Gas Metal Arc Welding (GMAW)

-

Continuous Seam

Gas Metal Arc Welding (GMAW)

-

Pulsed

Gas Metal Arc Welding (GMAW)-Spot

Plug Welds

SkipWelding

Troubleshooting The Gas Metal Arc Welding Process

SECTION 8

-

AUTO BODY REPAIR APPLICATION

8

-

1.

8

-

2.

8

-

3.

8

-

4.

8

-

5.

8

-

6.

Pointers For Welding Auto Body Sheet Metal

Procedure For Welding Mild Steels

Procedures For Welding Door Panels

How To Prevent Glass Breakage And Spatter On Windows

Procedures For Welding Fenders And Quarter Panels

Welding Frames And High Strength (HSS) Steels

33

34

34

35

35

36

39

39

39

40

40

40

26

26

27

27

27

28

28

23

23

23

24

24

26

SECTION 1

-

SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE~

1-1.

INTRODUCTION

-

We learn by experience.

Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and un wise. Let the experience of others teach you.

Safe practices developed from experience in the use of welding and cutting are described in this manual.

Research, development, and field experience have evolved reliable equipment and safe installation, opera tion, and servicing practices.

Accidents occur when equipment is improperly used or maintained.

The reason

Some for the safe practices may not always be are based on common sense, others may given.

require technical volumes to explain.

It is wiser to follow the rules.

Read and understand these safe practices before at tempting to install, operate, or service the equipment.

Comply with these procedures as applicable to the par ticular equipment used and their instruction manuals, for personal safety and for the safety of others.

Failure to observe these safe serious practices may cause injury or death. When safety becomes a habit, the equipment can be used with confidence.

These safe

1

-

General practices are divided into two Sections:

Precautions, common to arc welding and cutting; and 2

-

Arc Welding (and Cutting) (only).

Reference standards: Published Standards on safety are also available for additional and more complete pro cedures than those given in this manual.

They are listed in the Standards Index in this manual.

ANSI Z49.1

is the most complete.

The National Electrical

Health

Code, Occupational Safety and

Administration, local industrial codes, and local inspection requirements also provide a basis for ment installation, use, and service.

equip

1-2.

GENERAL PRECAUTIONS

Different arc welding processes, electrode alloys, and fluxes can produce different fumes, gases, and radiation levels. in addition to the information in this manual, be sure to consult flux and elec trode manufacturers for specific technical data and precautionary measures material.

concerning their

A.

Burn Prevention

Wear protective clothing

gauntlet gloves designed for use in welding, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wea(cuffless trousers to avoid entry of sparks and slag.

Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates

(protected by clear cover glass).

This is a

MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and flying metal.

Replace cover glass when broken, pitted, or spattered.

See 1-3A.2.

Avoid oily or greasy clothing.

A spark may ignite them.

Hot metal such as electrode stubs and should never be handled without gloves.

workpieces

Medical first aid and eye treatment.

First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close mediate treatment of flash burns by for im of the eyes and skin burns.

Ear plugs should be worn when working on overhead or in a confined space.

A others work overhead.

hard hat should be worn when

Flammable hair sons preparations should not be used by per intending to weld or cut.

B.

Toxic Fume Prevention

Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen that welding (or cutting) may enrichment or depletion produce.

Prevent them with adequate ventilation as described in ANSI Stan dard Z49.1 listed 1 in Standards index.

NEVER ventilate with oxygen.

Lead

-, cadmium

-, zinc

-, mercury

-, and beryllium

-

bearing

and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes.

Ade quate local exhaust ventilation must be person in the area as well as used, or each the operator must wear an air-supplied respirator.

For beryllium, both must be us ed.

Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ven tilated, or the operator wears an air-supplied respirator.

Work in tilated a confined space only while it is and, if necessary, while wearing an being ven air-supplied respirator.

Gas leaks in

Leaked gas in a confined space should be avoided.

large quantities can change oxygen con centration a dangerously.

Do not bring gas cylinders into confined space.

Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidently opened or left open.

Check to be sure that the space is safe before re-entering it.

Vapors from chlorinated solvents can be decomposed by the heat of the arc

(or flame) to form PHOSGENE, a

113336 Page 1

highly toxic gas, and other lung and eye irritating pro ducts.

The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and per chloroethylene vapors to form phosgene.

DO NOT

WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichioroethylene or per chloroethylene.

C.

Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached by the arc, flame,

flying

sparks, hot slag or heated material; misuse of compressed gases and cylinders; and short circuits.

BE AWARE THAT flying sparks or

falling

slag can pass through cracks, along pipes, through windows or doors, and of the through wall or floor openings, out of sight goggled operator.

Sparks and slag can fly 35 feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.

If combustibles are in area, do the work if practicable, to

NOT weld or cut.

Move an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage areas, yen tilators.

If the work cannot be moved, move com bustibles at and least 35 feet away out of reach of heat; or protect against ignition sparks with suitable and snug-fitting, fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on

(or cut).

Walls, work should be ceiings, and floor near protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire ex tinguishing equipment during and for some time after welding or cutting if: a.

b.

appreciable combustibles (including building construction) are within 35 feet appreciable combustibles are further than 35 c.

feet but can be ignited by sparks openings (concealed or visible) in floors or walls within 35 feet may expose com bustibles to d.

combustibles sparks adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.

Hot work permit should be obtained before operation to ensure supervisors approval that adequate precautions have been taken.

After work is done, check that area is free of sparks, glowing embers, and flames.

An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must

113 336 Page2 never be welded been cleaned as on or cut, unless container has first described in AWS Standard A6.O, listed 7 in Standards index.

This includes: a a thorough steam or caustic cleaning (or solvent or water washing, depending on the com bustibles with solubi~ity) followed by purging and inerting nitrogen or carbon dioxide, and using protective equipment as recommended in A6.O.

Waterfilling just below working level may substitute for inerting.

A container with unknown contents should be cleaned

(see smell paragraph above).

Do NOT depend on sense of or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before welding or cutting.

They can explode.

Explosive atmospheres.

Never weld or cut where the air may contain flammable dust, gas, or liquid vapors

(such as gasoline).

D.

Compressed Gas Equipment

Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-i, SAFE

HANDLING OF COMPRESSED GASES IN

CYLINDERS, listed 11 in Standards index.

1.

Pressure Regulators

Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment.

Provide protection with one or more relief devices.

such

Never connect a gas regulator to a cylinder containing other than that for which the regulator was designed.

Remove for faulty regulator from service immediately repair (first close cylinder valve).

The following symptoms indicate a faulty regulator:

Leaks

if gas leaks

Excessive externally.

Creep

if delivery pressure continues to rise with downstream valve closed.

Faulty stop

Gauge

if gauge pointer does not move off pin when pressurized, nor returns to stop pin after pressure release.

Repair.

Do NOT attempt repair.

Send faulty regulators for repair to manufacturers designated repair center, where special techniques and tools are used by trained personnel.

2.

Cylinders

Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:

Avoid electrical circuit contact with cylinders in cluding third rails, electrical wires, or welding cir cuits.

They can produce short circuit arcs that lead to a serious accident.

(See 1-3C.) may

ICC an or

DOT assurance marking must be on each cylinder.

It is of safety when the cylinder is properly handled.

Identifying gas content.

Use only cylinders name of gas marked on with them; do not rely on color to identify gas content.

Notify supplier if unmarked.

NEVER DEFACE or alter name, number, or other markings on a cylinder.

It is illegal and hazardous.

Empties: mark

Keep valves closed, replace caps securely;

MI; keep them separate from FULLS and return promptly.

Prohibited use.

Never use a other than its intended use, cylinder or its contents for

NEVER as a support or roller.

Locate or secure cylinders so they cannot be knocked over.

Passageways and work areas.

Keep cylinders areas where they may be struck.

clear of

Transporting cylinders.

With a crane, use a secure sup port such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.

Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc.

that may cause rupture.

Do not allow contents to exceed 130F.

Cool with water spray where such exposure exists.

Protect cylinders particularly valves from bumps, falls, falling objects, and weather.

Replace caps securely when

moving

cylinders.

Stuck valve. Do NOT use a hammer or wrench to a cylinder valve that can not be opened open by hand.

Notify your supplier.

Mixing gases. Never try to mix any gases in a cylinder.

Never refill any cylinder.

Cylinder ed.

fittings should never be modified or exchang

3.

Hose

Prohibited use.

Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases.

Use ferrules or clamps designed for the hose dinary wire or other substitute) as a binding

(not or to connect hoses to fittings.

No copper tings to tubing splice splices.

hose.

Use only standard brass fit

Avoid long runs to prevent kinks and abuse.

Suspend hose off ground to keep it from on, or otherwise damaged.

being run over, stepped

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sparks, slag, and open flame.

sharp edges, and by

Examine hose regularly for leaks, wear, and loose con nections. Immerse pressured hose in water; bubbles in dicate leaks.

Repair leaky or worn hose by cutting area out ing (1-2D3).

Do NOT use tape.

and splic

4.

Proper Connections

Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator.

Except for hydrogen, crack valve momentarily, pointing outlet away from with a people clean lintless cloth.

and sources of ignition. Wipe

Match that the regulator to cylinder.

Before connecting, check regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match.

NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

Tighten connections. When assembling threaded con nections, clean and smooth seats where necessary.

Tighten.

If connection leaks, disassemble, clean, and retighten using properly fitting wrench.

Adapters.

Use a

CGA adapter (available from your sup plier) between cylinder and regulator, if one is required.

Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads.

Regulator outlet (or hose) connections may be iden tified by threads right hand threads for oxygen and left hand

(with grooved hex on nut or shank) for fuel gas.

5.

Pressurizing Steps:

Drain before regulator of residual gas through suitable vent opening cylinder (or manifold valve) by turning adjusting screw in (clockwise).

Draining prevents ex cessive compression heat at high pressure seat by allowing seat to open on pressurization.

Leave adjusting screw engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in creases slowly.

When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible leak.

For fuel gas, open to less than one turn to permit quick emergency shutoff.

Use pressure charts safe and

(available from your supplier) for efficient, recommended pressure settings on regulators.

Check for leaks on first pressurization and regularly there-after.

Brush with soap solution (capful of Ivory

113 336 Page 3

Liquid* or equivalent per gallon of water).

Bubbles in dicate leak. Clean off soapy water after test; dried soap is combustible.

E.

User Responsibilities

Remove leaky or defective equipment from service im mediately for repair.

See User Responsibility statement in equipment manual.

F.

Leaving Equipment

Unattended

Close gas supply at source and drain gas.

G.

Rope Staging-Support

Rope staging-support should not be used for welding or cutting operation; rope may burn.

1-3.

ARC WELDING

-

Comply with precautions in

1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble.

The equipment carries high currents at significant voltages.

The arc is very bright and hot.

Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weidments are hot, and compressed gases may be us ed. The wise operator avoids unnecessary risks and pro tects himself and others from accidents.

Precautions are described here and in standards referenced in index.

A.

Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright.

Its radia tion can damage eyes, penetrate lightweight clothing, reflect from and eyes.

light-colored surfaces, and burn the skin

Skin burns resemble acute sunburn, those from

DONT gas-shielded arcs are more severe and painful.

GET BURNED; COMPLY WITH PRECAU

TIONS.

1.

Protective Clothing

Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to necessary, use gloves, hat, and shoes (1-2A).

As additional protective clothing such as leather resistant jacket or sleeves, flame-proof apron, and f ireleggings.

Avoid outergarments of untreated cotton.

Bare skin

Button protection.

Wear dark, substantial clothing.

collar to protect chest and neck and button pockets to prevent entry of sparks.

2.

Eye and Head Protection

Protect eyes from exposure electric arc without to protection.

arc.

NEVER look at an

Welding helmet or shield containing a filter plate shade no.

12 or denser must be used when welding.

Place over face before striking arc.

*Trademark of Proctor & Gamble.

113 336 Page4

Protect filter plate with a clear cover plate.

Cracked worn; or broken radiation can helmet or shield should NOT be pass through to cause burns.

Cracked, broken, or loose filter plates must be replaced

IMMEDIATELY.

Replace clear cover plate when broken, pitted, or spattered.

Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck.

eyes

Looking at an arc momentarily with unprotected

(particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision.

3.

Protection of Nearby Personnel

Enclosed welding area.

For production welding, a separate room or surround the enclosed operation bay with is best.

In open areas, low-reflective, noncombustible screens or panels.

Allow for free air circula tion, particularly at floor level.

Viewing the weld.

Provide face shields for all persons who will be looking directly at the weld.

Others working in area.

See that all persons are wearing flash goggles.

Before starting to weld, make sure that screen flaps or bay doors are closed.

B.

Toxic Fume Prevention

Comply with precautions in 1 -2B.

Generator engine exhaust must be vented to the outside air.

Carbon monoxide can kill.

C.

Fire and Explosion Prevention

Comply with precautions in 1 -2C.

Equipments rated capacity.

Do not overload arc welding equipment.

It may overheat cables and cause a fire.

Loose cable connections cause a fire.

may overheat or flash and

Never strike an vessel. It creates arc on a a brittle cylinder area that or can other pressure cause a violent rupture or lead to such a rupture later under handling.

rough

D.

Compressed Gas Equipment

Comply with precautions in 1-2D.

E.

Shock Prevention

Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment becomes a can fatally shock a conductor.

DO NOT person whose

STAND, SIT, body

LIE,

LEAN ON, OR TOUCH a wet surface when welding, without suitable protection.

To protect against shock:

Keep body and clothing dry.

Never work in damp area without adequate insulation against electrical shock.

Stay on a dry duckboard, or rubber mat when damp ness or sweat can not be avoided.

moisture between

Sweat, sea water, or body and an electrically HOT part

or electrical grounded metal

reduces the body surface resistance, enabling dangerous and possibly lethal currents to flow through the body.

1.

Grounding the Equipment

When arc welding equipment is grounded the National Electrical accOrding to

Code, and the work is grounded according to

ANSI Z49.1

Safety In Welding And Cut ting, a voltage may exist between the electrode and any conducting object.

Examples include, but are not limited to, of conducting buildings, objects electrical tools, work benches, welding power source cases, workpieces, etc.

Never touch the electrode and any metal object unless the welding power source is off.

When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground.

Conductors must be adequate to carry ground currents safely.

Equipment made electrically HOT by stray current may shock, possibly fatally.

Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable li quid such as oil or fuel.

Three-phase connection.

Check phase equipment before

installing.

If requirements of only 3-phase power is available, connect wires of the single-phase equipment

3-phase line.

Do NOT to connect only the two equip ment ground lead to the third (live) wire, or the equip ment will become electrically HOT

a dangerous condi tion that can shock, possibly fatally.

Before welding, check ground for continuity.

Be sure conductors are touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox.

If a threeprong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only.

If the line cord comes with a three-prong plug, connect to a grounded mating recep tacle.

Never remove the ground prong from a plug, or use a plug with a broken off ground prong.

2.

Electrode Holders

Fully insulated electrode holders should be used.

Do

NOT use holders with protruding screws.

3.

Connectors

Fully insulated lock-type connectors should be used to join welding cable lengths.

4.

Cables

Frequently inspect cables for wear, cracks and

IMMEDIATELY REPLACE those with

damage.

excessively worn or damaged insulation to avoid possibly

lethal shock from bared cable.

Cables with taped to damaged areas may be give resistance equivalent to original cable.

Keep cable dry, free of oil and grease, and protected from hot metal and sparks.

5.

Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units should have

insulating

covers secured before operation.

6.

Electrode a.

Equipment with output on/off control (con tactor)

Welding power sources for use with the gas metal arc

welding

(GMAW), gas tungsten arc welding (GTAW) and similar processes normally are equipped with devices that per mit on-off control of the welding power out put.

When so equipped the electrode wire becomes source electrically HOT when the power switch is ON and the welding gun switch is closed.

Never touch the electrode wire or with the any

conducting

object in contact electrode circuit unless the

welding

power source is off.

b.

Equipment without output on/off control

(no contactor)

Welding power sources used with shielded metal arc welding (SMAW) and similar pro cesses power may not output be on-off equipped with welding control devices.

With such equipment the electrode is electrically

HOT when the power switch is turned ON.

Never touch the electrode unless the welding power source is off.

7.

Safety Devices

Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out.

Before installation, inspection, or service, of equip ment, shut OFF all power and remove line fuses (or lock

113 336 Page 5

or red-tag switches) to prevent accidental power.

source,

turning

ON of

Disconnect all cables from and welding power pull all 115 volts line-cord plugs.

Do not open power circuit or

change

polarity while welding.

If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing.

Leaving equipment unattended.

Always shut OFF and disconnect all power to equipment.

Power disconnect switch must be available near the welding power source.

F.

Protection For Wearers Of Electronic

Support Devices (Pacemakers)

Life

Magnetic fields from high currents can affect pacemaker operation.

Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations.

1-4.

STANDARDS BOOKLET INDEX

For more or their information, refer to the following standards latest revisions and comply as applicable:

1.

ANSI

AND

Standard Z49.1, SAFETY IN WELDING

CUTTING obtainable from the American

Welding Society, 550 Le Jeune Rd, P.O.

Box

351040, Miami, FL 33135.

2.

NIOSH, SAFETY AND HEALTH IN ARC

WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of

Documents, U.S.

Government Printing Office,

Washington, D.C.

20402.

3.

OSHA, SAFETY AND HEALTH STANDARDS,

29CFR 1910, obtainable from the U.S.

Govern ment Printing Office, Washington, D.C. 20402.

4.

ANSI Standard Z87.1, SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE AND

FACE PROTECTION obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

5.

ANSI Standard Z41.1, STANDARD FOR MENS

SAFETY-TOE FOOTWEAR obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

6.

ANSI Standard

THE

Z49.2, FIRE PREVENTION IN

USE OF CUTTING AND WELDING PRO

CESSES obtainable from the American National

Standards Institute, 1430 Broadway, New York,

NY 10018.

7.

AWS Standard A6.0, WELDING AND CUT

TING CONTAINERS WHICH HAVE HELD COM

BUSTIBLES obtainable from the American

Welding Society, 550 Le Jeune Rd.

P.O.

Box 351040, Miami FL 33135.

8.

NFPA Standard 51, OXYGEN

-

FUEL GAS

SYSTEMS FOR WELDING AND CUTTING ob tainable from the National Fire Protection

Association, 470 Atlantic Avenue, Boston, MA

02210.

9.

NFPA Standard 70-1978, NATIONAL ELEC

TRICAL CODE obtainable from the National Fire

Protection Association, 470 Atlantic Avenue,

Boston, MA 02210.

10.

NFPA Standard 51 B, CUTTING AND WELDING

PROCESSES obtainable from the National Fire

Protection Association, 470 Atlantic Avenue,

Boston, MA 02210.

11.

CGA Pamphlet P-i, SAFE HANDLING OF COM

PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association, 500 Fifth

Avenue, New York, NY 10036.

12.

CSA Standard Wi 17.2, CODE FOR SAFETY IN

WELDING AND CUTTING obtainable from the

Canadian Standards Association, Standards

Sales, 178 Rexdale Boulevard, Rexdale, Ontario,

Canada M9W 1 R3.

13.

NWSA booklet, WELDING SAFETY

BIBLIOGRAPHY obtainable from the National

Welding Supply Association, 1900 Arch Street,

Philadelphia, PA 19103.

14.

American Welding Society Standard AWSF4.1

Recommended Safe Practices for the Prepara tion for Welding and Cutting of Containers and

Piping That Have Held Hazardous Substances, obtainable from the American Welding Society,

550 LeJeuneRd. P.O.

Box351040, McmI, FL33135.

15.

ANSI Standard Z88.2 Practice for Respiratory

Protection obtainable from the American Na tional Standards Institute, 1430 Broadway, New

York, NY 10018.

113 336 Page 6

SECTION 2

-

INTRODUCTION

Rated Weld

Outout At

600h

Duty

Cycle

150 Amperes

@

23 Volts

Input At Rated Load Output

60 Hz Single-Phase

Max.

Open-

Circuit

Amperes At

Volts 200V 230V 460V 575V kva

32 26.5

24 12 9.6

kw

Control

Circuit

Voltage

At Gun

Electrode Wire

Feed Speed

Electrode Wire

Diameter

Capability

Overall

Dimensions

Weight

Net Ship

5.5

4.8

24 Volts DC

60-486 ipm

(1.512.3

mpm)

.0231.025, .030,

& .035 in.

(0.6

0.8, &

0.~ mm)

Heiaht: 30 in.

7~2 mm)

Vidth:

13-1/2 in.

(343 mm)

Deoth: 27 in.

(~86mm)

205 lbs.

(93 kg)

215 lbs.

(98 kg)

Add 5 lbs.

(2.3 kg) for units with optional spot panel.

Figure 2

-

1.

Specifications

2

-

1.

VOLT-AMPERE CURVES (Figure 2-2)

OUTPUT

The the volt-ampere curves show the available output of welding power source in each of the output recep tacle taps with the FINE TUNGING/ WIRE SPEED con trol at the maximum position.

Different settings on the

FINE TUNING/WIRE SPEED control provide difterent volt-ampere curves.

4

V

C

In a a.

30 35 40 50 60

% DUTY CYCLE

70 60 90 100

Figure 2 -3.

DutyCycleChart

6-057 436-1

I

-I

0

I

U

6 HIGH

5

4

3

2

1 LOW

0 25 50 75 100 125

DC AMPERES

150 175 200

6-057 436-lA

Figure 2

-

2.

Volt-Ampere

Curves

2

-

2.

DUTY a

CYCLE (Figure 2-3)

-

The duty cycle of welding power source is the percentage of a ten minute period that a welding power source can be operated at a given output without causing overheating and damage to the unit. This welding power source is rated at 60 percent duty cycle.

This means that the welding power source can be operated at rated load for six minutes out of every ten.

During the remaining four minutes, the unit should idle to permit proper cooling.

If the welding amperes are increased the duty cycle will decrease.

Figure 2-3 enables the operator to determine the output cycles.

of the welding power source at various duty

CAUTION EXCEEDING DUTY CYCLE RATINGS

________ will damage the welding power source.

Do not exceed indicated duty cycles.

2 -3.

GENERAL INFORMATION AND SAFETY

A.

General

Information presented in this manual and on various labels, tags, and ment plates on this unit pertains to equip design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equip ment.

The for nameplate of this unit uses international labeling the front panel controls. The symbols symbols also appear at the appropriate section in the text.

B.

Safety

The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others.

Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all ap plicable codes such as, but not limited to, those listed at the end of Section 1

-

Safety Rules For Operation Of

Arc Welding Power Source.

113336 Page 7

Safety instructions specifically pertaining to this unit ap pear throughout this manual words WARNING

____________ ____________ and different levels of hazard.

highlighted

CAUTION

___________ by the which signal identify

IYiTIJ:i~ll~eI statements include installation, operation, and maintenance procedures or practices which if not carefully followed could result in serious personal injury or loss of life.

CAUTION statements

____________ and maintenance include procedures or installation, practices operation, which if not carefully followed could result in minor personal injury or damage to this equipment.

A third signal word, Il~I~s]:lf~Il highlights instruc tions which need efficient special emphasis to obtain the most operation of this equipment.

2

-

4.

this

RECEIVING-HANDLING

-

Before equipment, clean all installing packing material from around the unit, and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading will be furnished by the manufacturer on re quest if occasion to file claim arises.

When requesting information concerning this equip ment, it is essential that Model Description and Seria)

Number of the equipment be supplied.

2

-

5.

DESCRIPTION

This unit is a single-phase constant voltage dc arc welding power source and wire feeder system designed for Gas Metal Arc Welding (GMAW).

It is designed primarily for use as a dc Electrode Positive/Reverse

Polarity machine. Rated weld output is 150 amperes,

23 volts dc, at 60% duty cycle.

Models with the optional SPOT PULSE WELD PANEL provide the controls for regulating spot weld time/pulse on time, burnback time, and pulse off time.

2

-

6.

SUPPLIED EQUIPMENT (Figure 2-4)

The following equipment is supplied with the welding power source and requires customer installation or assembly:

A.

Running gear with gas cylinder rack and bracket.

B.

Wall receptacle (200/230 volt models only).

C.

Work cable, work clamp, and jack plug.

D.

MWG-200 and gun two contact with 5/8 inch (16 mm) tubes for each wire size.

nozzle

E.

Drive rolls for .023/.025, .030, and .035

in.

(0.6, 0.8, and 0.9

mm) hard wire.

F.

Optional SPW-1 Spot Panel and three nozzles.

The ft.

welding power source is factory equipped with a

9

(2.7 m) power cord and gas valve.

Spreader

Bar

A

113336 Page 8

Figure 2-4.

Supplied Parts

2

-

7.

ADDITIONAL REQUIRED

(Figure 2-5)

EQUIPMENT

IMPORTANT Contact your supplier

______________ yellow pages of the local telephone or see the book for the loca tion of the nearest Auto Arc Distributor.

Gas Hose

Gas

Cylinder

I

Helmet

Wire

Gloves

Figure 2-5.

Additional Supplies Required

A.

Gas Cylinder

Two types of gas mixtures are

Metal Arc generally used with Gas

Welding (GMAW) of thin gauge sheet steel.

Carbon dioxide with this

(C02)

is the gas recommended for use welding power source/gun combination.

A mixture of 75 dioxide also percent argon and 25 percent carbon gives favorable results.

Obtain a cylinder of selected shielding gas from your supplier.

B.

Regulator/Flowmeter

Regulator/flowmeters provide a constant shielding gas pressure and flow rate during the welding process.

Because gases have different properties, each regulator/flowmeter is designed to be used with a specific gas or mixture of gases.

Regulator/flowmeters cannot be changed from one gas to another unless the proper adapters are installed.

Obtain the regulator/flowmeter for the type of gas used.

proper

C.

Gas Hose

Measure distance from gas source.

Obtain cylinder to good quality 5/8 in.

welding

(16 mm) power

O.D.

S.A.E. gas hose, and install 5/8-18 fittings on both ends of hose.

right hand thread

D.

Spool Of Wire

Selection of the correct welding wire is important in Gas

Metal Arc Welding (GMAW).

There are many types to choose from, but certain wires are best suited for welding thin gauge sheet steel. The American Welding

Society (AWS) classification for GMAW wires is usually indicated on the label of the wire classes recommended are spool.

Two AWS wire

E7OS-6 and E7OS-3.

The

E7OS-6 a flatter provides a more fluid (wetter) weld puddle and bead; however, E7OS-3 is acceptacle for use with this welding power source.

Obtain a spool of selected wire.

E.

Personal Safety Equipment

When using this welding power source, wear a welding helmet, fitted with the proper filter lens, to protect the eyes from the welding arc.

Also important is wearing protective clothing, safety vent injury.

glasses, and gloves to pre

F.

Offset/Punching Tool (Figure 2-6)

The welding process in the repair of automotive sheet steel can be made easier with the use of a special Off set/Punching Tool.

This tool has a dual purpose, rotating head. The damaged area is cut away and the jaws of the offset portion of the head are placed over the sheet steel.

When pressure is applied to the handles, the tool will indent a small offset in the sheet steel. A new piece of sheet steel is then cut to size and placed in position to overlap the offset portion.

The new piece of sheet steel is then welded into place, sanded, filled with body putty and finished sanded. The head of the tool can be rotated one-half turn to be used as a punching tool. The punching tool will expedite riveting operations.

The use of this tool will help keep material use and finishing time to a minimum.

Figure 2-6.

Offset/Punching Tool

113336 Page 9

2

-

8.

OPTIONAL EQUIPMENT

The following equipment can be obtained to extend the capabilities of the basic unit or to suit special applica tions:

A.

SPW-1, Spot, Pulse, three

Continuous Panel (includes spot nozzles) (for installation see

Section

3-3)

B.

Gun cable holder

C.

25 Ft.

(7.6 m) power cord extension

2

-

9.

CONSUMABLE PARTS

The following parts are subject to wear or damage in normal use:

A.

Contact tubes

B.

Nozzles

C.

Gun liner

D.

Drive rolls

WARNING

.

.

SECTION 3

-

INSTALLATION

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Disconnect input power conductors from deenergized supply line BEFORE moving unit.

If the welding power source is not installed on a running gear, holes a lifting eye is provided for moving the unit, and are provided in base for mounting purposes.

The location should allow room to remove the top cover and side panels for installation, maintenance, and repair procedures.

The service life and when the unit is efficiency of this unit are reduced subjected to high levels of dust, dirt, moisture, corrosive vapors, and extreme heat.

Figure 3

-

1.

Completely Assembled Unit

3

-

1.

LOCATION (Figure 3-2)

WARNING FALLING EQUIPMENT can cause

___________ serious personal injury and equipment damage.

Use lifting eye to lift unit only, NOT running gear, accessories.

gas cylinders, or any other heavy

Use equipment of adequate capacity to lift the unit.

If using lift forks to handle this unit, be sure the lift forks are long enough to extend out of the op posite side of the base.

Using lift forks too short will expose internal com ponents to damage should the tips of the lift forks penetrate the bottom of the unit.

RESTRICTED AIR FLOW causes overheating and

possible

damage to internal parts.

Maintain at least 18 inches(457 mm) of unrestricted space on all sides of underside free of obstructions.

unit, and keep

Do not place any filtering device over the intake air passages of this we/ding power source.

Warranty is void if any type of filtering device is used.

113 336 Page 10

18 In.

(457 mm)

/

TB-072 513-C

Figure 3

-

2.

Location

3 -2.

3-3)

RUNNING GEAR INSTALLATION (Figure

CAUTION

________

PING of unit

UNCONTROLLED TILTING OR TIP can result in personal injury or equip ment damage.

Use equipment of adequate capacity to lift the unit.

If using lift forks to handle this unit, be sure the lift forks are long enough to extend out of the op posite side of the base.

Do not place any part of the body under the unit while it is suspended.

Place blocks under frame of unit before attaching runfling gear.

Cap

Two Front

Cap Screws

Running

Flat Washers

Cylinder Rack

Flat Washers

Cotter

Pin

Nut

Washer

Axle

Cap Screw

Nut

Wheel

Casters

TC-049 808C

Figure 3

-

3.

Running Gear Installation

1.

Install the two 4 in.

(102 mm) swivel casters and spreader bar on the front corners of the welding power source base as shown in

3/8 in. hardware.

Figure 3-3 using

2.

Block the unit up securely stallation of rear in middle wheel/gas to ease cylinder in rack assembly.

3.

Slide axle through cylinder rack, and install a wheel onto each end of axle with a

3/4 in. flat washer on each side of wheel.

4.

Secure wheels in place with cotter pins by ben ding both one legs direction or of cotter by pin bending around one leg the axle in clockwise and the other leg counterclockwise conform to contour of axle as

(legs should tightly as possible).

5.

Install base cylinder rack on welding power source using 5/16-18 x

3/4 cap screws and associated hardware (see Figure 3-3).

6.

Remove the two front cap screws in top of welding power source wrapper and discard.

In stall running gear handle to wrapper using

1/4-20 x

3/4 cap screws as shown in Figure 3-3.

7.

Install power

1/4-20 cylinder bracket to rear source as shown in x

3/4 cap screws and panel of

Figure 3-3 using existing welding holes in rear panel.

8.

Set gas cylinder in rack, and lock in position with safety chain.

Cylinder must be secured at all times.

3 -3.

OPTIONAL SPW-1 PANEL INSTALLATION

(Figure 3-4)

Figure

IiYLithII~e~

3

-

4.

SPW-1 Panel Installation

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down welding power source and disconnect input power employing lockout!

tagging pro cedures before inspecting or installing.

Lockout/tagging procedures consist of removing input power plug from switch in open receptacle, padlocking position, removing line disconnect fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

IMPORTANT Retain all hardware removed during this procedure for reinstallation. All directions, such as left or right, are with respect to the operator facing the front panel.

113 336 Page 11

Flow

Adjustment

Adju

1.

Remove module cover corner of front panel.

plate from upper right

2.

Locate wiring harness clamped to air baffle in side unit.

Remove wiring harness from first clamp, and carefully with connectors pull end of through wiring opening harness in front panelthe harness will come through approx imately 2 in.

(51 mm).

3.

Disconnect

PLG2.

jumpered connector from plug

4.

Connect receptacle RC55 from SPW-1 panel to

PLG2.

Be sure the connectors are locked together (see Figure 3-4).

5.

Install SPW-1 panel into upper right corner of front panel, and secure using screws removed in

Step 1.

3 -4.

SHIELDING GAS INSTALLATION

Connection

(5/8-18 Male

Fitting Required)

C02 Installation

I~I..~l~lI~cg PRESSSURIZED CYLINDERS can rupture causing serious personal injury and loss of life; FALLING CYLINDERS can cause serious injury and equipment damage.

Keep cylinders away electrical circuits.

from any we/ding or other

Never allow a we/ding e/ectrode to touch any cylinder.

A/ways fasten cylinder securely to running gear bracket, a wa/I, or other stationary support.

B.

Regulator/Flowmeter (Customer Supplied)

(Figure

3-5)

1.

With the cylinder correctly installed, remove cylinder cap.

Stand to one side of the cylinder valve, and open the valve flows from cylinder, close slightly.

valve. This

When gas procedure gets rid of any dust that may have accumulated around the valve seat.

2.

Regulator/flowmeter must be properly equipped with a stem, nut connectors and gasket for use with either C02 cylinders or

Argon/CO~

cylinders.

Il~I~I1.If~.UI~ A gasket should be installed to pre vent leaks.

Do not use lubricants or sealing agents.

3.

Install gas regulator onto gas cylinder valve; keep the face of the regulator/flowmeter gauge in a vertical onto gas position, and tighten stem nut securely cylinder.

4.

A shielding gas output fitting is provided at the rear of the welding power source for making gas connections.

this output hose to the

Attach one end of the gas hose to fitting.

Attach other end of the gas regulator/flowmeter.

3

-

5.

WORK CABLE ASSEMBLY

A 10 foot (3 m) work cable with a end lug attached to one is supplied with the unit. To install work clamp and jack plug onto cable, proceed as follows:

A.

Work Clamp Installation (Figure 3-6)

Connection

(5/8-18 Male

Fitting Required)

Angon Installation

T8-~O9 492

Figure 3

-

5.

Typical Regulator/Flowmeter

A.

Gas

2-5)

Cylinder (Customer Supplied) (Figure

Secure the gas cylinder to the running gear with sup plied chain. If the running gear is not to be used, chain cylinder to a wall or other stationary support to prevent the cylinder from falling over and breaking off the valve.

113 336 Page 12

Step 1 &5

Figure 3

-

6.

Work Clamp Installation

1.

Insert the end of the work minal clamp with the ter lug on it through one of the two supplied insulating sleeves.

2.

Lay the work cable inside the handle of the work clamp which has the flattest inner surface.

3.

Align the smaller hole in the work clamp handle with the hole in the work cable terminal

Secure the terminal lug.

lug to the work clamp with the supplied nut and bolt.

4.

Bend the tabs on the end of the work clamp handIe around the work cable.

5.

Slide the insulating sleeve on the work cable over the work clamp handle.

6.

Twist tie wire (B) until entire tie wire is twisted and is tight around insulation of cable.

7.

Cut off looped ends of tie wire.

8.

Bend the twisted tie wire over and along the side

(C) of uninsulated portion of cable.

9.

Wrap the strip of copper foil tightly around unin sulated end of cable and twisted tie wire (D).

6.

Slide the other work remaining insulating sleeve over the clamp handle.

B.

Jack Plug Installation (Figure 3-7)

The jack plug, included in the parts package, must be installed onto the remaining end of the work cable as follows:

A

10.

Push the jack plug onto cable over copper foil

(E).

11.

Insert the 1/4-20 setscrews into the center and bottom holes in jack plug and tighten (E).

12.

Remove cable from vise, and insert jack plug into insulating sleeve.

Slide insulating sleeve over jack plug and cable until hole in insulating sleeve lines up with remaining hole in jack plug (F).

13.

Insert the hole in

8-32 self-tapping screw

(F) through insulating sleeve into jack plug and tighten.

B

3

-

6.

WELD POLARITY SELECTION (Figure 4-1)

WARNING ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

___________________

-

L

_______________

Shut down welding power source and disconnect

D

E

F

~

input power employing lockout/tagging pro cedures before inspecting or changing connec tions.

~~----~____________________

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other disconnecting device.

TA-901 024-4

Figure 3

-

7.

Jack Plug Installation

This unit should be connected for Electrode

Positive/Reverse Polarity

welding

for most wire feeding operations.

Make cable connections as follows:

1.

Remove 1 in.

of cable.

(25.4 mm) of insulation from end i.

Insert jack plug from work cable into NEGATIVE

(-) weld output turn clockwise.

receptacle, and rotate plug 1/4

2.

Clamp cable in a vise with uninsulated end exten ding upward out of vise approximately 1-3/4 in.

(44.5 mm).

2.

Insert jack plug on weld cable from unit into

POSITIVE (+) weld output rotate plug 1/4 turn clockwise.

receptacle, and

3.

Place steel tie wire in.

(item A) approximately 1/4

(6.4 mm) from end of insulation.

IMPORTANT When removing jack plugs from receptacles, rotate while withdrawing plug it from

1/4 turn receptacle.

counterclockwise

4.

Make half turn around cable ends of tie wire together.

bringing looped

5.

Insert a

3/8 in.

(9.5 mm) diameter rod through looped ends of tie wire.

IMPORTANT For Electrode Negative/Straight

_______________

Polarity connections, reverse cable connections to weld output terminals; electrode becomes negative.

113 336 Page 13

Hub

Hex Nut

Wire Outlet

Guide

Drive Roll

Cover

Front Panel

Of Unit

Gun/Feeder

Connector

Gun/Feeder

Connector

Securing Knob

Retainer p.,.,

Figure 3

-

8.

Gun/Feeder Connector And Wire Spool Installation

3 -7.

GA-20C WELDING GUN INSTALLATION

(Figures

3-8 And 3-9)

IYATI–~a~ll~C~ ELECTRIC SHOCK can kill.

Do not touch five electrical parts.

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting or installing.

Lockout/tagging procedures consist of removing input power plug from switch in open receptacle, padlocking position, removing fuses line disconnect from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

A.

Gun/Feeder Connector Installation

3-8 and 3-9)

(Figures

TA-072 573

I I~I ~i] 1 f~WI ~ that the rip of the

Wire guides should be installed so guide is as close to the drive rolls as possible without touching.

3.

Insert the outlet gun/feeder connector, which includes guide, through the access hole in the welding power source front drive assembly panel and into the opposite the wire inlet guide as il lustrated in Figures 3-8 and 3-10.

4.

Tighten the gun/feeder connector securing knob.

5.

Close and secure access door.

B.

Gun Switch Connection (Figure 3-9)

GUN

TRIGGER

I Wil ~s] I V ~ the gun assembly.

The outlet guide is provided as part of

1.

Open access door.

2.

Loosen the gun/feeder connector securing knob

(Figure 3-8).

The GUN TRIGGER switch control receptacle is provided for making connections.

Align the keys on the gun switch connector with the keyway on the GUN TRIG

GER collar receptacle, insert connector, and rotate threaded fully clockwise.

When the gun switch is closed, the welding power source contactor energizes,

shielding

gas flows, and wire feeds.

113336 Page 14

A.

B.

3 -8.

INSTALLATION OF OPTIONAL SPOOL GUN

WARNING: ELECTRIC SHOCK can kill, ARC

SPARKS can cause fire.

Do not touch ilve electrical parts.

Do not source connect two at guns the same time.

to this we/ding power

Shut down welding power source and disconnect input power cedures before employing lockout/tagging pro inspecting or insta/llng.

Watch for fire.

Keep a fire extinguisher nearby, and know how to use it.

Lockout/tagging procedures consist of removing input power plug from switch in open receptacle, padlocking position, removing line disconnect fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

If two guns are connected to this both electrode wires will be source, either gun is operated.

welding power energized when

A.

Shielding Gas Connections

IMPORTANT Use aluminum wire pure we/ding.

argon shielding gas for

Connect the shielding gas hose from the

Spool Gun to the gas regulator/flowmeter ly.

The connector has 5/8-18 on the right shielding gas supp hand threads.

B.

Weld Cable Connections (Figure 4-1)

Insert Spool Gun welding cable plug into POSITIVE welding output receptacle with flat side facing the receptacle key.

Rotate plug clockwise 1/4 turn.

C.

Wire Feed

3-10)

Receptacle Connection (Figure

The 3-socket SPOOL GUN receptacle RC3 provides a junction point for connecting a

Spool Gun to the control circuitry of the welding power source.

To make connec tions, align keyway, insert plug, and rotate threaded collar fully clockwise.

The sockets on

SPOOL designated as follows:

GUN receptacle RC3 are

SOCKET A: +24 volts ac.

SOCKET B: Machine contactor on/off; +24 volts gives machine output; open

(zero volts) equals no out put

SOCKET C: +24 volts ac.

C.

Figure 3

-

9.

Welding Gun Connections

TA-lfl 223

Figure 3-10.

Front View Of 3-Socket Receptacle

With Socket Locations

113 336 Page 15

3

-

9.

WELDING WIRE SPOOL INSTALLATION

(Figure 3-8)

1.

Open left side access door.

2.

Remove retainer ring from hub assembly.

3.

Slide spool of wire onto hub so that wire feeds off bottom of spool.

4.

Rotate spool until hole in spool aligns with pin in hub.

Slide spool onto hub until it seats against back flange of hub.

5.

Compression spring is not required for 12 in.

(305 mm) spools.

For 8 in.

(203 mm) spools, use compression spring.

Reinstall retainer ring onto hub.

6.

Close and secure access door.

3-10.

HUB TENSION ADJUSTMENT

3-8)

-

(Figure

Open left side access door, and check the hub tension by slowly pulling

The wire should unwind the wire toward the feed roll.

freely, but the hub tension should be sufficient to backlash when the wire keep the wire taut and prevent feeding ceases.

If adjustment is required, loosen or tighten the hex nut on the end of the spindle support shaft accordingly.

Close and secure side access door.

3-11.

ELECTRICAL INPUT CONNECTIONS

INPUT

A.

Electrical Input Requirements

This welding power source is designed to be operated from single-phase, 60 Hertz, ac input power which has a voltage rating that matches one of the electrical input voltages shown on the nameplate or

Consult the local electric utility input data if there is any label.

question about the type stallation site or power of electrical how source are to proper system available at the in connections to the be made.

welding

B.

Matching The

The Available

Welding

Input

Power Source

Voltage (Figure 3-11)

To

WARNING ELECTRIC SHOCK can kill.

.

Do not touch five electrical parts.

Shut down we/ding power source and disconnect input power employing cedures before inspecting lockout/tagging or installing.

pro

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other disconnecting device.

113336 Page

16

Air Baffle

Label

Input Terminal

Board

Ref. TD-072 507-F

Figure 3-11.

Electrical Input

Connections

t.1AUIll~E

INCORRECT INPUT VOLTAGE

JUMPER LINK PLACEMENT can damage unit.

Position jumper finks as shown on the input voltage label located on input terminal board.

Store unused jumper finks across linked terminals.

This welding power source is equipped with input voltage jumper links either installed or in a bag on the in put terminal board to allow operation from different line voltages.

If installed, the jumper links are positioned for the highest voltage stated on the nameplate or input data label.

If in a bag, proper installation is necessary before operation.

Remove the wrapper.

the

Reposition or install if applicable jumper links onto the input terminal board to match the available line voltage positions shown on the input voltage label (see Figure 3-1 1).

Reinstall wrapper.

C.

Wall tions

Receptacle And Power Cable Connec

(Figure 3-12)

WARNING

Install a

ELECTRIC SHOCK can kill.

_________

Do not touch five electrical parts.

fusible line disconnect switch in the input

The circuit to the welding power source.

input circuit switch provides a safe and convenient means to completely remove all electrical power from the welding power source whenever it is necessary to inspect or service the unit.

Employ lockout/tagging line before making input procedures connections on to input the welding power source.

Lockout/tagging procedures consist of padlocking line disconnect switch in from fuse box, or open position, removing fuses shutting off and red-tagging circuit breaker or other

When disconnecting device.

making input power connections, work from welding power source power cable, to wall receptacle, if applicable, to deenergized line disconnect switch.

circuits when

Always work on deenergized making input power connections.

All models are equipped with a three-conductor power cable.

Models requiring 200 or

230 volts input are

equipped with a three-prong polarized plug and wall receptacle.

The wall receptacle convenient location should be installed in a by a competent electrician. Install the wall top, receptacle with the grounding terminal at the allowing the power cable to hang downward without undue bending or twisting.

Models having an electrical input voltage above 230 volts have tors.

prewired power cables with three conduc

The black and white conductors must be con nected to the line disconnect switch and the green con ductor must be connected to a proper ground (see

Figure 3-12).

Use a grounding method that is accep tacle to the local electrical inspection authority.

WARNING ELECTRIC SHOCK can kill.

_________

Do not connect an input (white or black) conduc tor to the ground terminal.

Do not connect the ground (green) conductor to an input line terminal.

Incorrect input connections can result in an electrically energized welding power source chassis.

The ground conductor is connected to the welding power source chassis and is for grounding purposes only.

Table 3-1.

Input Conductor & Fuse Size

3-12.

THREADING WELDING WIRE (Figure 3-8)

WARNING ELECTRIC SHOCK can kill.

_________

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting or installing.

Do not energize welding power source until in structed to do so.

The gun

Do not touch live electrical parts.

welding wire is electrically energized whenever the trigger is depressed.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other disconnecting device.

CAUTION WELDING WIRE can cause

__________ wounds; HOT SURFACES can burn skin.

puncture

Do not activate gun so.

trigger until instructed to do

Do not point gun toward any part of the body, other personnel, or any conductive surface when threading welding wire.

Allow gun to cool before touching.

1.

Open left side access door.

2.

Install welding wire spool according to

Section

3-7.

lnpui Conductor Size

-

AWG

200V

10

(10)

230V

10

(10)

460V

14

(14)

Fuse Size In Amperes

575V

14

(14~J

I

200V 230V 460V 575V

40 35 20 15 input conductor sizes are based on tions for allowable

National Electrical Code specifica ampacities of insulated copper conductors, having a temperature or of 75C, cable. Numbers in ( with

) not more are than three equipment ground conductors in a conductor sizes.

raceway

Ground

Conductor

IMPORTANT Spooled wire has a tendency to

______________ unravel when loosened from the spool.

Maintain a firm grip on the wire during the threading operation.

3.

Unreel and straighten approximately 6 in.

(152 mm) of wire from wire spool.

4.

Cut off any wire that is burrs or sharp edges.

bent, and remove any

5.

Release pressure spring on drive roll assembly, and pivot upper drive roll up, away from lower drive roll.

6.

Route welding wire into wire inlet guide, along lower drive roll groove, and into wire outlet guide

(see Figure 3-8).

7.

Pivot upper drive roll downward onto lower drive roll, and reinstall pressure spring.

Be sure that welding wire is in groove of drive rolls.

8.

Lay gun cable assembly out as straight and flat as possible.

TA-112 075

Figure 3-12.

WaIl Receptacle And Power Cable

Connections

ITATf~h~II~C~ ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

The welding wire is electrically energized whenever the gun trigger is depressed.

WELDING WiRE can cause puncture wounds.

Do not point gun toward any part of the body, other personnel, or any conductive surface when threading welding wire.

113336 Page 17

9.

Energize welding power source.

If power source has spot welding switch in the capabilities,

CONTINUOUS place the position.

Selector

10.

Depress and hold the gun feeds approximately 1/4 in.

trigger until the wire

(6 mm) out the gun nozzle. If wire feeds more than 1/4 in.

out noz zle, cut wire off to

1/4 inch.

11.

Deenergize welding power source.

12.

Adjust hub tension according to Section 3-9, if necessary.

13.

Close and secure access door.

SECTION 4

-

OPERATOR CONTROLS

Selector

Switch

Spot

Time/Pulse

On Time

Control

Burnback Time

Control

Pulse Off

Time Control

Speed

Gun Trigger

Receptacle And Plug

Pilot Light

Switch

Spool Gun

Receptacle

TB-087 313-C

4

-

1.

POWER SWITCH (Figure 4-1)

ION

POWER

OFF

Figure 4

-

1.

Operator Controls

Placing the POWER switch in the ON position energizes the welding power source, making the unit operational.

Placing the POWER switch in the OFF position shuts down the unit.

113 336 Page 18

4

-

2.

PILOT LIGHT

(Figure

4-1)

-

The pilot light comes on when the POWER switch ON push button is depressed and indicates that the welding power source is energized.

4-3.

THICKNESS/VOLTS SELECTOR (Figure 4-1)

THICKNESS

VOLTS

CAUTION: ARCING can damage contact sur faces.

Do not change

THICKNESS! VOLTS selector plug position while welding or under load.

Arcing causes the contacts to become pitted and even tually inoperative.

The THICKNESS/VOLTS selector jack plug and recep tacles provide a selection of heat input to the weld from

1 through 6. The higher the numbered tap the hotter the weld.

IMPORTANT: After installing selector plug into

_________

VOL TAGE ADJUSTMENT receptacle, rotate plug 1/4 turn clockwise to secure in place.

When removing plug from receptacle, rotate plug 1/4 turn counterclockwise while withdrawing it from receptacle.

4

-

4.

FINE

(Figure 4-1)

TUNING/WIRE SPEED CONTROL

O Q

FINE

WIRE

TUNING

SPEED

4

-

6.

CIRCUIT BREAKERS

Two circuit breakers, located behind the access door immediately above the drive roll assembly, are provided to protect the welding power source in the event of an overload.

Circuit breaker mature

CB1 protects the motor ar and circuit breaker CB2 protects the welding power source control circuitry.

If either circuit breaker opens, wire feeding stops.

See Section 6-8 for circuit breakers.

resetting

The FINE TUNING/WIRE SPEED control provides a means of varying both the speed of the wire feed motor and weld current of each THICKNESS/VOLTS tap.

Rotating the FINE TUNING/WIRE SPEED control in a clockwise direction increases the rate of the wire feed and weld current within the

THICKNESS/VOLTS tap.

range of the selected

When the FINE TUNING/WIRE SPEED control is set at

0, wire feeds at the slowest speed and weld current is at minimum in the selected wire feeds at the fastest range; when set at

100, the speed and weld current is at maximum in that range.

The scale surrounding the FINE TUNING/WIRE SPEED control is a relative scale only; it does not represent an actual inches per minute or weld current value.

IMPORTANT The FINE

___________ control may be adjusted while

TUNING/WIRE SPEED welding.

IMPORTANT In the PUL SE mode, the FINE TUN

____________

ING!

WIRE SPEED control must be set at 50 percent or less when using THICKNESS!

VOL TS taps

5 and 6.

4

-

5.

FAN-ON-DEMAND

FAN

CONTROLLED

BY THERMOSTAT

Fan motor FM is fan thermostatically controlled to provide cooling of main transformer Ti and rectifier assembly SRi if these components require cooling.

The fan will run only when cooling is required.

Two normally-open thermostats, TP 1 in rectifier assembly

SRi and TP2 in main transformer Ti, and relay CR2, regulate fan motor operation.

When the main transformer and/or rectifier to close assembly heat up enough thermostat(s) TP1 and/or TP2~, fan relay CR2 energizes, energizing the fan motor.

The fan motor will continue to rectifier operate until the main transformer and/or assembly have cooled enough to permit ther mostats power

TP1 source and TP2 to is shut down.

open or until the welding

4

-

7.

OPTIONAL SPOT PULSE PANEL CON

TROLS

(Figure

4-1)

IMPORTANT In the PULSE mode, the WIRE

_____________

SPEED FINE ADJUSTMENT control must be set at 50 percent or less when taps

5 and 6.

using VOL TAGE ADJUSTMENT

A.

Selector Switch

The Selector switch tinuous, spot, or enables the operator to select con pulsed wire feed operation.

1.

Continuous Position

Placing the Selector switch in the CON

TINUOUS position and depressing the gun trig ger feeds welding wire for as long as the gun trig ger remains closed.

2.

Spot Position

Placing the Selector switch in the SPOT position and depressing the gun trigger feeds welding wire for the length of time set on the SPOT TIME control.

3.

Pulse Position

Placing the Selector switch in the PULSE posi tion and depressing the gun trigger feeds welding wire for the length of time set on the

PULSE ON TIME control. At the end of the pulse on time, welding wire stops feeding for the length of time set on the PULSE OFF TIME con trol. The welding wire continues to pulse feed on and oft for the selected times until the gun trig ger is released. The pulse option provides better control of the heat input to the weld on thin gauge metals, thereby the likelihood of decreasing melt-throughs.

distortion and

B.

Spot Time/Pulse On Time Control

The SPOT TIME/PULSE ON TIME control enables the operator to select from 0.5

to 4 seconds of weld time for spot operation or

0.25

to 2 seconds of pulse time for pulse operation.

Rotating the control clockwise in creases spot/pulse on time.

The control scale is calibrated in percent and does not indicate actual spot/pulse on times.

113 336 Page 19

C.

Pulse Off Time Control

The PULSE OFF TIME control enables the select from 0.25

to 1 second of operator to pulse off time for pulse operation.

Rotating the control clockwise increases pulse off time. The control scale is calibrated in percent and does not indicate actual pulse off time.

D.

Burnback Time Control

The BURN BACK TIME control provides a means of ad justing the time period (up to a seconds) that the maximum of 0.25

welding wire remains electrically energized after the wire feeding has stopped.

By adjusting this control properly, the welding wire will neither freeze in the weld of the gun. If the welding puddle nor in the contact tube wire freezes to the work, in crease the burnback time.

If the welding wire burns back into the contact tube, decrease the burnback time.

Rotate the control clockwise to increase the burnback time, and rotate the control counterclockwise to decrease the burnback time. The scale surrounding the control is calibrated in percent and does not represent an actual burnback time.

SECTION 5

-

SEQUENCE OF OPERATION

I~Li:I~kC~ ELECTRIC SHOCK can kill; MOVING

PARTS can cause serious injury; IMPROPER AIR

FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts.

Do not touch five electrical parts.

Keep clear of pinch points.

Keep all covers and panels in place while operating.

Warranty is void if the wire feeder is operated with any portion of the outer enclosure removed.

ARC RAYS.

SPARKS, AND HOT SURFACES can burn eyes and skin; NOISE can damage hearing.

Wear correct eye, ear,

FUMES AND and

GASES can body protection.

seriously harm your health.

Ventilate to keep from breathing fumes and gases.

If ventilation is inadequate, use approved breathing apparatus.

WELDING WIRE can cause puncture wounds.

Do not point gun toward any part of the body, any conductive surface, or other personnel.

HOT METAL, SPATTER.

AND SLAG can cause fire and burns.

Watch for fire.

Have a fire extinguisher nearby, and know how to use it.

Allow work and equipment to cool before handl ing.

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

Wearers should consult with their doctor before going near arc operations.

welding, gouging, or spot welding

See Section 1

-

Safety Rules For Operation

Welding Power Source for basic welding

Of Arc information.

5

-

1.

GAS METAL ARC WELDING

(GMAW)

-

CONTINUOUS AND GAS METAL ARC

WELDING-PULSED ARC (GMAW-P)

WARNING: Read and follow safety information at beginning of entire Section 5 before proceeding.

IMPORTANT

______________ to NEGA TIVE (-)

Be sure weld that work cable is installed in output receptacle and weld cable from unit is installed into POSITIVE (+1 weld output receptacle.

Thoroughly clean joint area of workpiece.

CAUTION WELDING CURRENT can

3.

Connect work clamp to workpiece.

4.

Turn on

shielding

gas at the source.

damage

_________ vehicle computers and other electronic com ponents.

Disconnect both batter, cables before welding on a vehicle.

5.

2.

Place work to avoid c/amp as close to the weld as possible long electrical paths.

Be sure gun to power source as well as cable con nections to work c/amp are clean and tight.

To be 100 percent free of risk, disconnect the computer(s) from the vehicle.

Open drive roll purge and

housing

to prevent wire feed, and adjust gas system as follows: a.

Open left side access door, release pressure spring per on drive roll assembly, and pivot drive roll up, away from up lower drive roll.

I~I~lI~rcg

The

ELECTRIC SHOCK can welding wire and all metal parts in kill.

Do not touch five e/ectrical parts.

Do not touch we/ding wire or any metal contact with it while we/ding.

contact carry weld current whenever the gun trigger is part in with it depressed.

b.

Energize welding power source, and depress gun trigger for approximately 15 seconds to adjust regulator/flowmeter and to gas hose.

purge the

1.

Install and connect unit according to

Section 3.

113336 Page 20

Table 5

-

1.

Voltage Adjustment Jack Plug Positions For Mild Steel

Voltage Adjustment

Receptacle 1 2 3 4 5

METAL GAUGES

THICK-

NESS

INCHES

MILLIMETERS

*AMPERAGE For

.030 in.

(0.8mm) WIRE

.

22-18

.035+

.8+

30-55

18-16 16-14

.047+

1.2+

.059+

1.5+

55-85

14-12

.067+

1.9+

12-10

.104+

2.6+

85-105 105-130 130-150

6

10

Or, Heavier

.134+

3.4+

150-180

*AMPERAGE For

.035 in.

(0.9mm) WIRE

35-65 65-95 95-115 115-140 140-180 175-220

*Amperage values are obtained by adjusting

Control.

the WIRE SPEED FINE ADJUSTMENT

IMPORTANT Shielding gas flow rate of 15 to 25 cfh

______________ is typical.

We/ding Out of position at high wire feed speeds or welding in a drafty environment will require more shielding gas.

c.

Deenergize welding power source.

d.

Close drive roll housing as follows: pivot up per drive roll down reinstall pressure onto lower drive adjustment spring roll, onto and pin on top drive roll cover.

e.

Close and secure side access door.

6.

If applicable, place the Selector switch on the optional SPW-1 Panel in the CONTINUOUS position if continuous welding, and place the switch in the PULSE position if pulse welding

(see Section 4-7).

7.

If pulse welding, rotate the SPOT TIME/PULSE

ON TIME and PULSE OFF TIME controls to desired settings (see Section 4-7).

8.

Place the THICKNESS/VOLTS selector jack plug in the appropriate THICKNESS/VOLTS receptacle for the thickness of metal being weld ed (see Section 4-3 and Table 5-1).

uI~la.1;1v~i~ It is important that the selected voltage be appropriate for type of weld and thickness of material. Be sure that the weld bead is throughly fused with the base metal along the total length of the bead. If the weld bead does not penetrate the base metal, in crease the weld voltage.

If the edges of the bead cut in to the base metal, decrease weld voltage.

9.

Rotate the FINE TUNING/WIRE SPEED control to 50.

(The control can be adjusted as required while welding.)

10.

Energize welding power source.

11.

Be sure in.

welding wire extends approximately 1/4

(6.4 mm) out gun nozzle, position gun over joint, lower welding helmet, and depress gun trigger.

IMPORTANT: The welding wire is not energized un

______ til the gun trigger is pressed; therefore, the operator can accurately position gun on weld joint before he/met and pressing gun trigger.

lowering

12.

Readjust FINE TUNING/WIRE SPEED control as necessary.

IMPORTANT Adjust the wire speed to keep weld

_____________ spatter at a minimum while

maintaining

a steady, quickcrackling sounding arc.

(When optimum arc length is reached, arc will sound like frying bacon).

13.

If pulse welding, readjust SPOT TIME/PULSE

ON TIME and PULSE OFF TIME controls as necessary.

5 -2.

GAS METAL ARC WELDING (GMAW)

SPOT (Models With Optional SPW-1 Panel Only)

WARNING: Read and follow safety information at beginning of entire Section 5 before proceeding.

1.

Install and connect unit according to

Section 3.

2.

Thoroughly clean joint area of workpiece.

CAUTION WELDING CURRENT can

_________ vehicle computers damage and other electronic com ponents.

Disconnect both battery cables before welding on a vehicle.

Place work clamp as close to the weld as possible to avoid long electrical paths.

Be sure gun to power source as nections to work clamp are well as clean and cable con tight.

To be 100 percent free of computer(s) from the vehicle.

risk, disconnect the

113336 Page 21

3.

Connect work clamp to work piece.

4.

Turn on shielding gas at the source.

5.

Adjust shielding gas pressure, and purge shielding gas hose as follows: a.

Open left side access pressure door of unit, release spring on drive roll assembly, and pivot upper drive roll up, away from lower drive roll.

WARNING ELECTRIC SHOCK can kill.

_________

Do not touch ilve

Do not touch electrical parts.

we/ding wire or any metal part in contact with it while welding.

Welding wire and all metal parts in contact with it carry weld current whenever the gun trigger is depressed.

b.

Energize welding power source, and depress gun trigger for approximately 15 seconds to adjust the regulator/flowmeter and to purge the gas hose.

Ik~I~s];If..t~Ig is

Shielding gas flow rate of 15 to25 cfh typical.

Welding out of position at high wire feed speeds or welding in a drafty environment will require more shielding gas.

c.

Deenergize welding power source.

d.

Pivot upper drive roll down onto lower drive roll, and reinstall pressure adjustment spring onto pin on top drive roll cover.

e.

Close and secure side access door.

6.

Set feed spot weld parameters (weld voltage, wire speed, spot weld time, and burnback time) as follows: a.

Obtain type, sample pieces of metal but the same approximately twice the thickness of the final workpiece.

b.

Place Selector Switch on optional SPW-1 panel in CONTINUOUS position, and set welding voltage and wire feed speed parameters according

Section 5-1.

(Set to Steps voltage

8 thru and wire

12 in feed speed for metal thickness of sample metal.) c.

After voltage and wire feed speed parameters have been set,

deenergize

welding power source, remove continuous welding nozzle from gun, and replace nozzle with appropriate spot welding nozzle.

d.

Obtain sample metal of the same type and thickness of final workpiece.

e.

Place welding power source and rotate in SPOT mode,

SPOT TIME/PULSE ON TIME and BURNBACK TIME controls to desired

IMPORTANT: The correct burnback time allows the wire to burn back just free of the weld puddle.

If the welding wire freezes to the workpiece at the end of the weld cycle, increase burnback time. If the welding wire burns back into the contact tube, decrease burnback time. If the wire burns back into the contact tube, it may be necessary to

(see gun Owners replace the contact tube in the gun.

Manual for contact tube replacement procedure.) f.

Make several practice spot welds to deter mine if weld parameters are set

(Refer to Tabe 5-2 to check correctly.

sample weld.)

To spot weld, place gun nozzle directly on workpiece, hold gun motionless, and depress gun trigger.

When depressed, trigger is welding wire and shielding gas well feed for the length of time set on the

SPOT TIME/PULSE ON TIME Control.

IMPORTANT The welding wire is not energized un til the gun trigger is pressed, therefore, the operator can accurately position gun on weld joint before lowering he/met and pressing gun trigger.

IMPORTANT The gun trigger must be held closed

_____________ until the SPOT TIME/PULSE ON TIME control has tim ed out, completing the spot weld cycle.

If the trigger is released before the cycle is complete, the cycle stops, and the unit resets for another weld cycle.

7.

After all weld final workpiece.

parameters have been set, weld

5 -3.

SHUTrING DOWN

1.

Stop welding.

2.

Shut down welding power source.

3.

Turn off shielding gas at the source.

~

HIGH CONCENTRATION

SHIELDING GAS can harm health or kill.

Shut off gas supply when not in use.

OF

113 336 Page 22

Table 5

-

2.

Checking

Weld Parameters

Weld Appearance Cause Correction Procedure

Dark blue circle or small protrusion visible on reverse side of weld.

Voltage and wire feed speed parameters are set correctly.

None.

Small burn-through on reverse side of weld.

Voltage and wire feed speed parameters are set correctly, but spot time too long.

Decrease SPOT TIME/PULSE ON TIME Control setting.

Excessive burn-through on reverse side of weld.

Welding voltage set too high.

Repeat Steps 6a thru f in Section 5-2 to reset voltage and wire feed speed parameters.

No dark blue circle or small protrusion on reverse side of weld, but when welded pieces are pulled apart, a small hole is torn in bottom piece of metal.

Voltage and wire feed speed parameters set correctly, but spot time too short.

Increase setting.

SPOT TIME/PULSE ON TIME Control

No dark blue circle or small protrusion on reverse side of weld, and when welded pieces are pulled apart, there is minimal penetration into lower piece of metal.

Welding voltage set too low,

Repeat Steps 6a thru f in Section 5-2 to reset voltage and wire feed speed parameters.

SECTION 6

-

MAINTENANCE & TROUBLESHOOTING

IMPORTANT Every six months inspect the labels on

______________ this unit for legibility.

All precautionary labels must be maintained in a c/early readable state and replaced when necessary. See the Parts List for part number of precautionary labels.

6

-

1.

FAN MOTOR

-

This unit is equipped with an exhaust fan and relies on forced draft for adequate cool ing.

The fan motor is manufactured with lifetime sealed bearings and requires no maintenance.

6

-

2.

INSPECTION AND UPKEEP

-

WARNING: ELECTRIC SHOCK can kill.

____

Do not touch live electrical parts.

Shut down unit and disconnect input power employing lockout!

tagging procedures before inspecting, maintaining, or servicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlockingline disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other disconnecting device.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

Usage and shop conditions will determine the of maintenance. At minimum, frequency and type inspect equipment every three months as follows:

1.

Inspect all cables and hoses for breaks in the insulation damage jacket, particularly at or the plugs or ends.

Repair or replace cable(s) or hoses as necessary.

2.

Remove grease and dirt from components, and remove moisture from electrical parts and cables.

3.

Be sure that all connections are clean and tight.

6 -3.

INTERNAL CLEANING

WARNING ELECTRIC SHOCK can kill.

_________

Do not touch five electrical parts.

Shut down welding power source and disconnect input power employing /ocko ut/tagging pro cedures before inspecting, maintaining, or ser vicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other disconnecting device.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

Annually blow out or vacuum dust and dirt from around welding power source internal components.

If dirty or dusty conditions are present, clean unit monthly.

113336 Page 23

Key Drive Roll

Ring

Drive Roll

Cover Pivot Pin

Cotter Pin

Gun/Feeder

Connector Opening

Lower Drive

Roll Shaft

Lower Drive

And Key

Wire Drive

Terminal Nut

Insulator

Brush (2)

TC-072 511

Figure 6

-

1.

Replacing

Drive Rolls And Motor Brushes

6 -4.

CLEANING DRIVE ROLLS (Figure 6-1)

UI~I~s1~f Failure to properly maintain the drive rolls can result in a decrease the buildup of wire particles which will efficiency of the wire feeding operation.

Every time welding wire is installed or the wire groove on particles.

changed, each drive roll for a inspect buildup of wire

WARNING ELECTRIC SHOCK can kill.

_________

Do not touch live electrical parts.

Keep c/ear of pinch points.

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting, maintaining, or ser vicing.

Lockout/tagging procedures consist of removing input power plug switch in from open receptacle, position, padocking removing line disconnect fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

1.

Open left side access door.

2.

Remove drive rolls according to

Section 6-5.

WARNING HIGH ROTATIONAL SPEED may

_________ cause damage to drive rolls and injure personnel.

S Do not allow drive rolls to rotate at high speed if compressed air is used for cleaning drive roll assembly.

3.

Using a wire brush, clean the drive roll groove in each drive roll.

4.

Reinstall the drive rolls into the unit according to

Section 6-5.

5.

Close and secure side access door.

6.

Resume operation.

6

-

5.

REPLACING DRIVE ROLL AND WIRE INLET

GUIDE (Figure 6-1)

-

As a result of wear or a change in wire size, it may be necessay to replace the drive rolls and wire inlet guide.

Proceed as follows:

A.

Replacing Upper Drive Roll

1.

Disassembly a.

Open and secure left side access door.

b.

Release pressure drive roll cover.

spring from spring pin on

113336 Page24

c.

Remove cotter pin from drive roll cover pivot pin.

d.

Remove cover pivot pin, thereby freeing from drive assembly.

drive roll e.

Remove from one retaining ring and flanged end of drive roll shaft.

bearing f.

Push drive roll shaft out drive roll cover until drive roll falls from cover.Be

sure that key re mains in slot in drive roll shaft.

2.

Assembly a.

Install drive roll into drive roll cover with gear section of drive roll cover

(side facing facing the rear of the motor insulator).

Be sure to two align clearance hole in drive roll with the shaft clearance holes in drive roll cover.

b.

Align key in drive roll shaft with keyway drive in roll, and route end of drive roll shaft without retaining ring and bearing through hole in rear side of drive roll cover, through drive roll, and Out front side of cover.

c.

Reinstall flanged bearing and retaining ring removed in Step le onto end of drive roll shaft.

d.

Reinstall drive roll cover and pivot pin into drive roll assembly.

-e.

Reinstall cotter pin onto pivot pin.

f.

If installing or changing lower drive roll, pro ceed to Section 6-5B; otherwise, reengage pressure cover, spring over spring pin on drive roll and close and secure access door.

B.

Replacing Lower Drive Roll

1.

Disassembly a.

If applicable, release pressure spring from spring pin on drive roll cover.

b.

If applicable, pivot upper drive roll up, away from lower drive roll.

c.

Remove self-locking nut from end of lower drive roll sure that shaft, and remove drive roll.

Be key remains in slot in drive roll shaft.

2.

Assembly a.

Install drive roll onto lower drive roll sh~ft aligning keyway in drive roll clearance hole with key in drive roll shaft.

(Drive roll must be installed with gear section facing the motor insulator.) b.

Reinstall shaft.

self-locking nut onto drive roll c.

Adjust horizontal position of lower drive roll in or out as necessary.

To move the drive roll in towards the motor insulator, rotate the self-locking nut clockwise.

drive roll out away

To move the from the center panel of the unit, rotate the nut counterclockwise.

IMPORTANT: Be sure that upper and lower drive roll gears are properly meshed and the drive roll grooves aligned when adjusting horizontal position are of lower drive roll.

d.

Reengage pressure spring over spring pin on drive roll cover.

e.

If replacing wire inlet tion 6-5C; otherwise, guide, proceed to

Sec close and secure side access door.

C.

Replacing Wire Inlet Guide

1.

Loosen wire guide securing screw.

2.

Remove wire guide from drive housing.

3.

Install new wire left side of drive guide through mounting housing (see hole in

Figure 6-1).

IMPORTANT Wire close to guide should be installed as the drive rolls as possible without touching them.

4.

Tighten wire guide securing setscrew.

5.

Close and secure side access door.

113 336 Page 25

Ring

Keyed

Washer

Fiber

Washer

Brake

Washer

Flat

Washer

Spring

Brake

Fiber Washer

Ref TD-072 509-0

Figure6 -2.

Hub Assembly

6

-

6.

REALIGNING DRIVE HOUSING (Figure 6-1)

WARNING ELECTRIC SHOCK can kill.

.

Do not touch live electrical parts.

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting, maintaining, or ser vicing.

Lockout/tagging procedures consist of removing input power plug from switch in open receptacle, position, padlocking removing line disconnect fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

The wire drive housing is made with mounting holes of sufficient clearance to provide adjustment of the wire guides up or down in relation to the drive rolls. This ad justment has been factory set, but if readjustment becomes necessary proceed as follows:

1.

Open left side access door.

2.

Loosen drive housing mounting screws and the weld cable terminal nut securing wire drive hous ing to the air baffle.

3.

Slide drive housing up or down until the wire can be fed straight through the wire inlet guide and wire outlet guide while wire is seated in drive roll groove.

4.

Tighten mounting screw and weld terminal nut.

5.

Close and secure access door.

-

6

-

7.

REPLACING HUB ASSEMBLY (Figure

6-2)

-

If it should become necessary to all of the hub assembly, reinstall the new replace hub part or assembly as follows:

1.

Slide the following items onto the spindle sup port shaft in order given: a.

Fiber Washer b.

Brake Washer c.

Hub d.

Brake Washer e.

Fiber Washer f.

Keyed Washer g.

Spring h.

Flat Washer

2.

Rotate hex nut onto support shaft.

Hex nut should be rotated only until a slight drag is felt while turning hub.

3.

Install welding wire according to Section 3-9.

4.

Reinstall retaining ring onto hub.

6

-

8.

RESETTING CIRCUIT BREAKERS CB1 AND

CB2

WARNING ELECTRIC SHOCK can kill.

Do not touch five electrical parts.

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting, maintaining, or ser vicing.

113336 Page26

Lockout!

tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Cicuit breakers CB1 and CB2 are the provided to protect welding power source in the event of an overload.

Circuit breaker CB1 protects the motor armature, and

CB2 protects the welding power source control cir cuitry.

When the circuit breakers are in (ON position), the circuit breakers are functional.

When the circuit breakers are out (OFF position), the circuit breakers are open.

If CB1 and/or CB2

Reset CB1 and/or open,

CB2 as follows: wire feeding stops.

1.

Open left side access door.

2.

Check for jammed wire or clogged gun liner, and correct problem.

If motor overload happens often, repair or replace the motor or liner.

3.

Check for binding drive gear or misaligned drive rolls, and correct problem.

4.

Reset circuit breaker(s) be necessary to allow a

(depress button); it may cooling period before the breaker can be reset.

5.

Close and secure access door.

6.

Resume operation.

6

-

9.

RECTIFIER PROTECTION (Thermal Shut down)

-

Rectifier SR3 is protected from overheating by a normally-closed thermostat TP3 wire in the relay

CR1 and contactor W coil circuit. Should overheating occur,

TP3 would open necessary to allow a causing CR1 and thereby the contactor to weld output.

drop out

(deenergize) thereby stopping all

If this condition occurs, it will be

cooling

period before resuming operation.

6

-

10.

INSPECTING AND REPLACING MOTOR

BRUSHES (Figure 6-1)

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down welding power source and disconnect input power employing lockout!

tagging pro cedures before inspecting, maintaining, or ser vicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, shutting off and removing red-tagging fuses from fuse circuit breaker or box, other disconnecting device.

1.

Open left side access door.

2.

Remove the two brush holder cap screws.

3.

Remove brushes.

4.

Examine brushes, and replace them if they are chipped or broken or if less than 1/4 in.

(6.4

mm) of brush material remains.

5.

Install brushes, arid reinstall brush holder capscrews.

CAUTION DISASSEMBLY OF MOTOR FIELD

MAGNETS can result in personal injury and equip ment damage.

Limit wire drive motor repairs to brush replace ment.

The field magnets are very strong.

If disassembly is at tempted, injury to fingers and hands may result from the magnets

The field drawing magnets are the armature back into the matched sets and motor.

operation may be affected if the magnets are tampered with.

Warranty is void if the motor is tampered with.

6.

Close and secure access door.

6-11.

REPLACING SPW-1

BOARD (Figure 6-3)

PANEL CIRCUIT

Circuit Board

PC5O

Circuit Board

Securing Screw

~-~-

Receptacle

RC55

TC-086 924-A

Figure 6

-

3.

SPW-1 Panel Components

WARNING ELECTRIC SHOCK can kill.

__________

Do not touch live electrical parts.

Shut down welding power source and disconnect input power employing cedures before

lockout/tagging

pro

inspecting,

maintaining, or ser vicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing fuses from fuse box, shutting off and red-tagging circuit breaker or other

disconnecting

device.

If the printed circuit board is at fault for a problem with the unit, replace the board using the

following

pro cedure.

Do not nearest attempt board repair.

Contact the

Factory Authorized Service Station for correct replacement part.

113336 Page27

CAUTION ELECTROSTATIC DISCHARGE can

_________ damage circuit board

Put on components.

properly grounded wrist strap

BEFORE handling circuit boards.

Transport all static-sensitive components in pro per static-shielding

Perform work only carriers at a or packages.

static-safe work area.

IWAl~.]:lf~UIf All directions, such as left or right, are with respect to the operator facing the unit front

Retain all hardware removed panel.

during this procedure for reinstallation unless specifically told otherwise.

1.

Remove screws securing SPW-1 Panel to

welding

power source front panel.

2.

Pull SPW-1 Panel out of unit.

3.

Disconnect wiring harness plug PLG2 from receptacle RC55 on

SPW-1 Panel, and remove panel from unit.

4.

Remove

SPW-1 screws securing circuit board PC5O to

Panel, and remove circuit board.

5.

Install new circuit board PC5O to securing screws removed in Step 5.

panel using

6.

Reconnect tacle wiring harness plug PLG2 to recep

RC55 on

SPW-1 Panel, and reinstall panel into welding power source.

6-12.

REPLACING SPW-1 PANEL

WARNING ELECTRIC SHOCK can kill.

Do not touch live

Shut down electrical parts.

welding power source and disconnect input power employing cedures before lockout/tagging inspecting, maintaining, or pro ser vicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, switch in open padlocking line disconnect position, removing fuses from fuse box, breaker or other or shutting off and red-tagging circuit disconnecting device.

CAUTION

ELECTROSTATIC DISCHARGE can

_______ damage circuit board components.

Put on properly grounded wrist strap

BEFORE handling circuit boards.

Transport all static-sensitive components in pro per static-shielding

Perform work only carriers at a or packages.

static-safe work area.

IMPORTANT All directions, such as left or

_______________ with respect to the operator facing right, the unit front are panel.

Retain all hardware removed during this procedure for reinstallation unless specifically told othe,wise.

1.

Remove screws securing SPW-1 Panel to welding power source front panel.

2.

Pull SPW-1 Panel out of unit.

3.

Disconnect wiring harness plug PLG2 from receptacle RC55 on

SPW-1 Panel, and remove panel from unit.

4.

Connect wiring harness plug PLG2 to receptacle

RC55 on new

SPW-1 Panel, and install panel in to welding power source.

5.

Secure SPW-1 Panel to welding power source using screws removed in Step 1.

6-13.

TROUBLESHOOTING CHART

WARNING: ELECTRIC SHOCK can kill.

____

Do not touch live electrical parts.

Shut down welding power source and disconnect input power employing lockout/tagging pro cedures before inspecting or servicing.

Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open or position, removing shutting off and red-tagging fuses from fuse circuit breaker or box, other disconnecting device.

MOVING PARTS can cause serious injury.

Keep clear of moving parts.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

Troubleshooting to be performed only by qualified per sons.

It is assumed that the unit was properly installed accor ding to Section 3 of this manual, the operator is familiar with the function of controls, the welding power source was working properly, and that the trouble is not related to the welding process. The to following chart is designed diagnose and provide remedies for some of the troubles that may develop in this welding power source.

Use while this chart in performing conjunction with the circuit diagram troubleshooting procedures.

If the trouble is not remedied after cedures, the nearest performing these pro

Factory Authorized Service Sta tion should be contacted.

In all malfunction6 the manufacturers cases of equipment recommendations should be strictly followed.

113336 Page28

TROUBLE PROBABLE CAUSE REMEDY

No weld not feed.

output; wire does Line Disconnect Switch in

Off position.

Place Line Disconnect Switch in On position.

Improper electrical input connections.

See Section 3-1 1 for proper input connections.

Input voltage not in proper jumper position.

links See Section 3-1 1 for proper jumper link position.

Line fuse(s) open.

Check and replace open line fuses.

Gun leads.

switch, or gun switch

See gun Owners Manual.

POWER switch 51.

Replace Si.

Switch control relay CR1.

Replace CR1.

No weld output; wire feeds.

Main rectifier SRi overheating (thermal shut down).

Allow rectifier to cool down (see Section 6-9).

THICKNESS/VOLTS not secure in plug receptacle..

Secure connection.

Low weld output.

Work loose or clamp connection incomplete due to rust, of paint, etc.

on surface workpiece.

Check work connection for good metal to metal contact.

Contact tube.

Low input voltage.

See gun Owners Manual.

Check for proper input voltage.

Electrode wire feeding while stops welding.

Input voltage jumper link not in proper position.

See Section 3-1 1 for proper jumper link position.

Circuit breaker CB2.

Check and reset CB2 if necessary

(see Section

6-8).

Sharp or excessive bend in gun cables or liners,

Straighten gun cables and/or replace liners (see gun Owners

Manual).

Incorrect hub tension.

Readjust hub tension (see Section 3-10).

Contact tube opening restricted; burnback of wire into tube.

See gun

Owners Manual.

Friction in gun.

Gun liner dirty, restricted.

See gun

Owners Manual.

See gun Owners Manual.

Broken or liner.

damaged gun

See gun Owners Manual.

Worn drive rolls.

Drive rolls misaligned.

Replace drive rolls according to

Section 6-5.

Realign drive rolls and/or 6-6.

according to

Section 6-5

113336 Page

29

TROUBLE PROBABLE CAUSE REMEDY

Electrode wire stops feeding while welding.

Excessive motor.

loading of drive Clear restriction in drive assembly.

Drive motor brushes.

Check and tion 6-10).

replace brushes if necessary (see Sec

Drive motor M.

Check and replace motor if necessary.

Gun trigger switch inoperative or leads broken.

See gun Owners Manual.

Unit shuts down while welding.

Fan motor FM.

No open-circuit voltage.

Check and replace FM if necessary.

THICKNESS/VOLTS not secure in plug receptacle.

Secure plug in receptacle.

Contactor W points.

Gun switch.

Transformer Ti.

Contact nearest tion.

Factory Authorized Service Sta

See gun

Owners Manual.

Contact nearest tion.

Factory Authorized Service Sta

Plug PLG2 not secure in receptacle RC55 (models with optional Spot Weld

Panel only).

Secure PLG2 into RC55.

Wire does not feed; open circuit voltage normal.

Circuit breaker CB1 or

CB2.

Rectifier SR2.

Reset CB1 or

CB2 (see Section 6-8).

Contact nearest Factory Authorized Service Sta tion.

Wire feed motor

M.

Spot weld timer does not time out

(modes with

SPW-1 panel).

SPW-1 panel.

Pulsed wire feed not available.

operation SPW-1 panel.

Replace M.

Replace SPW-1 circuit board PC5O (see Section

6-11), or replace SPW-1 Panel, if necessary (see

Section 6-12).

Replace SPW-1 circuit board PC5O (see Section

6-1 1), or replace SPW-1 Panel, if necessary (see

Section 6-12).

113336 Page3O

PC I

AC B

S

2

4

<

SI

PLGI

TE

PLG2

9

POSITIVE

~GATIVE

Circuit Diagram No. B-119 008

Figure 6

-

4.

Circuit Diagram For Welding Power Source

CON 1.

SPOT

PULSE

PC50

7

9 a

8

5

56

Circuit Diagram No.

A-090 568-A

Figure 6

-

5.

Circuit Diagram For SPW-1 Panel

113 336 Page 31

113336 Page32

---

~~~1

I

Circuit Diagram No.

B-092 817-A

Figure 6

-

6.

Circuit Diagram For SPW-1 Panel Printed Circuit Board PC5O

CAUTION

SECTION 7

-

WELDING TECHNIQUES & TROUBLESHOOTING

WELDING CURRENT can

_________ vehicle computers damage and other electronic com ponents.

Disconnect both battery cab/es before we/ding on a vehicle.

P/ace work c/amp as close to the we/d as possible to avoid long electrical paths.

Be sure gun to power source as well as nections to work cab/e con clamp are clean and tight.

To be 100 percent free of computer(s) from the vehicle.

risk, disconnect the

7

-

1.

GAS METAL ARC WELDING (GMAW)

-

CONTINUOUS SEAM

The gun can movement be moved known as the along the seam in a steady drag technique (see Figure

7-3), or i~ can be oscillated a few degrees beyond each side of the seam.

The travel speed will be regulated by the type of weld bead required, the thickness of the material, welding current selected and the technique us ed.

However, the average minute (0.4-0.5

mpm).

speed is 15 to

20 inches per

~.

.

.

~s ~ .

TA057 46916

Figure 7 -3.

Welding Techniques

Other welding techniques that affect the weld characteristics in the GMAW welding process include the backhand and forehand up and vertical down technique, and the vertical positions.

In the backhand techni que the gun is positioned so that the electrode wire is feeding in the opposite direction of arc travel. The filler metal is being fed into the weld metal previously deposited.

In the forehand technique the gun is angled so that the electrode wire is fed in the same direction as the arc a more travel. The backhand stable arc technique generally yields and less spatter on the workpiece.

Figure 7

-

1.

Continuous Seam

The ability to produce a good bead while using the Con tinuous Seam Gas Metal Arc process is several factors.

One of the most dependent important, on after wire and shielding gas selection, is the way the gun is held.

Cradle the gun in one hand and rest the side of the hand on the workpiece (avoid doing this on hot material); use other hand

Position the to gun hold gun and either toward control or away the gun from the a

45 to

60 degree lead angle (see Figure 7-2).

trigger.

body at

This will give a good view of the arc and make it easier to follow the seam while

5/16 inch wearing a helmet.

Maintain a

1/4 to

(6-8 mm) distance from the bottom of the gun nozzle to the workpiece during the arc starting and welding period.

Do not pull the gun back from the seam when the arc starts, as this will create a long wire exten sion and result in a poor weld.

The welding wire is not energized until the trigger is pressed.

Therefore the welding wire can be extended

1/4 inch the seam

(6 mm) before beyond the gun nozzle and placed on lowering the helmet and pressing the gun trigger.

Direction of Arc Travel

Backhand Technique

Figure 7

-

2.

Gun Position

TA-057469-IIB

Direction of Arc Travel

Forehand Technique

Figure 7

-

4.

Longitudinal Gun Positions

113336 Page33

The vertical up and/or vertical down describe the direction of arc techniques travel when the welding must be done in the vertical position.

In both of these techniques gun positioning is extremely important because the arc must be kept on the leading edge of the puddle to ensure complete weld penetration.

The drag technique is generally employed when welding in the vertical position, but when bridging a gap, the arc can be oscillated from one side of the work to the other.

In pulsed welding the filler metal is transferred to the work during the period of Pulse On Time, and cools dur ing the period of Pulse Off Time.

When the selector switch is placed in the PULSE position and the gun trig ger is gun depressed, the welding wire feeds through the for the length of time set on the SPOT

TIME/PULSE ON TIME control. At the end of the pulse on time the welding wire stops feeding for the length of time set on the PULSE OFF TIME control. This on and off sequence continues for the amount of time selected on the time control until the gun trigger is released. The pulse option provides better control of the heat input to the weld on thin gauge metals, thereby decreasing distortion and the likelihood of burn throughs.

Set-up procedures for pulsed seam welding are the same as those for continuous seam welding except that the SELECTOR SWITCH is placed in the PULSE posi tion and the SPOT TIME/PULSE ON TIME control and

PULSE OFF TIME controls must be set to the desired positions.

7

-

3.

SPOT

GAS METAL ARC WELDING (GMAW)

-

A1~t~

F

,~4

Vertical Up

Figure 7

-

7.

Spot Weld r.

,.

.11

Instead of two having a continuous or pulsed weld to join pieces of sheet steel together, welding in spot of 1 to 1 1/2 inches (25-38 mm) apart can be done.

The

MIG spot steel welding process fuses two pieces together by penetrating entirely through of sheet one of the pieces into the other. The spot process is designed to be used in any other than position.

Little joint preparation is required cleaning the surfaces and ensuring that the two pieces overlap.

Vertical Down

Figure 7

-

5.

Welding In The Vertical Up And Vertical

Down Position

7

-

2.

GAS METAL ARC WELDING

PULSED

(GMAW)

-

Spot welding is based on the same principles as con tinuous seam welding except that there is no travel speed involved; instead, there is a welding time interval.

The weld is made the top sheet and by placing the welding gun directly on holding it motionless as shown in

Figure 7-8. When the gun trigger is depressed, the elec trode wire and shielding gas will be continuously fed.

The arc will be maintained for the full length of time set on the SPOT TIME/PULSE ON TIME control and it will continue to time has penetrate in one place until the top sheet is welded with the bottom sheet. After the preset welding elapsed the wire will stop feeding, the contac tor will open and the arc will be broken.

Figure 7

-

6.

Pulsed Seam

The GMAW spot welding process produces little heat, therefore little distortion results.

Because of the low heat characteristics of this technique, it is often used when welds are made in close proximity to upholstery, rubber, or other flammable materials.

113336 Page34

Figure 7

-

8.

Fender Repair With Spot Nozzle

7

-

4.

PLUG WELDS

-

Plug welds provide a means of joining two pieces of metal where the thickness of the top sheet is beyond the normal range of the welding power source or where sheet metal sections are too thin to be spot distortion welded or burn or pulsed welded without producing throughs.

The plug weld is made by drilling or punching a hole in the top sheet, clamping the metal sections tightly together, and filling the hole with a weidment. The timer or untimed.

plug weld can be timed using the spot

Plug welds should be spaced 1 to 1

1/2 inches (25-38 mm) apart.

Plug welds on sample materials should be made so that proper parameters can be set.

7

-

5.

SKIP WELDING means of

-

Skip welding provides a making a series of short welds, usually less than 3/4 in.

and

(18 mm) in length each, consistent in size appearance.

Skip welding can be accomplished with this unit the gun by setting a spot weld time and jogging trigger off and on again each time the spot timer times out.

Skip welds on sample material should be made so that proper parameters can be set.

113336 Page 35

7

-

6.

TROUBLESHOOTING THE GAS METAL ARC WELDING PROCESS

A.

Porosity

Possible Causes

1.

Inadequate shielding gas coverage.

2.

Gas contamination.

3.

Electrode contamination.

4.

Workpiece contamination.

5.

Excess tip-to-work distance.

Figure 7

-

9.

Porosity

Corrective Actions

Remove spatter from the gun nozzle.

Check gas hoses for leaks.

Eliminate drafts (from fans open doors, etc.) blowing into the welding arc.

Reduce nozzle-to-work distance.

Increase gas flow to displace all air from the weld zone.

Decrease excessive gas flow to avoid turbulence and the of air in the weld zone.

entrapment

Hold gun at end of weld until molten metal solidifies.

Check for frozen C02 regulator flow meter.

Use welding grade shielding gas.

Use only clean and dry electrode.

Eliminate pick up of oil or conduit.

lubricant on electrode in electrode feeder or

Remove all grease, oil, moisture, from work surface before welding.

rust, paint, undercoating, and dirt

Use a more highly deoxidizing electrode wire.

Reduce stick-out.

113336 Page 36

B.

Incomplete Fusion (Lack of fusion)

Figure 7

-

10.

Incomplete Fusion

Possible Causes Corrective Actions

1.

Weld zone surfaces not free of film or excessive oxide.

Clean weld zone surfaces of impurities prior to welding.

2.

Insufficient heat input.

3.

Improper weld technique.

Select higher voltage tap.

When using a weaving technique dwell momentarily on the side walls of the groove.

Provide improved access at root of joints.

Keep electrode directed at the leading edge of the puddle.

Provide proper gun angle.

4.

Improper joint design (Heavy material Provide included angle of groove joint large only: trailer hitches, etc.) bottom of the groove and sidewalls with enough proper to allow access to electrode extension and arc characteristics, or use a

J or

U groove.

C.

Lack Of Fusion

Possible Causes

1.

Improper joint preparation.

2.

Improper weld technique.

3.

Inadequate heat input.

Figure 7

-

11.

Lack Of Penetration

Corrective Action

Material too thick. Joint preparation and design must be adequate to provide access to the bottom of the groove while maintaining proper electrode extension and arc characteristics.

Reduce excessively large root face.

Provide or increase the root gap in butt joints and increase the depth of back gauge.

Maintain electrode angle normal to work surface to achieve maximum penetration.

Keep arc on leading edge of the puddle.

Select higher voltage tap and wire speed.

Reduce the travel speed.

Maintain proper electrode extension.

113336 Page 37

D.

Excessive Penetration (Burn-Through)

-

Figure 7

-

12.

Excessive Penetration

Possible Causes

1.

Excessive heat input.

Corrective Actions

Select lower voltage tap and reduce wire speed.

Increase travel speed.

E.

Cracks In Weld

Metal

Possible Causes Corrective Actions

1.

Improper joint design (Heavy material).

Maintain proper groove dimensions to allow deposition of adequate filler metal to weld area.

2.

Heat input too high causing shrinkage and distortion.

excessive Select lower voltage tap and reduce wire speed.

Increase travel speed.

F.

Waviness of B

I

Possible Causes

1.

Excessive electrode extension.

2.

Unsteady hand.

Figure7 -13.

W aviness Of Bead

Corrective Actions

Reduce electrode extension.

Support hand on solid surface.

G.

Humping

Possible Causes

1.

Too much heat input.

Figure 7

-

14.

Humping

Corrective Actions

Select lower voltage tap or increase travel speed.

Weld in small segments and allow to cool between welds.

H.

Excessive Spatter

Possible Causes Corrective Actions

1 .Excessive

shielding gas.

spatter when using

C02

Select lower voltage tap or adjust WIRE SPEED ADJUSTMENT.

113 336 Page 38

3.

If door has an outer panel reinforcement, break the weld.

4.

Grind off the hem flange and remove the old panel.

5.

Repair any damage to the inner panel.

6.

Position new outer panel over door and bend the end flange over the inner flange.

7.

Spot weld outer panel reinforcement to new door panel.

8.

Spot weld new hem flange to inner panel.

9.

Metal finish exterior surface, paint and assembly interior trim and hardware.

spot welded in the place.

Car and body manufacturers have panels welded in different places, so it will be necessary to inspect the body to determine where the welds are located in each case.

After the old panel is removed, the inner panels must be carefully checked, straightened or replaced.

Continuous Seam

Welds

Hem Flange

Strip

Spot Weld On

Outer Panel

Reinforcement nner

Reinforcement

TA087 296

Figure 8

-

2.

Hem Flange Removal

8-4.

HOW TO PREVENT GLASS BREAKAGE

AND SPATTER ON WINDOWS

-

Spatter and ex cessive heat can become problems when welding near windows.

Protect the windows by keeping them covered and as far away from the heat zone as possible.

When welding must be performed near windows, the windows should be covered and protected from ex cessive heat by using wet rags.

A putty which reduces heat transfer is available like substance through your welding supplier.

If burn through and spatter become problems, ensure that the correct voltage tap is being used for the size material and being welded.

Use an argon

C02 gas mixture and check travel speed.

8

-

5.

PROCEDURES FOR WELDING FENDERS

AND QUARTER PANELS

-

When a complete panel must bolts to cut be replaced it will be necessary to remove the securing the panel to the rest of the structure, or through the spot welds if the panel is welded in place.

In most cases a front fender will be bolted in place, while the other panels will be either spot welded or continuous seam welded.

The alignment of front fenders is usually simple because the bolt holes are often elongated so that the position of the new front fender can be shifted and correctly aligned.

Generally all other panels are welded into place.

If the whole panel is to be replaced, the old panel must be removed by cutting along the weld if welded by con tinuous seam, or by drilling out the spot welds if it is

113336 Page4O

TA087 298

Figure 8

-

3.

Automotive Body Sections

Assembled With Continuous Seam,

Pulsed, And Spot Welds

The new outer panel can then be placed and held in position by vice-grips or c-clamp.

When welding, start at the center and proceed first in one direction and then the other.

In order to ensure reduced distortion due to heat, weld time.

It is only a section of 2 or

3 in.

(51 -76 mm) at a important to constantly check the over all temperature of the sheet steel around the welding area, because it is in this concentrated heat area that warpage and distortion will begin.

Leave a gap and then weld another short section.

When the weld is completed it can be hammered down, filled with body putty and sanded.

8

-

6.

WELDING FRAMES AND HIGH STRENGTH

(HSS) STEELS

-

The new

HSS steels are used on many can of the new economy be found in the steel compact cars.

HSS steels gussets, brackets, floor pans and support members of these new models. HSS steels are thinner for

As heat is weight applied, the reduction and strength are heat sensitive.

decreases and cracking can occur, therefore the heat affected zone must be kept as small as possible.

For this reason welding process has become the preferred the GMAW method for welding HSS steels, and the oxacetylene welding or brazing processes, with its wider heat affective area, are normally not recommended.

Figure 8

-

4.

Application Of Body Putty

SECTION

8

-

AUTO BODY REPAIR APPLICATION

CAUTION: WELDING CURRENT can damage

_____ vehicle computers and other electronic com ponents.

Disconnect both battery cables before we/ding on a vehicle.

P/ace work c/amp as close to the we/d as possib/e to avoid long electrical paths.

Be sure gun to power source as nections to work clamp are well as clean and cable con tight.

To be 100 percent free of computer(s) from the vehicle.

risk, disconnect the

8

-

1.

POINTERS FOR WELDING AUTO BODY

SHEET METAL

-

Before using this equipment to weld on a finished on a piece of work, make a few practice welds sample piece of material the same as that of the finished workpiece.

Whenever possible, weld in the flat position since this is the easiest position to learn.

Be sure that the material to be welded is clean and free of paint and rust.

The work cable clamp must be attached to the parts per being welded. Clean surface to ensure pro grounding and to complete the current path.

Use a

.023 in.

(0.6

mm) E7OS-6 wire and argon/carbon dioxide shielding gas.

Use direct current straight polarity for reduced burn through.

Open left side access door, and visually check position of polarity changeover jumper links on polarity changeover board on center baffle of unit. If necessary, reposition jumper links according to

Section 3-3.

IMPORTANT For maximum materials such as

18 gauge penetration on thicker

(1.22

mm) and thicker, reconnect for direct current reverse polarity (work lead to negative, e/ec (rode wire to positive).

8

-

2.

PROCEDURE FOR WELDING MILD

STEELS

-

The following are some basic guidelines that can be used when weld mild or using this welding high strength steels: power source to

1.

Use a power wire brush or sander to remove paint to bare metal in the area to be repaired.

Two to three inches (51 -76 mm) on either side of the weld area should be cleaned for applying body filler after welding is completed.

2.

Remove damaged metal shears, or a power hand using grinder hand equipped cutters, with a cutting wheel.

3.

Fit a new which was piece of sheet steel over the section removed.

The new material should overlap the cut away section mm).

by one inch (25

4.

Clamp the new metal in place, and prepare to spot weld.

5.

Place the VOLTAGE the 3 position.

ADJUSTMENT switch in

Inner

7.

With the shielding gas and power source turned on, place the spot nozzle and press firmly against the new material about 1/2 to

3/4 in.

(12-18 mm), from the edge.

Fit up must be tight to assure good, repeatable spot welds.

8.

Begin spot welding from the center Out on each side.

Distortion may occur if welding begins at the corners.

9.

Space spot welds

1 to

1 1/2 in.

(25-38 mm), apart around the about repair. Spot welds should be

3/16 in.

(5 mm) in diameter.

~ Do not make continuous welds around the repair as this will promote distortion and warpage.

10.

After welding, remove the clamp and grindspot flush to surface.

11.

Smooth the joints with body filler and finish.

8

-

3.

PROCEDURES

PANELS

FOR WELDING DOOR

I W~ h~S1 I I ~ Every experienced autobody repair man will have his own method of performing the follow ing procedures.

However, this in formation is presented to show how, in most cases, this we/ding power source can make the job easier and less time consuming.

If the door is severly damaged, but the damage is primarily in the outer panel, or skin, the door can be easily repaired without necessarily installing a whole new door.

1.

Remove exterior molding and hardware. It is not necessary to control remove mechanisms, window lock or regulator, runs.

remote

2.

Remove door assembly, and place on flat surface with edges of door extending over edges of sur face to provide room to work.

Door

Skin

Of Skin Crimped

TA-087 297

6.

Install the spot nozzle on the gun.

Figure 8

-

1.

Cutaway Of Door Panel Damage

113 336 Page 39

PARTS

LIST

May 1988

FORM: 113 336A

Effective With Serial No.

JJ3flISO

Ca 3 3 a -u

0 C 0

Parts

List

See

Gun

934

112

For

Of

From:

-

A

Main

Figure

Assembly

Item

No.

Dia.

Mkgs.

Figure A

Replace Coils at Factory or

Factory Authorized Service Station

Part

No.

Description

Main Assembly

17

18

19

20

21

22

23

24

25

26

27

8

9

10 ii

12

13

14

15

16

28

29

30

31

32

33

34

35

GS1

PLG 1

Z

R2

TP2

Ti

5

6

7

1

2

3

4 PLG2

115521

115522

008040

008 073

058 972

Figure B

Figure C

604550

089 120

035630

010296

010678

073433

039778

023210

010290

083912

605741

079781

092239

093 173

092 028

083 175

Figure D

023 100

026 843

010368

039 901

026 978

101 219

019833

010521

602 178

602 160

++

113227

089 899

113280

089 120

113 129

112863

112811

113603

113605

113606

WRAPPER

PANEL, side

CONNECTOR, jumper

HOUSING RECEPTACLE & SOCKETS(consisting of)

TERMINAL, female

BAFFLE, air-w/components (Pg 4)

PANEL, rear-wi components

HOSE, No.1

x3/16 ID (order

(Pg 6) byft)

CLAMP, hose 3/16

VALVE, 24 volts ac/6 volts dc 2 way 1/4 IPS port 1/8 orifice

FITTING, hose-elbowM 1/4 NPTx 5/8-18 RH

FITTING, pipe-elbow street

1/4 NPT LH

FITTING, barbed male 3/16 TBG x

1/4 NPT

RECEPTACLE, straight 3 pole 50 amp 250 volts

CABLE, powerl0/39ft50ampcap

BUSHING, strain relief 1 .09

x

1 .03

hole

STABILIZER

CLIP, mtg-resistor

RESISTOR, WW fixed 25 watt 50 ohm

THERMOSTAT, NO

TRANSFORMER, power-main (208/230)

COIL, pri/sec

SKID, base

PANEL, front-w/components (Pg 8)

(consisting of)

CABLE, interconnecting-ground

INSULATOR, vinyl

CLAMP, ground 100 amp

PLUG, jack-black (consisting

INSULATOR, jack of) plug-black

PLUG, jack

STRIP, copper

WIRE, tie

SCREW, set 1/4-20 x

3/8

SCREW, self-tapping 8-32 x

1/4

GUN

LABEL, instructions

LATCH, slide flush style

Running Gear (Fig F Pg 11)

HOSE, air (consisting of)

CLAMP, hose 3/8

-

.450 dia

TUBING, 1/4 IDx1/16 (order byft)

FITTING, adapter

LABEL, Auto Arc emblem (rear panel)

LABEL, Auto Arc MW-4i 50 (top of front panel)

LABEL, Auto Arc MW-41 50 (left side panel)

LABEL, Auto Arc MW-41 50 (right side panel)

+ +For Parts List of Gun See FORM: 112 934

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Quantity

1

2

1

1

1

1

1

2

1

1

1

1

2

1

1

1

2

1

1

1

1

1

2

1

1

1

8

1

1

1

3ft

1

1

1

1

1

1

1

1

1

1

1

2

4ft

1

113336 Page 2

7

10

11

113336 Page 3

24 23

Figure B

-

Baffle, Air

-

W/Components

TD-072 509-E

Item

No.

Dia.

Mkgs.

Figure B

Part

No.

Description

Baffle, Air

-

W/Components (Fig A Pg 2 Item 5)

3

4

1

2

11

12

13

14

15

16

17

18

19

8

9

10

5

6

7

CR2,3

CR1

C6

W

24

25

26

27

28

20

21

22

23

29

30

TEl

VR1,2

SR2,3

CB1,2

R3

R5

058 427

085 980

605941

057 543

057 745

057 971

010191

058 628

058428

026 837

006 393

072 817

044 995

083 147

082 907

031 728

082 902

082 875

034 260

035 519

024 493

038 620

026 189

082 722

035 914

083 431

120 663

605 741

059 642

010014

006 537

052 704

RING, retaining-spool

NUT, hex-full 5/8-1 1

WASHER,flat-41/64lDxl ODxl4ga

SPRING,

SPRING, compression compression 2.215 OD x

2-1/2 (used with 8 spool)

WASHER, flat-keyed 1-1/2 dia

WASHER,fiber5/8lDxl-1/200xl/8

WASHER, steel-brake

HUB,spool

INSULATOR, terminal-nylon

RELAY, enclosed 24 volts ac

DPDT flanged

RELAY, enclosed24 voltsac DPDTflanged

BAFFLE, air

GROMMET, push in

ANGLE, mtg-RH capacitor

CAPACITOR, electrolytic 20,000 uf 35 volts dc

STRIP, mtg-center capacitor

ANGLE, mtg-LH capacitor

LINK, connector-contactor

CONTACTOR, 40 amp 3 pole 24 volts (consisting of)

.

COIL, 24 volts

LINK, jumper

BLOCK, terminal3oamp3 pole

VARISTOR,0.6wattl75voltsdc

RECTIFIER, integrated

CIRCUITBREAKER,

25 amp

400 volts manuallyreset5amp250volts

DRIVEASSEMBLY,wire(FigBl Pg5)

CLIP, mtg-resistor

RESISTOR, WWfixed25wattl0ohm

CLAMP,3/4x13/64hoIe

RESISTOR, WW fixed 12 watt 0.5

ohm

CLIP, mtg-resistor

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Quantity

1

6

1

6

1

1

2

1

1

1

1

2

1

1

2

2

1

1

1

1

1

1

2

1

2

1

2

1

1

2

2

2

113336 Page4

19

20

21

22

23

24

25

26

11

12

13

14

15

16

17

18

5

6

7

2

3

4

8

9

10

Item

No.

Dia.

Mkgs.

Figure Bi

Part

No.

Description

120 663 Drive Assembly, Wire (Fig B Pg 4 Item 25)

M

010 929

093 153

*031

057

595

432

079 624

602 213

010 910

044 994

601 838

079 633

044 954

079 772

058 359

604 741

605 854

072 649

112 909

605 287

058 360

058 363

072 585

010 918

057 551

056 081

605 525

112 907

RING, retainer

BEARING, flanged

GEAR, drive .030-.035

wire

KEY,1/16x1/4

SHAFT

COVER

BEARING,flanged5/16x7/16x3/8

PIN, spring 5/32 x

1-1/2

SPRING, pressure

LINER, monocoil

NUT, self-locking hex 5/16-24

GEAR, drive .024

WASHER, flat-spring 3/8

MOTOR, gear(consisting of)

BRUSH, w/spring

SCREW, brush holder cap

SCREW, cap-hex hd3/8-16x2-114

WASHER, lock-split 3/8

WASHER, flat-SAE 3/8

INSULATOR, motor

NUT, brass-hex jam 3/8-16

FITTING, hose-barbed nipple 3/16 TBG

HOUSING, drive-roll feeder

KNOB

PIN, pivot

PIN, cotter-hair 0.042

x

15/16

456 7 8 1 9 10

1

4

26

2

23

22

18

Figure Bi

-

Drive Assembly, Wire

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113 336 Page 5

TC-072 511

Quantity

2

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

1

1

1

2

1

1

2

Item

No.

Dia.

Mkgs

Figure E

Part

No.

Description

SPW 1 Spot Panel

9

10

11

6

7

8

2

3

2

3

4

5

12

13

14

R50

R51

R52

R51

R52

028 769

028 770

028 768

028 770

028 768

POTENTIOMETER, carbon 1 turn2watt 750K ohm

POTENTIOMETER, carbon 1 turn

2 watt 1 meg ohm

POTENTIOMETER, carbon 1 tur$2watt35OKo

POTENTIOMETER, carbon 1 turn 2 watt 1 meg ohm

POTENTIOMETER, carbon 1 turn

2 watt 350K ohm

S50

R53

086 895

073 914

605 890

080 509

PLG51 072 669

PLG5O 079 798

SWITCH, rotary 3 position

WASHER, centering 7/l6dia

RESISTOR, WW fixed 15 watt

0.25 ohm

GROMMET, SCR No.

8/10

HOUSING, terminal 9 position

HOUSING, terminal 13 position

PC5O 097 897 CIRCUIT CARD

RC55

(Fig El Pg 10)

008 072 HOUSING PLUG & PINS (consisting of)

058 971 TERMINAL, male

.

086 650 PANEL

113 471 NAMEPLATE (order by model & serial number)

097 922

112 770

KNOB, pointer

NOZZLE, spot-outside corner

112 772

112 768

NOZZLE, spot-inside corner

NOZZLE, spot-flat

Quantity

1

1

1

3

1

1

2

1

1

1

1

1

4

8

1

1

1

1

1

1

10 Fig El

2 3

5

7~

14

TC-086 924-B

Figure E

-

SPW 1 Spot Panel (Optional)

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113336 Page9

Item

No.

Dia.

Mkgs.

Figure D

Part

No.

Description

Panel, Front

-

W/Components (Fig A Pg 2 Item 22)

Quantity

34

35

36

37

38

29

30

31

32

33

39

40

41

42

43

44

19

20

21

22

23

24

25

26

27

28

Si

PL1

6

7

4

5

1

2

3

15

16

17

18

8

9

10 ii

12

13

14

RC3

Ri

RC1

039 801

091 542

010 291

RECEPTACLE ASSEMBLY, jack-black(consisting of)

.RECEPTACLE&NUT

.

WASHER, flat-nylafil 5/8 ID x

1-1/4 OD x

1/8

604 668

605 787

601

+ 119

881

.

NUT, self-locking hex 1/2-20

.

.

WASHER, lock-internal tooth 1/2

NUT, hex-jam 1/2-20

543 NAMEPLATE(order by model & serial number)

113 604

119 191

087 274

073 383

LABEL, warning

PANEL,front

COVER, open-module

RECEPTACLE,3socketMS-3102A-14S-1S

039 800 RECEPTACLE ASSEMBLY,

010 291

.

WASHER, jack-red(consisting of) flat-nylafil 5/8 ID x

1-1/4 OD xi /8

604 668

.

NUT, self-locking hex 1/2-20

605 787

601 881

091 541

.

WASHER, lock-internal tooth 1/2

.

NUT, hex-jam 1/2-20

.RECEPTACLE&NUT

605 828

090 328

097 924

RHEOSTAT,WW5Owattl.5ohm

048 282 RECEPTACLE W/SOCKET (consisting of)

079 534 TERMINAL, female

.

SWITCH, toggIe2PST4O amp

600 voltsac

KNOB, pointer

057

601

608 RECEPTACLE ASSEMBLY, jack-yellow(consisting of)

881

605 787

.

NUT, hex-jam 1/2-13

WASHER, lock-internal tooth 1/2

.

604 668

010 291

072 334

.

.

.

NUT, self-locking hex 1/2-20

WASHER, flat-nylafil 5/8 ID x

1-1/4 OD xi /8

RECEPTACLE & NUT

023 084 CABLE & PLUG ASSEMBLY, jack (consisting of)

039 878 PLUG ASSEMBLY, jack-yellow (consisting of)

.

602 160 SCREW, self-tapping 8-32x1/4

..

026 975

101 219

..

INSULATOR, jack

..

PLUG plug-yellow

602 178

019 833

600 318

048 573

010 325

..

SCREW, set

1/4-20 x

3/8

.

..

STRIP, copper

CABLE, weld No. 3 (order by ft)

LIGHT, indicator-red lens 28 volts

BUSHING, strain-relief

044 943 CABLE & PLUG ASSEMBLY, jack (consisting of)

600 318

039 608

.

CABLE, weld-No. 3 (order byft)

PLUG ASSEMBLY, jack-red (consisting of)

.

019 833

602 178

101 219

..

..

STRIP, copper

SCREW, set

1/4-20 x3/8

P1..UG

..

602 814

602 160

..

..

INSULATOR, jack plug-red

SCREW, self-tapping 8-32 x

1/4

+

When

BE ordering a component originally displaying a precautionary label, the label should also be ordered.

SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS

1

3ft

1

2

1

2 ft

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

4

1

1

1

1

6

113336 Page 8

Item

No.

Dia.

Mkgs.

Figure C

Part

No.

Description

Panel, Rear-W/Components (Fig A Pg 2 Item 6)

FM

8

9

6

7

10

4

5

2

3

SRi

TP3

Ci-4

TP1

032 678

032 662

083 916

089 733

057 496

037 306

086

037

323

305

031

604

689

515

MOTOR, fan 230 volts ac

BLADE, fan 60 Hz 10 inch 6 wing

PANEL, rear

RECTIFIER, silicon diode (consisting of)

BRACKET, mtg-rectifier & fan

DIODE, 150 amp 300 volts RP motor

THERMOSTAT, NO

DIODE, l5Oamp300voltsSP

CAPACITOR, ceramic 0.01 uf 500 volts dc

THERMOSTAT, NC

Quantity

2

1

2

4

1

1

1

TD.072 508B

Figure C

-

Panel, Rear-W/Components

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113336 Page 6

113 336 Page 7

Figure D

-

Panel, Front-W/Components

TB-072 510-E

Quantity

Dia.

Mkgs.

Figure El

Part

No.

Description

097 897 Circuit Card (Fig E Pg 9 Item 10)

A50,51

C50

C51 ,53,55

C52,56

C54,57,58

C59

CR50

CR51

CR52

050-54,57-66

D56

Q50,51

Q52

R50

R51

R52,71

R53,57,61 ,68,70

R54,56,59,60,62,

66,67

R55,58

R63

R64,69

R65

RC5O

RC51

PLG5O

009 159

039 482

032 820

073 714

073 739

090 573

027 810

099 019

099 018

079 844

091 861

1C, linear

CAPACITOR, electrolyte 100 uf 35 volts dc

CAPACITOR, tantalum 2.2

uf 35 volts dc

CAPACITOR, tantalum0.22 uf35 volts

CAPACITOR, ceramicO.1

uf5Ovoltsdc

CAPACITOR, electrolyte 10 uf 50 volts

RELAY, enclosed24voltsdc4PDT

RELAY, enclosed 24 volts dc SPDT

RELAY, enclosed 24 voltsdc SPDT

SPRING, hoiddown-relay

SOCKET, relay

026 202

037 449

037 200

073 535

030 018

035 823

035 884.

039 331

DIODE, 1 amp 400 volts SP

DIODE, zener

15 volts 1 watt SP

TRANSISTOR, 200MA40 volts NPN

TRANSISTOR, lOOMA3OvoltsNPN

RESISTOR, carbon 1 watt 820 ohm

RESISTOR, carbon film 0.25

watt

100 ohm

RESISTOR, carbon film 0.25

watt lOOK ohm

RESISTOR, carbon film 0.25

watt 4.7K ohm

035 827

035 886

039 333

039 327

035 887

092 648

079 795

072 670

+079 798

RESISTOR, carbon film 0.25

watt 10K ohm

RESISTOR,carbonfilm0.25watt22Kohm

RESISTOR, carbonfilm0.25wattl8K

ohm

RESISTOR, carbon film 0.25

watt

220 ohm

RESISTOR, carbon film 0.25

watt 220 ohm

RESISTOR, carbon film 0.25

watt zero ohm

TERMINAL, head 13 pin

TERMINAL, header 9 pin

HOUSING, terminal header 13 pin

I

00

~~-O

U

0

1

___________

J ~~~D5I

_____ __

C55

053–

F~

11~0 fl

L1J0

052

~

050

<

LP%~ ~~

:~ ~:a

CR52

R51

.~~j~J57

CR51

0 I I

y_I~J_

~06I 3

P70

58

____

__

050

I I

CR50

055

-fJ

P52 ~

P6

~

P56

R1~~~T

058

ri

I H

PRSTUVWXV ABCDEFGHJI~LMN

RC5O

a

AS~Y

097897

RC SI

1

Ret: C.097

895

COMPONENTS TO BE

REPLACED

BY QUALIFIED

PERSONNEL ONLY

Figure El

-

Circuit Card

+

Not part of circuit card.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113336 Page 10

2

3

1

1

2

1

3

1

1

1

2

5

1

1

1

1

15

1

2

7

2

1

2

1

1

1

1

1

Item

No.

Part

Mkgs.

Figure F Running Gear

Description

1

2

108940

025 193

604 423 3

6

7

4

5

8

9

10

057 478

022617

602 389

602 387

602 384

052 693

602250

032524 11

12

13

14

070799

052692

601 944

15

16

602211

601 869

008999 17

18

19

052691

602213

20 601 871

SCREW, cap

hex flanged hd 1/4-20 x

3/4

HANDLE, running gear

GRIP, handle

BRACKET, support

tank

CHAIN, cylinder rack

HOOK

.CHAIN

.SNAP

RACK, cylinder

WASHER, flat SAE 3/4 in

PIN,cotter3/16x1-1/2

WHEEL, rubber, 3/4 bore 10 x2-3/4

AXLE, running gear

SCREW, cap-hex hd 5/16-18 x3/4

WASHER, lock-split 5/16

NUT,

hex-jam

5/16-18

CASTER, swivel 4 inch dia

BAR, spreader cylinder rack

WASHER, lock-split 3/8

NUT, hex jam 3/8-16

4.

I

5

Quantity

2

1

4

2

4

4

4

2

2

20

19

S-t 16

1 1

7

Figure

F

-

Running Gear

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

113 336 Page 11

TC-049 808-B

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