Miller | KE14 | Owner Manual | Miller MSW-42T User manual

Miller MSW-42T User manual
March 1994
Form: OM-708D
Effective With Style No. KE-14
OWNER’S
MANUAL
MSW-41T, MSW-42T,
And LMSW-52T
Manually Operated, 1.5 kVA And 2.5 kVA Portable Spot Welders
For Resistance Spot Welding
Rated Output Varies With Tong Length
Models Use 110 Or 220 V, 50/60 Hz, Single-Phase Input Power
Equipped With 10 ft (3 m) Input Power Cord With Plug
Equipped With 0 To 5 Second Spot Timer
Read and follow these instructions and all
safety blocks carefully.
cover 1/94 − ST-146 013
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
© 1994 MILLER Electric Mfg. Co.
PRINTED IN USA
RESISTANCE SPOT WELDING SAFETY PRECAUTIONS
SPOT WELDING can be hazardous.
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In resistance spot welding, as in most jobs, exposure to certain hazards occurs. Spot welding is safe when
precautions are taken. The safety information given below is only a summary of the more complete safety
information that will be found in the Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
RESISTANCE SPOT WELDING can
cause fire or explosion.
5. Watch for fire, and keep a fire extinguisher nearby.
Sparks can fly off from the weld. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns.
7. Do not weld where atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
1. Protect yourself and others from flying sparks and hot metal.
2. Do not spot weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the weld. If this is
not possible, tightly cover them with approved covers.
4. Be alert that welding sparks can easily go through small cracks
and openings to adjacent areas.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
internal circuits are also live when power is on.
Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Disconnect input power before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29
CFR 1910.147 (see Safety Standards).
4. Properly install and ground this equipment according to this
manual and national, state, and local codes.
5. Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug
is connected to a properly grounded receptacle outlet − always
double-check the supply ground before applying power.
6. Do not spot weld on closed containers such as tanks or drums.
8. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
9. After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
10. Do not exceed the equipment rated capacity.
11. Use only correct fuses or circuit breakers. Do not oversize or
bypass them.
6. When making input connections, attach the grounding conductor
first.
7. Keep cords dry, free of oil and grease, and protect from hot metal
and sparks.
8. Frequently inspect input power cord and ground conductor for
damage − replace immediately if damaged. Check ground
conductor for continuity.
9. Turn off all equipment when not in use.
10. For water-cooled equipment, check and repair or replace any
leaking hoses or fittings. Do not use any electrical equipment if
you are wet or in a wet area.
11. Use only well-maintained equipment. Repair or replace
damaged parts at once.
12. Wear a safety harness if working above floor level.
13. Keep all panels, covers, and guards securely in place.
SPARKS can cause injury.
HOT METAL can cause burns.
Wear gloves or allow cooling period before servicing
tongs or tips.
Very often sparks fly off from the joint area.
1. Wear approved face shield or safety goggles with side shields.
2. Wear protective garments such as oil-free, flame-resistant
leather gloves, heavy shirt, cuffless trousers, high shoes, and a
cap. Synthetic material usually does not provide such protection.
3. Protect others in nearby areas by using approved
flame-resistant or noncombustible fire curtains or shields. Have
all nearby persons wear safety glasses with side shields.
MOVING PARTS can cause injury.
The tong tips, tongs, and linkages move during
operation.
FUMES can be hazardous to your
health.
Coatings, cleaners, paints, and platings can produce
fumes when welded. Breathing these fumes can be
hazardous to your health.
1. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the weld to
remove fumes.
1. Always wear welding-type, insulated gloves when using this
equipment.
2. Do not touch workpiece, tips, or tongs with bare hands.
1.
2.
3.
4.
Keep away from moving parts.
Keep away from pinch points.
Do not put hands between tips.
Keep all guards and panels securely in place.
3. In confined spaces, use an approved air-supplied respirator.
4. Do not weld on metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area,
the area is well ventilated, or if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
5. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, coatings, and cleaners.
sr4 4/93
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
EMF INFORMATION
NOTE
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
mod10.1* 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 2 − SPECIFICATIONS
2-1.
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 3 − INSTALLATION
3-1.
3-2.
3-3.
Tong And Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tong Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
4
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection For 220 Volts Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dressing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Tongs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Tongs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
7
7
7
7
8
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
SECTION 7 − PARTS LIST
Figure 7-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-2. Transformer, Power Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-3. Timer, Spot (230V Illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 7-1. Spot Welder Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
sr4 4/93
10
12
13
14
OM-708D − 3/94
SECTION 1 − SAFETY INFORMATION
mod1.2 4/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
2
WARNING
MOVING PARTS can injure.
• Do not touch live electrical parts.
• Disconnect input power before
• Do not put hands between tips.
• Keep away from pinch points.
• Keep guards in place.
4
installing or servicing.
5
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
6
Safety Alert Symbol
2
Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION
3
ELECTRIC SHOCK can kill.
1
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And Result
4
Safety Instructions To Avoid
Hazard
5
Hazard Symbol (If Available)
6
Safety Banner
Read safety blocks for each symbol shown.
7
NOTE
7
NOTE
Special instructions for best operation − not related to safety.
Turn Off switch before checking pressure.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Resistance Spot Welders
Specification
Description
Welding Process
Resistance Spot Welding
Type Of Input Power
Single-Phase; 110 Volts AC, 50/60 Hz, And 220 Volts AC, 50/60 Hz, 50% Duty Cycle
Input Power Cord
Input Power Cord 10 ft (3 m)
Overall Dimensions
Spot Welder − Length: 16 in (406 mm); Width: 4-1/2 in (114 mm); Height: 6 in (152 mm)
Control Box − Length: 6-3/4 in (171 mm); Width: 11 in (279 mm); Height: 11 in (279 mm)
Options
See Rear Cover
Model
1.5 KVA, 110 V
1.5 KVA, 220 V
2.5 KVA, 220 V
Work Capacity Combined 1/8 in (3.2 mm)
Thickness Mild Steel
1/8 in (3.2 mm)
3/16 in (4.7 mm)
Weight
Net: 34 lb (15.4 kg)
Ship: 38 lb (17.2 kg)
Net: 42 lb (19.1 kg)
Ship: 45 lb (20.4 kg)
Net: 34 lb (15.4 kg)
Ship: 38 lb (17.2 kg)
Rated Output Amperes*
Model
6 in (152 mm) Tongs
12 in (305 mm) Tongs 18 in (457 mm) Tongs
Tong Gap
1.5 kVA, 110 Volts
5500
4500
3600
3-1/2 in (89 mm)
1.5 kVA, 220 Volts
5500
4500
3600
3-1/2 in (89 mm)
2.5 kVA, 220 Volts
6750
5800
4850
3-1/2 in (89 mm)
*Calibrated with standard type tongs (see Chart 7-1)
OM-708 Page 1
2-1. Duty Cycle
CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
•
Do not exceed 50% duty cycle.
warn7.1* 2/92
The duty cycle of a resistance spot welder is the percentage of a one minute period that a resistance spot welder can
be operated without causing overheating or damage to the unit. These resistance spot welders are rated at 50% duty
cycle, which means that they can be operated for thirty seconds out of every minute.
SECTION 3 − INSTALLATION
3-1. Tong And Tip Installation
WARNING
ELECTRIC SHOCK can kill.
•
•
•
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug from receptacle before inspecting or installing.
Allow tongs and tips to cool before touching.
NOTE
Keep tips dressed down to within a 1/8 in (3.2 mm) diameter or less for 1.5 kVA
models, and to within 5/32 in (4 mm) diameter or less for 2.5 kVA models (see
Section 5-3).
Be sure ends of tongs are clean and free of corrosion before installing.
1
Tip
2
Tip Threads
3
Tong
Coat tip threads with supplied heat
sink compound, thread tip into tong,
and tighten. Do not overtighten. Repeat procedure for remaining tip.
10
9
Bottom Tong Installation:
4
8
Bottom Tong
5
Hole In Spatter Guard
6
Insulator Plug
7
Bottom Tong Securing Screw
Loosen the four (4) screws.
5
6
7
4
Slide tong through hole in spatter
guard, and into bottom tong holder
as far as possible, and position tong
so that tip is pointing straight up.
Tighten screws to lock tong in
place.
Top Tong Installation:
1
8
Top Tong
9
Top Tong Holder/Pivot Casting
10 Top Tong Securing Screw
Loosen the four (4) screws.
Slide tong into pivot casting as far
as necessary, so that tip mates with
bottom tip when tongs are closed.
2
Tools Needed:
3
Tighten screws to lock tong in
place.
3/16 in
9/16 in
ST-800 154 / ST-800 155-A
Figure 3-1. Tong And Tip Installation
OM-708 Page 2
3-2. Tong Pressure Adjustment
WARNING
ELECTRIC SHOCK can kill.
•
•
•
EXCESSIVE TONG PRESSURE can
damage tips.
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting or installing.
Allow tongs and tips to cool before touching.
NOTE
•
Do not use tongs as a clamp or vice to hold
workpiece together.
If the two pieces of material to be welded do not make
good contact at the point of the intended weld, clamp
material to provide good contact between surfaces.
Tong pressure is adjustable, and must be checked and/or set before operation.
Correct tong pressure is necessary to create a quality weld and to prevent damage
to tips.
Too much tong pressure causes the weld nugget to dimple and material to splash
out around the nugget area.
If tong pressure is too weak, parts are loose when the tongs are closed, severe
arcing occurs between workpieces, and no weld can be made.
2
1
1
Front Nut
2
Rear Nut
3
Pivot Casting
4
Hand Lever
5
Tongs
To increase tong pressure, loosen
front nut. The farther the front nut is
turned out, the greater the pressure
on the tips when the hand lever is
closed. Turn the rear nut up to the
pivot casting to lock the position.
To decrease tong pressure, loosen
the rear nut and turn the front nut up
to the pivot casting.
6
3
4
6
Machine Screw
The farther down the screw is
turned, the farther the hand lever
will close. Adjustment of this screw
will determine if the tongs lock on
the material, or just pull up tight. Adjust screw to allow lever to be raised
easily after the weld has been completed.
5
Tools Needed:
11/16 in
Ref. ST-800 156
Figure 3-2. Tong Pressure Adjustment
OM-708 Page 3
3-3. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill.
•
•
•
Do not touch live electrical parts.
Do not cut ground terminal off plug.
Input supply wiring and receptacle must meet National Electrical Code and all other codes.
swarn3.1* 2/93
Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size
input conductors (see Table for correct size).
1
Rating Label (Not Visible As
Shown On Spot Welder)
Model
Input Conductor
Size (AWG)
Fuse/Circuit
Breaker Size
In Amperes
2
Cord
3
Parallel Plug On 110 Volts AC
Models
1.5 kVA 110 Volt
No. 10
30
4
1.5 kVA 220 Volt
No. 12
15
Tandem Plug On 220 Volts
AC Models
2.5 kVA 220 Volt
No. 10
30
Do not cut ground terminal off plug.
5
Grounded Receptacle
Connect plug
to
grounded receptacle.
5
matching
1
4
3
Or
1
2
ST-800 233
Figure 3-3. Input Power Connections
OM-708 Page 4
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
SPARKS AND HOT METAL can injure.
•
•
•
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrical parts.
Keep all panels and covers securely in place.
MOVING PARTS can injure.
FUMES AND GASES can be hazardous
to your health.
•
•
•
•
•
•
Keep your head out of the fumes.
Ventilate area, or use suction device at weld area.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for metals, coatings,
and cleaners.
Do not put hands between tips.
Keep away from pinch points.
Keep guards in place.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
•
•
WELDING can cause fire or explosion.
•
•
•
•
•
Wear face shield or safety goggles.
Wear body protection.
Allow tips and work to cool before handling.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Allow work and equipment to cool before handling.
Do not locate unit over combustible surfaces.
Protect area and persons from flying sparks.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near resistance spot welding operations.
See Safety Precautions at beginning of manual for basic welding safety information.
swarn6.1* 10/91
2
1
1
Power Switch
2
Spot Weld Timer
3
Hand Lever
4
Start Switch
3
4
ST-146 013
Figure 4-1. Controls (220 Volts Model Shown)
1
Hand Lever
Use lever to open and close tongs.
See Section 3-2 for tong pressure
adjustment. Closing the hand lever
compresses the material between
the tips during the welding process.
1
2
2
Start Switch
Use switch to turn weld current On
and Off. Move switch sideways in
either direction to start weld current.
Release switch to stop weld current.
Ref. ST-145 104
Figure 4-2. Hand Lever And Start Switch
OM-708 Page 5
1
Spot Weld Timer
Use control as a way to select the
amount of time to make the spot
weld. The weld time may be adjusted from 0 to 5 seconds.
1
2
Weld time begins when the start
switch is closed (see Figure 4-2).
When the time set on the timer has
ended, or the start switch is released, weld output stops, and resets for another weld cycle. A light
in the timer turns off when the cycle
has ended.
2
Power Switch
Use switch to turn unit On and Off.
Ref. ST-800 233
Figure 4-3. Spot Weld Timer And Power Switch
Install &
Connect
Equipment
Put On
Personal Safety
Equipment
Set Control &
Turn On Unit
Begin Welding
Figure 4-4. Sequence Of Resistance Spot Welding
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting, maintaining, or
servicing.
MOVING PARTS can injure.
•
•
Do not put hands between tips.
Keep away from pinch points.
HOT PARTS can cause severe burns.
•
Allow cooling period before maintaining or servicing.
Maintenance to be performed only by qualified persons.
swarn8.1* 2/93
5-1. Routine Maintenance
Turn Off all power before maintaining.
6 Months
3 Months
See
Section
7
Replace
Unreadable
Labels
OR
−−
Blow Out
Or
Vacuum
Unit
Inspect
Tips
5-3
Ref. ST-800 156
Figure 5-1. Maintenance Schedule
OM-708 Page 6
5-2. Overload Protection For 220 Volts Model
Turn Off unit and disconnect input
power.
If fuse opens, unit shuts down. To
replace fuse proceed as follows:
1
Fuse Holder Cover
2
Fuse F1 (See Parts List For
Rating)
1
2
Ref. ST-800 233 / Ref. ST-800 185-A
Figure 5-2. Fuse F1 Location
5-3. Dressing Tips
WARNING
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Use a tip dresser according to its instructions. Do not file tips unless qualified. Incorrect filing methods can result in
mismatched tips and poor quality welds. A file can be used to remove the “mushroom” from the tips if filing is confined
to the tapered sides of the tips.
5-4. Replacing Tips
WARNING
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
To replace tip, remove present tip and go to Section 3-1.
5-5. Changing Tongs
For changing resistance spot welder tongs, see Section 3-1.
5-6. Cleaning Tongs
WARNING
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Wipe both tongs and tong holders clean. Bends or nicks near the tong ends that insert into the tong holders may reduce
the maximum efficiency and capacity of the spot welder. If corroded, polish tongs with crocus cloth.
OM-708 Page 7
5-7. Troubleshooting
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Turn Off unit, and disconnect input power cord plug
from receptacle before inspecting, maintaining, or
servicing.
MOVING PARTS can injure.
•
•
Do not put hands between tips.
Keep away from pinch points.
HOT PARTS can cause severe burns.
•
Allow cooling period before servicing.
Troubleshooting to be performed only by qualified
persons.
swarn9.1* 4/92
Table 5-1. Welding Trouble
Trouble
No weld output.
Low weld output.
Remedy
Check line fuses, and replace if necessary.
−−
For 220 V models, check fuse F1, and replace if necessary.
5-2
Check power switch S1 and/or start switch. Replace if necessary.
−−
Check tip threads. Replace tips if necessary.
3-1
Replace or dress tips.
Remove tongs. Remove insulator plugs from front housing, and
blow out tong clamps with compressed air.
Longer than normal Weld Time required.
Burn through at point of weld.
Replace or dress tips.
5-3, 5-4
3-1
5-3, 5-4
Check input line voltage.
−−
Clean work pieces.
−−
Adjust tong pressure.
3-2
Shorten weld time.
Figure 4-3
Adjust tong pressure.
3-2
Replace or dress tips.
5-3, 5-4
Realign tips.
OM-708 Page 8
Section
3-1
SECTION 6 − ELECTRICAL DIAGRAMS
SA-162 466
Figure 6-1. Circuit Diagram For 110 Volts Models
SA-072 065-A
Figure 6-2. Circuit Diagram For 220 Volts Model
OM-708 Page 9
SECTION 7 − PARTS LIST
11
10
3
10
6
7
8
12
9
13
14
15
5
16
17
18
19
4
20
21
3
2
1
30
29
31
28
27
20
22
26
44
23
3
32
25
24
33
34
38
39
43
42
41
37
36
35
Fig 7-2
40
Ref. ST-145 048
Figure 7-1. Main Assembly
OM-708 Page 10
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
41T 42T
52T
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 019 643 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 1 . . . . . . . . . . . . . 019 646 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 601 865 . . NUT, stl hex full fnsh .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 3 . . . . . . . . . . . . . 602 009 . . SCREW, cap stl sch .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . 7 . . . . 7 . . . .
. . . 4 . . . . . . . . . . . . . 023 659 . . WIRING HARNESS, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 4 . . . . . . . . . . . . . 023 660 . . WIRING HARNESS, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 023 199 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 5 . . . . . . . . . . . . . 082 090 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 010 714 . . PIN, spring CS .312 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 7 . . . . . . . . . . . . . 010 712 . . LINK, tgl connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 8 . . . . . . . . . . . . . 010 713 . . PIN, spring CS .312 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 9 . . . . . . . . . . . . . 010 715 . . BOLT, pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 10 . . . . . . . . . . . . . 601 876 . . NUT, stl hex jam .437-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 11 . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 12 . . . . . . . . . . . . . 017 668 . . HOLDER, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 13 . . . . . . . . . . . . . 010 709 . . CLAMP, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 14 . . . . . . . . . . . . . 010 623 . . BRAID, tong set of four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 15 . . . . . . . . . . . . . 010 716 . . CLAMP, connecting top tong braid . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 16 . . . . . . . . . . . . . 602 008 . . SCREW, mach stl rdh 10-32 x .250 . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 17 . . . . . . . . . . . . . 601 854 . . NUT, al hex .375-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 18 . . . . . . . . . . . . . 095 297 . . STUD, stl .375-24 x 3.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 19 . . . . . . . . . . . . . 026 607 . . GUARD, spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 20 . . . . . . . . . . . . . 128 237 . . SCREW, hexwhd-slt stl slffmg 10-32 x .500 . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 21 . . . . . . . . . . . . . 602 262 . . HANDLE, wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 22 . . . . . . . . . . . . . 601 778 . . BOLT, crg stl .250-20 x 4.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 23 . . . . . . . . . . . . . 070 017 . . INSULATION, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 24 . . . . S1 . . . . . *011 746 . . SWITCH, control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 011 291 . . . . CONTACT, assembly switch . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . 023 987 . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 011 292 . . . . TOGGLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . 070 035 . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 25 . . . . . . . . . . . . . 122 210 . . SCREW, hexwhd stl slffmg 10-32 x .625 . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 26 . . . . . . . . . . . . . 026 759 . . INSULATOR, plug sec scr . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 27 . . . . . . . . . . . . . . 010 711 . . PIN, spring .375-3.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 28 . . . . . . . . . . . . . 017 667 . . HOUSING, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 29 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and style number) . . . . . . . . 1 . . . . 1 . . . .
. . . 30 . . . . . . . . . . . . . 602 024 . . SCREW, drive U 2 x 3/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 31 . . . . . . . . . . . . . 010 708 . . RETAINER, clamp tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 32 . . . . . . . . . . . . . 026 605 . . INSULATION, bottom clamp . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 33 . . . . . . . . . . . . . 026 606 . . TUBING, fbr vulc .250 ID x .375 OD x .500 . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 34 . . . . . . . . . . . . . 026 604 . . INSULATION, fbr 1/32 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 35 . . . . . . . . . . . . . 602 004 . . SCREW, cap stl sch .250-20 x .750 . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 36 . . . . . . . . . . . . . 010 707 . . CLAMP, bottom tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 37 . . . . . . . . . . . . . 039 052 . . CLAMP, threaded connecting tong braid
(included w/Item 5, Fig 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 38 . . . . T1 . . . . +095 345 . . TRANSFORMER, pwr main 110V (Fig 7-2) . . . . . . . . . . . . . 1
. . . 38 . . . . T1 . . . . +095 350 . . TRANSFORMER, pwr main 220V (Fig 7-2) . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . T1 . . . . +095 354 . . TRANSFORMER, pwr main 220V (Fig 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 143 140 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 39 . . . . . . . . . . . . . 600 675 . . SPLICE, butt 16-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 40 . . . . . . . . . . . . . . 111 630 . . SCREW, hexwhd-slt stl 10-32 x .250 . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 41 . . . . . . . . . . . . . 019 642 . . COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 42 . . . . . . . . . . . . . 601 847 . . NUT, stl slflkg hex mscr 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 43 . . . . . . . . . . . . . . 115 104 . . CONNECTOR, clamp cable 1/2 in . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 44 . . . . . . . . . . . . . 026 763 . . TUBING, gl acrylic No. 7 x 2.500 . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3 . . . .
1
1
7
1
1
1
2
1
1
2
3
1
1
1
1
4
2
1
1
4
1
1
1
1
1
1
1
1
2
2
1
1
1
4
1
1
4
2
2
1
1
1
1
1
1
1
4
1
3
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 11
Replace Coils At Factory Or Factory Authorized Service Station.
Item
No.
Part
No.
Quantity
Model
41T 42T
52T
Description
Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38)
...
...
...
...
...
...
...
...
...
...
1
1
2
2
2
3
3
4
5
5
. . . . . . . 026 601
. . . . . . . 026 602
. . . . . . . 095 312
. . . . . . . 095 309
. . . . . . . 095 308
. . . . . . . 010 157
. . . . . . . 010 156
. . . . . . . 137 943
. . . . . . +033 123
. . . . . . +033 122
..
..
..
..
..
..
..
..
..
..
095 345 095 350 095 354
INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, pri 115V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, stl No. 10-32 x 8.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
STUD, stl No. 10-32 x 11.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, core stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
4
1
1
2
3
4
5
ST-141 482-A
Figure 7-2. Transformer, Power Main
+Item 37 on Figure 7-1 is included when ordering these items as replacement parts.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 12
Item
No.
Dia.
Mkgs.
Description
Quantity
Model
115V 230V
Figure 7-3. Timer, Spot (230V Illustrated)
041 081 041 082
Part
No.
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and style numbers) . . . . . . . . . . . . . 1 . . . . 1
. . . 2 . . . . S1 . . . . . . 124 511 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 3 . . . . . W . . . . . 605 855 . . CONTACTOR, 40A 3P (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 032 349 . . . . COIL, 115V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 034 260 . . LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 032 152 . . CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 5 . . . . . . . . . . . . . 072 042 . . BAFFLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 6 . . . . T2 . . . . . 605 856 . . TRANSFORMER, control 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 168 308 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 8 . . . . TD1 . . . . 605 952 . . TIMER, delay reset 5sec 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 9 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . F1 . . . . . *012 653 . . FUSE, mintr gl .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 603 110 . . HOSE, nprn .500 ID x .687 OD (order by ft) . . . . . . . . . . . . . . . . . . . 1ft . . . 1ft
. . . . . . . . . . . . . . . . . . . 601 157 . . BLANK, snap-in metal .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 600 342 . . CORD, No. 16 4/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft . . 10ft
. . . 13 . . . PLG1 . . . 023 618 . . CORD SET, 115V 16ga 3/c 600V 10ft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PLG1 . . . 023 625 . . CORD SET, 230V 16ga 3/c 600V 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 010 610 . . CONNECTOR, cable clamp .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
2
3
4
1
5
14
13
6
12
11
10
7
9
ST-146 012-B
8
Figure 7-3. Timer, Spot (230V Illustrated)
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-708 Page 13
Chart 7-1. Spot Welder Tips
3-1/2”
(89 mm)
STANDARD
3-1/2”
(89 mm)
MO OFFSET
6-1/2” (165 mm)
6” (152 mm) 040 197
12” (305 mm) 040 198
18” (457 mm) 040 199
6” (152 mm) 040 200
12” (305 mm) 040 201
Standard
040 211
040 212
MO
Offset
18” (457 mm) 040 202
12” (305 mm) 040 203
Flat
040 215
Standard
Flat
18” (457 mm) 040 204
TT-6
9-1/2”
(241 mm)
040 211
12” (305 mm) 040 205
Standard
040 212
Flat
18” (457 mm) 040 206
040 211
TT-9
7-1/2”
(190 mm)
8” (203 mm) 040 207
8” (203 mm) 040 208
040 213
5” (127 mm) 040 209
OM-708 Page 14
040 212
FF
FF
FH
Flat
Standard
040 211
G-7
040 212
FH
040 214
S-0550
OPTIONS AND ACCESSORIES
SWP-2 SPOT WELDER
PEDESTAL
(#040 872)
Leaves hands free to handle the
work. When foot control is
depressed, tongs close and Start
Switch is activated.
SPOT WELD TIMER
(#041 081) MSW-41
(#041 082) MSW-42 and
LMSW-52
Cannot be used on “T” model
units. Provides 0−5 second
mechanical weld timer.
GYRO BAIL
(#041 979)
Supports weight of welder.
Operates with boom and
counterweight or from springloaded cable. Spot welds in any
position.
9/93
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