Miller MILLERMATIC 150 Owner's Manual

 В April 1995 Form: OM-1310E
| ег Effective With Serial No. KF851163
OWNER’S
MANUAL
Millermatic® 150 And M-15 Gun
DC/CV Welding Power Source/Wire Feeder
For GMAW And FCAW Welding
120 Amperes, 21 Volts At 30% Duty Cycle
‘Uses 230 Volts AC, Single-Phase input Power
Feeds .023 Thru .035 in (0.58 Thru 0.89 mm) Wire
Overheating, Short-GCircuit, And Motor Overload Protection
Includes Gun And Gas Valve
a Read and follow these instructions and all = a E Give this manual to the operator.
safety blocks carefully.
m Have only trained and qualified persons
install, operate, or service this unit. E For help, call! your distributor
m Call your distributor if you do not understand E or: MILLER Electric Mfg. Co., P.O. Box 1079,
the directions. Appleton, Wi 54912 414-734-9821
cover 5/04 — ST-149 828-C © 1995 MILLER Electric Mig. Co. PRINTED IN USA
—<®
MILLER'S TRUE BLUE“ LIMITED WARRANTY
Effective January 1, 1995
(Equipment with a serial number preface of “KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantess or warránties expressed or implied.
LIMITED WARRANTY - Subject to the terms and conditions balow, MILLER Electric
Mig. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold attar (he affective data of this limited warranty is (ree of de-
tects in material and workmanship at the time it is shipped by MILLER. THIS WAR-
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted parta or components that fail dueto such defects in material of workmanship.
MILLER must ba notified in writing within thirty (30) days of such dafect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to ba
followed.
MILLER shall honor warranty claims on waranted equipment listed betow in tha
avant of such a failure within the warranty time pericds. All warranty time pariods
start on the date that tha equipment was delivered to the criginal retail purchasar, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor,
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers
2, 3 Years — Paris and Labor
+ TranstormerReciifier Power Sourcas
* Plasma Are Cutting Power Sources
* Semi-Automatic and Automatic Wire Feedsrs
* Robots
3. 2 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engina manufacturer.)
Air Compressors
+
4, 1 Year — Paris and Labor
* Motor Driven Guns
* Process Controllers
* Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
* SDX Transformers
" Running Gear/Trailars
* Plasma Cutting Torches (except APT, ZIPCUT & FLAZCUT Models)
* Tecumsen Engines
* Deutz Engines (oulside North America)
* Field Options
(NCTE: Field options are covered under True Blue ™ for the remaining
warranty period of the product thay are installed in, or for a minimum of
one year — whichever is greater.)
5. 8 Months — Batissies
6. 80 Days — Parts and Labor
* MIG Guns/TIG Torches
+
Remote Controls
* Accessory Kits
. Replacement Parts
MILLER'S True Выше! М Limited Warranty shall not apply 10:
t. Items fumished by MILLER, but manutaciured by oihers, such as engines or
trade accessories. These items are covered by the manufaciurer's warranty, if
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
and relays cr paris that fail due to normal wear.
3. Equipment that has been modilied by any party other than MILLER, or equip-
mand that has been improperly. Installed, improperdy operated or misused
based upon Industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been Used for operation
outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event ef a warranty claim covered by this warranty, tha exclusive ramedies
shall be, at MILLER'S option: (1) repaír; or (2) replacement; or, where authorized in
writing by MILLER In appropriate cases, (5) he reasonabie cost of repair or replace-
mentatan authorized MILLER service stalion; or (4) paymentofor credit for the pur-
chase price (less reasonable depreciation based upon aciualuse) upon retum ofthe
goods at customar's risk and expanse, MILLERS option of repair or replacement
will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. ata MILLER authorized ser-
vice facility as determined by MILLEA, Thereiore no compensation or reimbuise-
mént tor transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
НАВЕЕ FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL CR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY,
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR AMY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.À. do not allow limitations of how long an implied waranty
lasts, or the exclusion ot incidental, indirect, special or consequential damages, 59
the above limitation or exclusion may not apply to you. This warranty provides spe-
cific legal rights, and other rights may be available, but may vary from state to state.
In Canada, tegisiation In sème provinces provides for certain additional warrantiés
or féMédies other than as stated herein, and to the extent that they may not ba
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
* APT, ZIPCUT & PLAZCUT Modal Plasma Cutting Torches — 0 vary from province to province. Г”
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturer's
Transportation Department.
When requesting information about this equipment, always provide Model Designation and Serial or Style Number.
Use the following spaces to racord Model Designation and Serial or Style Number of your unit. The information is located on the rating label
or nameplate.
Model
Serial or Style No.
Date of Purchase
mitter 1/85
ARC WELDING SAFETY PRECAUTIONS
~~ & WARNING НЕ
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
Inwelding, as in most jobs, exposure to certain hazards occurs. 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.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can Kill.
Touching live electrical parts can cause fatal shocks
terminal in disconnect box or that cord plug is connected to a
properly grounded receptacie outlet,
circuits.
— or severe burns. The electrode and work circuit is 7. When making input connections, attach proper grounding
electrically live whenaver the output is on. The при conductor first — double-check connections.
power circuit and machine internal circuits are also | аня _
live when power is on. In semiautomatic or automatic 8. Frequently inspect input power cord for damage or bare wiring
wire welding, the wire, wire reel, drive roll hausing, replace cord immediately if damaged — bare wiring can kill.
and all metal parts fouching the welding wire are 9. Turn off all equipment when not in use.
electrically live. Incorrectly installed or improperly ; ;
grounded equipment is a hazard. 10. DO not use worh, damaged, undersized, or poorly spliced
1. Do not touch live electrical parts. | 11. Do not drape cables over your body.
2. Wear dry, hole-free insulating gloves and body protection. 12. Ifearth grounding of the workpiece is required, ground it directly
3. Insulate yourself from work and ground using dry insulating with a separate cable — do not use work clamp or work cable.
ats or are big enough to prevent any physical contact with 13. Do not touch electrode if you are in contact with the work,
the wor or groun | | | ground, or another électrode from a different machine.
4. Disconnect input power or stop engine before installing or 14. Use only well-maintained equipment. Repair or replace
servicing this equipment, Lockout/tagout input poweraccording ena oo f
to OSHA 29 CFR 1910.147 (see Safety Standards). damaged parts at once. Maintain unit according to manual.
5. Properly install and ground this equipment according to its 15. Wear a safety harness if working above floor level.
Owner's Manual and national, state, and local codes. 16. Keep all panels and covers securely in place.
6. Always verify the supply ground — check and be sure that input 17. Clamp work cable with good metal-to-metal contact to
power cord ground wire is properly connected to ground workpiece ar worktable as near the weld as practical.
ARC RAYS can burn eyes and skin, ARC RAYS
NOISE can damage hearing; FLYING |
№ > OR SPARKS can injure eyes 2. Wear a welding helmet filted with a proper shade of filter to
he protect yourface and eyes when welding or watching (see ANS!
= La Arc rays from fhe ran process aaa intense Z49.1 and Z87.1 listed in Safety Standards).
A, visible and invisible (ultraviolet and infrared) rays tha a
lh can burn eyes and skin. Noise from some processes 3. Wear approved safely glasses with side shields.
can damage hearing. Chipping, grinding, and welds 4, Use protective screens or barriers to protect others from flash
——-— cooling throw off pieces of metal or slag. and glare; warn others not to watch the arc.
NOISE 5. Wear protective clothing made from durabie, flame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material (wool and leather} and foot protection.
« | FUMES AND GASES can be hazardous 5, Work in a confined space only if it is well ventilated, or while
#| to your health. wearing an air-supplied respirator. Always have a trained
and aases. Breathing these watchperson nearby. Weldingfumes and gases can displace air
(amos ases can be hazardou s to your Pealth. and lower the oxygen level causing injury or death, Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
1. Keep your head out of the fumes. Do not breathe the fumes. operations. The heatand rays of the arc can react with vapors to
2. If inside, ventilate the area and/or use exhaust at the arc to form highly toxic and irritating gases.
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3, lt ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, unless the coating is removed trom the
4. Read the Material Safety Data Sheets (MSDSs) and the weld area, the area is well venlilated, and if necessary, while
manufacturer's instruction for metals, consumables, coatings, wearing an air-supplied respirator. The coatings and any metals
cleaners, and degreasers. containing these elements can give off toxic fumes if welded.
CYLINDERS can explode if damaged. 4, Never drape a welding torch over a gas cylindar.
Shielding as cylinders contain gas under high 5. Never allow a welding electrode to touch any cylinder.
- pressure. | damaged, a cylinder oan explode. Since 6. Never wald on a pressurized cylinder — explosion will result.
| gas cylinders are normally part of the welding sii ;
process, be sure to treat them carefully. 7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
1. Protect compressed gas cylinders from excessive heat, 8. Turn face away from valve outlet when opening cylinder valve,
mechanical shocks, slag, open flames, sparks, and arcs, 8. Keep protective cap in place over valve except when cylinders
2. Install cylinders in an upright position by securing to a stationary in use or connected for use.
support or cylinder rack to prevent falling or tipping. — 10. Read and follow instructions on compressed gas cylinders,
3. Keep cylinders away from any welding or other electrical associated equipment, and CGA publication P-1 listed in Safety
Standards.
sri.1.1 2/94
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can causa them to blow up. Sparks can fly
off from. the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, of
fire. Check and be sure the area is safe before doing
any welding.
+. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material,
3. Remove all flammables within 35ft(10.7 m) ofthe welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS F4.1
(see Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current fromtraveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousars, high shoes, and a cap.
12. Remove any combustibles, such asabutanelighteror matches,
from your person before doing any welding.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
—
Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes,
ENGINE FUEL can cause fire or
explosion,
Engine fuel is highly flammable.
1. Stop engine and letit cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Do not overfill tank — allow room for fuel to expand.
4, Do not spill fuel. If fuel is spilled, clean up before starting
engine.
E
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
NN cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4, To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery. |
5, Keep hands, hair, loose clothing, and tools away from moving
pans.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2, Stop engine before disconnecting or connecting battery
cables.
3. Donotallowtools to cause sparks when working on a battery.
4. Do nol use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and --) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin. —-
gh | tis best to check coolant level when engine is cold
E to avoid scalding.
1. Ifthe engine is warm and checking is needed, follow steps 2
and 3.
Wear safety glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly before
completely removing cap. :
no
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard 249.1, from American
Welding Society, 550 NW. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 28 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402,
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So-
clety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MÁ 02269.
sri.1.1 2/94
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3,
Safe Practices For Occupation And Educational! Eye And Face Protec-
tion, ANS! Standard Z87.1, from American National Standards
institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Procasses, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MÁ 02269.
CONSIGNES DE SÉCURITÉ POUR LE SOUDAGE À L’ARC
A MISEENGARDE —
UN MEDECIN,
LE SOUDAGE A L'ARC peut étre dangereux.
SE PROTÉGER ET PROTÉGER LES AUTRES CONTRE LES BLESSURES GRAVES VOIRE MORTELLES. TENIR LES ENFANTS À L'ÉCART. LES
D'AVOIR CONSUET RTENT UN STIMULATEUR CARDIAQUE NE DOIVENT PAS NON PLUS S’APPROCHER DU POSTE DE SOUDAGE, À MOINS
D'AVOIR C
Le soudage, comme la plupart des travaux, présente certains dangers, Par contre, le soudage peut être effectué en toute sécurité quand on prend les
mesures qui s'imposent. Les consignes de sécurité données ci-aprôs ne font que résumer l'information contenue dans les normes de sécurité énumérées
à la page suivante. Lire et respecter toutes ces normes de sécurité.
L'INSTALLATION, L'UTILISATION, L'ENTRETIEN ET LES RÉPARATIONS NE DOIVENT ÊTRE CONFIÉS QU'À DES PERSONNES QUALIFIÉES.
—
UN CHOC ELECTRIQUE peut tuer.
Un simple contact avec des piéces électriques peut
provoquer une électrocution ou des blessures graves.
L'étectrode et le circuit de soudage sont sous tension dès
que l'appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou
automatique, le fil, le dévideir, 18 logement des galets
d'entraînement et les pièces métalliques an contact avec
le fil de soudage sont sous tension. Des matériels mal
Instalés ou mai mis à la terre présentent un danger.
no —
Ne jamais toucher les pièces électriques sous tension.
Porter des gants ot des vêtements de protection sacs ne comportant
pas de trous.
S'isoler de la pièce et de la terre au moyen dé tapis ou d'autres
moyens isctants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Couper l'alimentation ou arrôter le Moteur avant de procéder à
l'installation, à la réparation ou & [entretien de l'apparoil.
Déverrouillerl'atimentation selon la norme OSHA 29 CFR 1910.147
(voir normes de sécurité).
Installer et Mettre à [a terre correctement cet apparoil conformément
à son manuel d'utilisation et au codes nationaux, provinciaux et
municipaux.
Toujours vérifier la terre du cordon d'alimentation - Vérifier et
S'assurer que le fil de terre du cordon d'alimentation est bien
11.
12.
13.
15.
16.
17.
raccordé à la borne de terre du sectionneur ou que la fiche du cordon
est raccordée à une prise correctemant mise a la terre.
En effectuant les raccordemants d'entrés fixer d'abord le conducteur
de misé à là terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d'alimentation pour voir s’il n’est pas
endommagé ou dénudé — remplacer le cordon immédiatement s'il
est endommagé — un câble dénudé peut provoquer une
élactrocution.
Mettre l'appareil hors tension quand on ne l’utilisa pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur
insuffisante où mal épissés.
Ne pas enrouler tes cäbles autour du corps.
Si la pièce soudée doit être mise à ia terre, le faire directement avec
un câble distinct — ne pas utiliser le connecteur de pièce ou le câble
de retour,
Ne pas toucher l'électroda quand on est an contact avec la pièce, la
terre ou une électrode provenant d'une autre machine.
N'utiliser qu'un materiel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l'appareil
conformément à ce manuel,
Porter an harnais de sécurité quand on travaille an hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixarle câble de retour de façon à obtenir un bon contact métai-métal
avec la pièce à souderou la table de travail, le plus près possible de ia
soudure. |
= ">
a
„708
veux et la peau. Le BRUIT peut endommager
l'ouïe; les PROJECTIONS DE LAITIER OU LES
ETINCELLES peuvent blesser les yeux.
L'arc de soudage produit des rayons visibles et invisibles
intenses (ultraviclets et infrarouges) qui peuvent brûler
les yeux et la peau. Le bruit produit par certains procédés
peut endommager l'ouïe, Des projections de métal ou de
laitier sont produites par le niguage, le meulage ou le
refroidissement des soudures,
1.
BRUIT
Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si
le niveau de bruit est élevé,
LE RAYONNEMENT DE L'ARC peut brûler les
RAYONNEMENT DE L'ARC
Porter un masque a searre-téte muni d'un verre filtrant de nuance
appropriée pour protéger le visage at tes yeux quand on soude ou
observe la travail de soudage (voir lés normes ANSI 249.1 et 287.1
données sous la rubrique Principales normes de sécurité).
Porter des lunettes de sécurité approuvées avec écrans latéraux.
Utiliser des paravonts ou des barrières de protection pour protéger
les personnes à proximité contre les coups d'arc et l'ébiouissement;
avertir lés Autres personnes de ne pas regarder l'arc.
Porter des vêtoments de protection en tissu ignifuge durable (laine et
cuir} et des chaussures de sécurité,
LES VAPEURS ET LES FUMÉES peuvent être
dangereuses pour ‘a santé.
Lé soudage produit des vapeurs et des fumées qu'il est
dangereux de respirer
Garder la tête à l'extérieur des vapeurs et des jumédes el ne pas les
respira).
À l'intérieur, ventiler le poste de travail ou utiliser un dispositif placé
au niveau de l'arc pour évacuer fos vapeurs et fumées de soudage.
Si la ventilation est mauvaise, utiliser un appareil respiratoire à
adduction d'air pur approuvé.
Consulter les fiches signalétiques et les consignes du fabricant
relatives au métaux, produits d'apport, revêtements, nettoyants et
dégraissants.
Ne travailler dans un espace confiné que s'il est bien ventilé, ou en
portant un appareil respiratoires à adduction d'air pur. Demander à un
observateur ayant reçu fa bonne formation d'© toujours se tenir à
proximité. Les vapeurs et fumées de soudage peuvent déplacer l'air
et abaisserie niveau d'oxygène at causer des blessures graves voire
mortelles. S'assurer que l'air est propre à la respiration. |
Ne pas souder à proximité d'opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l'arc
peuvent réagir avec les vapeurs pour former des gaz hautement
toxiques et irritants.
Ne pas souder sur des métaux revêtus comme l'acier galvanisé, au
plomb ou cadmié à moins que la pièce n'ait été entièrement décapée,
que la poste de travail soit bien ventilé. S'il y a lieu, porter un appareil
respiratoire à adduction d'air pur. Leés revêtements etes métaux qui
contiennent de tels élémonts peuvent dégager des vapeurs toxiques
lors du soudage.
LES BOUTEILLES peuvent expioser si elles
sont endommagées.
à>-| Les bouteilles contenant des gaz de protection sont à
| haute pression. Une bouteille endommagée peut
exploser. Etant donné que les bouteilles de gaz font
normatement partie du Matéria! de soudage, les traiter
avec le plus grand sein.
Protéger les houteilles de gaz comprimé contre la chaleur intense,
les chocs, le laitier, les flammes nues, les étincelles et l'arc.
Placer es bouteilles À la Verticale en les fixant à un support fixe ou à
un charict pour éviter qu'elles ne tombent ou ne basculent.
Tenir tes bouteiltes à l'écart du poste de soudage ou d'autres circuits
électriques.
ме ть
Ne jamais poser un chalumeau soudeur sur une bouteille de gaz.
Ne jamais laisser une électrode de soudage toucher une bouteille.
Ne jamais souder sur une boutelile sous pression : eile exploserail.
N'utiliser que des bouteilles de gaz de protection, des détendeurs,
des tuyaux souples et dés raccords appropriés conçus pour
l'application particulière; conserver ces matériels et leurs pièces еп
bon état.
Éloigner le visage de la sortie du robinet de la bouteille quand an
l’ouvre.
Replacer le chapeau sur |a bouteille après utilisation.
Lire et suivre les consignes relatives aux bouteilles de gaz comprimé,
au matériel connexe ainsi que fa publication P-1 de fa CGA donnée
sous la rubrique Principales normes de sécurité.
sr1.1.1 2/04
LE SOUDAGE peut causer un incendie ou une
explosion.
Ne pas souder sur des récipients fermés comme des
réservoirs, des fits ou des tuyaux : ils peuvent exploser.
L'arc de soudage peut produire des étincelles. Des
étincelles, une pièce chaude et un matériel chaud
peuvent provoquer des incendies et des blessures. Le
contact accidentel de l'électrode sur des objets
métalliques peut produire des étincalles, l'explosion, la
surchauffe ou un incendie, S'assurer que le lieu ne
présente pas de danger avant d'effectuer le Soudage.
1. Seprotégeret protéger les personnes à proximité des étincelles et du
métal chaud.
2. Ne pas souder dans un endroit où les étincelles peuvent atteindre
des matériaux inflammables,
3. Enlovertoutes les matières inflammables dans un rayon de moins de
10 m de l'arc. Si cela n’est pas possible, bien les recouvrir en utilisant
des bâches approuvées.
4. Prendre garde que los étincelles et les projections na pénétrant dans
des zones adjacentes an s'infiltrant dans des petites fissures et
ouvertures.
10. Enlever l'électrode enrobée du porte-électrode ou couper le fil de
12. Ne pas porter des matières combustibles sur soi comme un briquet à
5. Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
6. Serappelerque si l'on soude sur un plafond, un plancher, une cloison
ou autre, te teu peut prendre de l’autra côté.
7. Ne pas souder sur des récipients fermés comme des réservoirs, das
fûts ou des tuyaux à moins qu'ils ne sofant préparés de façon
appropriée conformément à la norme F4.1 de l'AWS (voir la rubrique
Principales normes de sécurité).
8. Raccorder le câble de retour à la pièce, le plus près possible de la
zoné de soudage, pour empêcher que Le courant de soudage ne
suive une trajectoire longue et éventuellement inconnue et qu'il ne
provoque des risques d'éjectrocution et d'incendie.
9. Ne pas utiliser le chalumeau soudeur pour dégeler des tuyaux,
soudage au ras du bec contact quand on né l'utilise pas.
11. Porterdes vêtements de protection non huileux comme des gants an
cuir, une chemise épaisse, des pantalons sans revers, des
chaussures montantes et un casque.
gaz ou des allumettes quand on soude.
‘À MISEENGARDE
LES MOTEURS peuvent présenter un danger.
LES GAZ D'ÉCHAPPEMENT DES MOTEURS
peuvent être mortels. |
Les moteurs produisent des gaz d'échappement nocifs.
1. Utiliser le matéris! 2 l'extériour dans des Veux ouverts et bilan
ventilés.
2. Si on utilise un moteur dans un local fermé, évacuer les gaz
d'échappement à l'extérieur et loin des prises d'air du bâtiment.
LE CARBURANT peut provoquer un incendie
ou Une explosion.
La carburant est hautement inflammable.
1. Arrêter |e moteur et |le-laisser refroidir avant de vérifier le Niveau de
carburant ou de refaire le plein.
2. Ne pas fumer en faisant le plein ou si l'appareil se trouve à proximité
d'étincelles ou de flammes nues.
3. Ne pas remplir \e réservoir & ras bord : prévoir de l'espace pour la
dilatation du combustible,
4. Ne pas renverser du carburant. Si on renverse du carburant,
hettoyer les Heux avant de faire démarrer le moteur.
LES PIÈCES EN MOUVEMENT peuvent causer
des blessures.
Les pièces en mouvement comme les ventilateurs, les
rotors ef ‘es courroies pecivent couper les doigts et las
mains et happer les vélements amples.
1. S'assurer que les portes, les panneaux, les capots et les protecteurs
sont bien fermés et bian à leur place.
2. Arrêter le moteur avant de mettre en place cu de raccorder un
dispositif.
—
3. Seules des personnes qualifiées doivent démonter les protecteurs
ou les capots pour faire l'entration ou les réparations nécessaires.
4, Pour empêcher un démarrage accidentel d'un système pendant
l'entretien ou les réparations, débrancher le câble négatif [-) de Ja
batterie.
5. Éloigner les mains, les cheveux, los vêtements amples et les outils |
des pièces on mouvement.
6. Heplacerles capots ou les protecteurs et refermeries portes une fois
l'entretien et las réparations terminés 6l avant de faire démarrer le
Moteur.
LES ÉTINCELLES peuvent faire EXPLOSER LE
GAZ DES BATTERIES; L'ELECTROLYTE peut
brûler la peau et les yeux.
Les batteries contiennent un produit acide et dégagent
des vapeurs explosives.
| +. Toujours porter un écran facial quand on travaille sur une batterie.
2. Arrêter |e moteur avant de brancher ou de débrancher les câbles de
la batterie.
3. Ne pas faire des elincelles avec les outils quand on travaille sur Une
batterie.
4. Ne pas utiliser la source de courant de soudage pour charger les
batteries ou pour faire démarrer un véhicule,
5. Nepas intervertir la polarité des batteries.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT BRULANT SOUS
PRESSION peuvent brûler ia peau et les yeux.
1 vaut mieux vérifier |8 niveau du liquide de
refroidissement quand le moteur est froid afin d'éviter les
brûlures.
1. Sil'on doit vérifier le niveau quand le moteur est chaud, suivre les
étapes 2 ot 3.
2. Forter des lunettes de sécurité et des gants et placer un chiffon sur le
bouchon.
3, Tourner lentement le bouchon et laissér la pression s'échapper
lantement avant d'enlever complètement le bouchon.
PRINCIPALES NORMES DE SÉCURITÉ
Safely in Welding and Cutting, norme ANSI Z49.1, de l'American Weiding
Socioly, 550 NW. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402,
Recommended Safe Practice for the Preparation for Welding and Cuiting
of Confainers That Have Held Hazardous Eubsiances, norme AWS F4.1,
de l'American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269,
sr1,1.1 2/94
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de
la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Regles de sécurité en soudage, coupage el procédés connexes, norme
CSA W117.2, de l'Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection,
norme ANSI Z87.1, de l'American National Standards Institute. 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 518, de la National Fire
Protection Association, Batterymarch Park, Quincy, MÁ 02269,
EMF INFORMATION
NOTE (7 Considerations About Welding And The Effects Of Low Frequency Electric And
| Magnetic Fields
The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace, use the following
ofthe U.S. Congress, Office of Technology Assessment, Biological procedures:
Effects of Power Frequency Electric 8 Magnetic Fields - 1. Keep cables close together by twisting or taping them.
Background Paper, OTA-BP-E-53 (Washington, DC: US.
Government Printing Office, May 1989): ". .. there is now a very 2. Arrange cables to one side and away from the operator.
large volume of scientific findings based on experiments at the 3. Do not coil or drape cables around the body.
cellular level and from studies with animals and people which cleary A
establish that low frequency magnetic fields can interact with, and + Keep welding power source and cables as far away as
produce changes in, biological systems. While most of this work is practical,
of very high quality, the results are complex. Current scientific 5. Gonnect work clamp to workpiece as close to the weld as
understanding does not yet allow us ta interpret the evidence in a. . possible.
single coherent framework, Even more frustrating, it does not yet About Pacemakers:
allow us to draw definite conclusions about questions of possible The above procedures are among those also normally
risk or to offer clear science-based advice on strategies to minimize recommended for pacemaker wearers. Consuit your doctor for
or avoid potential risks.” complete information.
modi0.1 4/93
TABLE OF CONTENTS
SECTION 1 - SAFETY INFORMATION ........... 22000200 r0ir0rereererenvaear eri cine 6 1
SECTION 2 — SPECIFICATIONS et te a a a a ere Sa ee 1
2-1. Vol Ampere CUES Le eee ie ea ea 2
2-2. Duty Cycle eee aa 3
SECTION 3 - INSTALLATION ........ 2.20 000r0erere rei ear er ear e Crean i cana 3
3-1. Installing Work Clamp ...........e..e.e=0ssceererere re areri retener A eri ena 4
3-2. installing Gas Supply ............_.eserresrearroceri rason ererr reee 4
3-3. Gun Polarity For Wire Type .......... ox eeredrexerereeanere ri ares aa 5
3-4. Installing Welding GUN oo. i i ire re a 6
3-5. Selecting A Location And Connecting InputPower .................. sea ea res san» 7
3-6. Installing Wire Spool ... oe 8
3-7. Threading Welding Wire .... i i i i re en 8
SECTION 4 — OPERATION Lo i i tt et ea te cc ia anc, 10
SECTION 5 - MAINTENANCE & TROUBLESHOOTING ............ coins, 13
5-1, Routine Maintenance i i ie reat ies 13
5-2. Overload Protection «oo oi aia aa 13
5-3. Cleaning Or Repairing Drive Assembly .......... co iii 14
5-4. Changing Contact Tip, Liner, And Head Tube ............on:ierir reee 15
5-5. Unicable Repair ..... cri i rea aaa 17
5-6. Troubleshooting ... cco re re 18
SECTION 6 — ELECTRICAL DIAGRAMS eee, 19
SECTION 7 — WELDING METHODS & TROUBLESHOOTING ................ cians, 21
7-1. Flux Cored Arc Welding (FCAW) And Gas Metal Arc Welding (GMAW) ................ 21
7-2. Welding Troubleshooting .......o iii ea 23
SECTION 8 — PARTS LIST ott ee ee ee a ee ar eee 26
Figure 8-1. Main Assembly ............. 0.0.0 r0r0ereeraeraei aa er eran renacer rre 26
Figure 8-2. Baffle, Center w'Components ........—.—.._—rrvee-erre=reasrerresrerecr reee ren 28
Figure 8-3. GA-17C GUN 200000000 i i te eas 30
Figure 8-4, Drive Assembly, Wire . ...... oi EEE eno 32
OM-1310E — 4/95
SECTION 1 — SAFETY INFORMATION
mod1.1 2/83
N Read all safety messages throughout this manual.
Wm Obey all safety messages to avoid injury.
я Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
4 5 5 2 Signal Word
WARNING means possible death
7 or serious injury can happen.
CAUTION means possible minor
MOVING PARTS can injure. injury or equipment damage can
& Do not touch live electrical paris. 7 ® Kesp away from moving parts. happen.
® Disconnect input power bafore 4 ® Keep all panels and covers closed 3 Statement Of Hazard And
| installing or servicing. _ when operating. Result
/ 4 Safety Instructions To Avoid
5 Hazarcl
5 Hazard Symbol {If Available)
6 Safely Banner
READ SAFETY BLOCKS at start of
; . 5 Read safety blocks for each sym-
6 Section 3-1 before proceeding, bol shown.
7 NOTE
-— NOTE (7 Turn Off switch when using high frequency. Special instructions for best oper-
ation — not related to safety.
Figure 1-1, Safety Information
SECTION 2 — SPECIFICATIONS
Table 2-1. Welding Power Source
Specifications Description
Type Of Output Direct Current/Constant Voltage (DC/CV}
Rated Weld Output 120 Amperes, 21 Volts DC At 30% Duty Cycle (See Section 2-2)
Type Of Input Single-Phase; 230 Volts AC; 60 Hertz
Input Amperes At Rated Output 20 Amperes
Input Amperes While Idling 0.30 Amperes
KVA/KW Used At Rated Output 4.7 KVA/3.9 kW
KVA/KW Used While 1dling 0.07 kVA/0.45 kW
Max. Open-Circuit Voltage 32 Volts DC
Control Circuit Voltage At Gun 24 Volts DC
Welding Processes Gas Metal Arc Welding (GMAW) (Uses Solid Hard Or Aluminum Wire And External
Shielding Gas) |
ux Cored Arc Welding (FCAW) (Uses Wire With Flux Inside And Requires No External
Shielding Gas)
Wire Feed Speed Range 47 To 690 ipm (1.2 To 17.5 mpm)
Wire Diameter Range 023 To .035 in (0.58 To 0.89 mm)
Input Power Cord With Plug 5 it (1.5 m)
Overall Dimensions Length: 27 in (686 mm); Width: 12 in (305 mm), Height: 22-1/2 in (571 mm)
Weight Net: 117 lb (53 kg); Ship: 120 Ib (54 kg)
Options See Rear Cover
OM-1310 Page 1
Table 2-2. Welding Gun
Specifications
Description
| Ampere Rating
Duty Cycle
Wire Size Range
Cable Length
Cooling Method
150 Amperes
100% Using CO» Shielding Gas Or Self-Shielding (Flux Cored) Wire
(See Section 2-2)
023 To .035 in (0,58 To 0.89 mm)
10 ft (3 m)
Air
2-1. Volt-Ampere Curves
| The volt-ampere curves show the
minimum and maximum voltage
and amperage output capavillities of
the welding power source. Curves
40 of other settings fall between the
curves shown.
5 —
© > > R
- ANGE
0 20 E Po >
о №. “anse #3 В Ч
© SO —
to SNE +, па = -
pr ЧЩ CT
0
о 50 100 150 200 250
D.C. AMPERES
5501.1 10/91 / SB-124 625
OM-1310 Page 2
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
~~ & CAUTION -
WELDING LONGER THAN RATED DUTY CYCLE can damage unit or gun and void warranty.
® Do not weld at rated load longer than shown below. wiwarnB.2 8/03
Ba Definition
10
Duty Cycle is percentage of 10
minutes that unit or gun can
weld at rated load without over-
Minutes heating.
Chart
tu —
3 Minutes Welding 7 Minutes Resting
I 1.5 20 25 Jo 40 20 60 70 80 90 100
DUTY CYCLE %
100% Duty Cycle At 150 Amperes Using CO; И 60% Duty Cycle At 200 Amperes Using CO,
100% Duty Cycle At 120 Amperes Using Mixed Gases 60% Duty Cycle At 150 Amperes Using Mixed Gases
GUN GUN :
pe
Continuous Welding 6 Minutes Welding 4 Minutes Resting
sb1.3" 8/93 — SB-124 624
Figure 2-2. Duty Cycle
SECTION 3 - INSTALLATION
Table 3-1. ltems Inciuded With Welding Power Source
Нет Quantity
Welding Gun - Shipped Set To Feed .030 in (0.8 mm) Wire 1
10 ft (3m) Work Cable And Clamp i
Contact Tips (3 - .023 in, 2 — .030 in, And 3 - .035 in) 8
N OTE (7 Customer must obtain proper welding wire and shielding gas for desired
application.
OM-1310 Page 3
3-1. Installing Work Clamp
Tools Needed:
т
3/8, 7/16 in
Insulator
Bolt
Smaller Hole
Work Clamp Tabs
Bend tabs around work cable.
5 Work Cable From Unit
6 Nut
& D Го —
Ref, ST-025 190-D
Figure 3-1, Work Clamp Installation
3-2. Installing Gas Supply
! A
CYLINDERS can explode if damaged.
electrical circuits.
® Never touch cylinder with welding electrode.
e Always secure cylinder to running gear, wall, or
other stationary support.
= x ® Keep cylinders away from welding and other ‘
BUILDUP OF SHIELDING GAS can harm
health or kill.
e Shut off shielding gas supply when not in use,
warnd, i 9/91
A. Installing Safety Chain
Tools Needed:
e
1 Cylinder Bracket For Small
Gas Cylinder (As Shipped)
2 S-Hook
Crimp between small hole in
bracket and chain.
3 Chain
4 Snap
Crimp onto open end of chain.
5 Cylinder Bracket For Large
Gas Cylinder
6 Gas Filling
51-160 797
Figure 3-2. Installing Safety Chain
OM-1310 Page 4
B. Installing Regulator/Flowmeter
;
Argon Gas
Tools Needed:
JD 1-1/8, 5/8 in CO» Gas
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
Install so tace is vertical,
5 Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
6 Flow Adjust
Typical flow rate is 20 cfh {cubic
feet per hour). Check wire man-
ufacturers recommended flow
rate.
Make sure flow adjust is closed
when opening cylinder to avoid
damage to the flowmeter.
7 CO» Adapter
8 O-Ring
Install adapter with O-ring between
regulator/flowmeter and CO»
cylinder.
ssb3.1" 5/94 — ST-158 697-A
Figure 3-3. Typical Regulator/Flowmeter Installation
3-3. Gun Polarity For Wire Type
A WARNING
ELECTRIC SHOCK can Kill.
® Do not touch live electrical parts.
e Turn Off welding power source, and disconnect input power before inspecting or installing.
swarni,1 2/93
STRAIGHT | REVERSE
POLARITY и For Solid
For Flux Steel Or
Core Sires Aluminum
Wires
Process) (GMAW
Process
DCEN 7
GUN POLARITY CHANGEOYER
5-116 559-0
1
Tools Needed:
J———T 3/8in
1 Polarity Changeover Label
2 Polarity Jumper Links
Always read and follow wire man-
ufacturer's recommended polarity.
There are two jumper links (1 set)
across each set of terminals. Be
sure to move each set of links
when changing polarity.
Close door,
Ref. ST-149 631-D
Figure 3-4. Gun Polarity Jumper Link Position
OM-1310 Page 5
3-4. Installing Welding Gun
> omo
5
6
WELDING GUN
=
Figure 3-5. Gun And Trigger Leads Connections
OM-1310 Page 6
Gun Opening
Gun Trigger Receptacle
Gun Securing Knob
Drive Assembly
Gun End
Loosen securing knob. Insert gun
end through opening and positian
as close as possible to drive rolls
without touching. Tighten knob.
Gun Trigger Plug
Insert into receptacle and tightan
threaded collar.
Close cover
ST-801 032 / Ref. ST-159 272
3-5. Selecting A Location And Connecting Input Power
A WARNING
ELECTRIC SHOCK can Kill. BLOCKED AIRFLOW causes
— e Do not touch live electrical parts. overheating and possible damage to
a e Turn Off welding power source, and disconnect unit.
input power before inspecting or installing. ® Do not block or filter airflow
- © Have only qualified persons install unit. Warranty is void if any type of filter Is used.
e |nstallation must meet National Electrical Code and
all other codes. swam3.1* 2/93
Have only qualified persons make
this installation.
1 18in {457 mm) Open Space
At Front And Rear
2 Rating Label
Supply correct input power.
+ Line Disconnect Device Of
Proper Rating
4 230 Voits AC Wall Receptacle
5 Input Conductors
6 Grounding Conductor
Select size and length using
Table 3-2. Conductor rating must
comply with national, state, and
local codes.
Instalt and connect grounding con-
ductor and input conductors in
conduit or equivalent between wall
receptacle and deenergized line
disconnect device.
Connect grounding conductor first,
then line input conductors.
7 Overcurrent Protection
Select type and size using
Table 3-2. Install into deenergized
line disconnect device (fused dis-
connect switch shown).
8 Input Power Plug
Turn Off unit Power switch, and
connect plug to wall receptacle.
Place line discannect switch in On
position before using welding
power source.
ssb2.2* 11/93 — ST-149 630-D
Figure 3-6. Location And Input Power Connections
Table 3-2. Electrical Service Guide
Input Voltage 230
Input Amperes At Rated Output 20
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30
Min Input Conductor Size In AWG/Kcmil 14
Max Recommended input Conductor Length In Feet (Meters) 65 (20)
Min Grounding Conductor Size In AWG/Kcmil 14
Reference: 1993 National Electrical Code (NEC). | S-0092J
OM-1310 Page 7
3-6. Installing Wire Spool
— ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Turn Off welding power source, and disconnect input power before inspecting or installing.
swarnt.1 2/93
NOTE (7 If hub tension is too tight, motor fuse F1 can open (see Section 5-2). If hub tension
is too loose, wire unravels and can become tangled inside unit.
Turn Off and unplug unit,
1 Wire Spool
2 Gun Contact Tip
li necessary, cut welding wire off at
contact tip, and retract wire onto
spool and secure.
3 Retaining Ring
Remove ring and pull off spool.
4 Compression Spring
Compression spring is used with 8
in (200 mm) spools.
5 Hub
6 Hub Pin
Slide spoal onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool. Reinstall
retaining ring.
7 Hub Tension Nut
Grasp spool in one hand and turn
while using a wrench to adjust hub
tension nut. When a slight force is
needed to turn spool, tension is
set.
Thread welding wire (see Section
3-7). Close door.
Tools Needed:
FB Tw
dE 15/16 in
Ref. ST-80$ 172-A / ST-G72 573-B
Figure 3-7. Welding Wire Spool Installation
3-7. Threading Welding Wire
! ir
CYLINDERS can explode if damaged. WELDING WIRE can cause puncture
® Keep cylinders away from welding and other wounds.
electrical circuits. e Do not press gun trigger until instructed to do so.
e Never touch cylinder with welding electrode. ® Do not point gun toward any part of the body, other
e Always secure cylinder to running gear, wall, or people, or any metal when threading welding wire.
other stationary support,
ELECTRIC SHOCK can kill.
HOT SURFACES can burn skin.
e Allow gun to coal before touching.
# Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and alt
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger. | swarn2.1 9/91 / swarn5.1 10/91
OM-1310 Page 8
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
~ E N фо © Mo =
Tools Needed:
SF
FB
7 Hold wire tightly to keep it from unraveling.
\
= 7 o?
(150 mm)
ha
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
Set switch,
Close and tighten pressure assembly, Remove gun nozzle
and let go of wire. and contact tip.
A Welding wire is electrically
live when feeding welding
wire with gun trigger.
DR, > Ln + DR, FH
Press gun trigger until wire Feed wire to check drive roll pressure, Cut off wire,
comes out of gun. Reinstall Tighten knob enough to prevent slipping. Close and latch door.
contact tip and nozzle.
Ref. ST-149 632-D / Ref. ST-150 193-D / Ref. 5T-159 270/ 5-0627-A
Figure 3-8. Threading Welding Wire
OM-1310 Page 9
! ie
ELECTRIC SHOCK can kill.
® Always wear dry insulating gloves.
® |nsuiate yourself from work and ground,
® Do not touch live electrical parts.
e Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
® Wear welding helmet with correct shade of filter,
e Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous
to your health.
* Keep your head out of the fumes.
e Ventilate area, or use breathing device.
* Read Material Safety Data Sheets (MSDSs) and
manufacturer's instructions for material used.
MOVING PARTS can cause injury.
e Keep away from pinch points such as drive rolls.
® Keep all doors, panels, covers, and guards closed
and securely in place.
WELDING can cause fire or explosion.
* Do not weld near flammable material.
Watch for fire; keep extinguisher nearby,
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
.
®
e
® Allow work and equipment to cool before handling.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
* Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Precautions at beginning of manual for ba-
sic welding safety information. swarn6.2* 8/92
Y
Wear the following while welding:
1 Dry, Insulating Gloves
2 Safely Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter {See ANSI
749.1)
sb3.1 1/94
Figure 4-1. Safety Equipment
i Work Cable
2 Work Clamp
Tools Needed:
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible,
Use wire brush or sandpaper to
clean metal at weld jeint area. Use
chipping hammer to remove slag
after welding,
sb4.1* 2/93 — Rel. ST-159 272-A
BUILDUP OF SHIELDING GAS can harm health or kill.
e Shut off shielding gas supply when not in use.
warni.1 9/91
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off.
Close valve on cylinder when fin-
ished welding. sb5.1* 6/92 -5-0521C |
Figure 4-3. Shielding Gas
OM-1310 Page 10
NEY Е
ARCING can damage switch.
e Do not change Voltage switch position while welding.
Arcing inside switch can damage contacts, causing switch to fall.
warn5.1* 2/93
1 Wire Speed Control
Use control to select a wire feed
speed. Às Voltage switch setting
increases, wire speed range also
increases. The numbers around
the control are not a wire feed
speed and are for reference only
(see Table 4-1).
2 Voltage Switch
Use switch to select an arc voltage.
The higher the selected number,
the thicker the material that can be
welded (see Table 4-1),
3 Power Switch
Use switch to turn unit On and Off,
[
BO NOT SWITCH
UNDER LOAD
O
V VOLTAGE
Ref, ST-150 092-A / Ref. ST-159 272-A
Figure 4-4, Controls
OM-1310 Page 11
Install & Turn On Do Readjust Controls
Connect Personal | Safety Alo & Gas Set Controls — Sample Weld And Prepare
Equipment Equipment If Applicable) For Production
ssb4.1 10/81
Figure 4-5. Sequence Of Operation For Hard And Flux Cored Wires
Install & Connect Adjust Hub Adjust Drive Roll Put On Personal Y urn On Equipmen Set Controls 4
Equipment Using Tension To ressure To Safety Equipment And Adjust Gas Keep Gun Cable
Knurled Groove Minimum Minimum y =Quip To 30 cfh Straight
Readjust Controls
Do Sample Weld And Prepare For
| Welding
Figure 4-6. Sequence Of Operation For Aluminum Welding
Table 4-1. Suggested Settings For GMAW And FCAW Welding
Wire Type, Wire Operator Material Thickness
Shielding Gas, | Diameter Control 1/4in | 3/16in | 1/8in
And Flow Rate (inch) Settings (6.4 mm) | (4.8 mm) | (3.2 mm) 14 ga | 16 ga | 18 ga | 22 ga | 24 ga
Range — 4 3 2 2 1 1 1
023
Feed Speed” — 100% 80% 70% 60% 55% 45% 35%
E705-6 Range 4 4 3 2 2 1 1 -
СО» ‚030
20 cfh+ Feed Speed* 80% 75% 60% 60% | 50% | 40% | 30% —
Range 4 4 3 2 1 1 1 —
035
Feed Speed* 65% 50% 50% 40% 20% 20% 15% —
Range — 4 3 2 2 1 1 1
023
Feed Speed” - 100% 90% 80% 70% 60% 50%. 40%
E705-8 Range 4 3 3 2 2 -
75% Ad on 030
25% CO + 5 o o o ©. 0 с _
2 Feed Speed 90% 80% 70% 60% 50% 45% 30%
20 cih+
Range 4 3 3 3 2 2 1 —
035
Feed Speed" 75% 70% 60% 50% 40% 33% 25% —
Range 3 3 2 i 1 1 — —
030 * o о o 4 © © 2 of
E70T-1 Feed Speed 40% 65% 45% 0% 30% 0% - -
Flux Core Range 3 3 2 1 1 1 — —
.035
Feed Speed” 60% 50% 40% 30% 20% 10% — —
Range 4 4 3 3 3 2 1 _
‚023
Feed Speed” 100% 100% 90% 85% 75% 70% 60% —
ER 308
Stainless Range 4 4 3 3 2 2 - —
Steel 030
Tri-Mix Feed Speed* 75% 75% 65% 60% 55% 50% — т
20 cfh+
Range 4 4 3 — — — — _
‚035
Feed Speed“ 60% 60% 59% - = — — —
Range 4 3 3 2 1 1 — —
.030
Aluminum Feed Speed” 90% 85% 80% 90% 90% 85% — —
Argon Range 4 4 3 2 2 1 7 -
20 cfh+ 035
Feed Speed* 85% 85% 85% 90% | 90% | 80% — -
*Adjust WIRE SPEED ADJUSTMENT control as required.
+cfh = cubic ft per hour
IMPORTANT: fin doubt, set VOLTAGE ADJUSTMENT switch for voltage desired and set WIRE SPEED ADJUSTMENT to 50. The weld
can be started and fine tuned during operation. If input voltage is low, a higher VOLTAGE ADJUSTMENT setting may be required to obtain
desired weld. Rel. 5-128 155-A
OM-1310 Page 12
SECTION 5 — MAINTENANCE & TROUBLESHOOTING
' AH
— ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
© ® Do not touch live electrical parts. ® Keep away from moving parts.
e Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
® Keep away from pinch points such as drive rolls,
HOT PARTS can cause severe burns.
® Allow cooling period before maintaining or
servicing.
Maintenance to be performed only by qualified
emilia
persons. swarnB.2 2/93
5-1. Routine Maintenance
4) Turn Off all power before maintaining.
md 3 Months md 3 Months wd 6 Months
fx un NE Replace Replace Blow Out
See AR Unreadable Cracked V Or
Section Labels Parts acuum
8 a Trigger Cord
Tape Or
Replace Clean
Cracked > Drive
Weld Rolis
-- Cable Gas Hose Gun Cable 5-3
Figure 5-1. Maintenance Schedule
5-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
minutes
Start welding.
Let fan run for
15 minutes.
When overheated, tharmostat
opens, output stops, and cooling
fan keeps running,
ssb10.1 1/94 - ST-149 628-C
Figure 5-2. Overheating
B. Short Circuit Shutdown
If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, release gun
trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn On unit to
continue operation.
OM-1310 Page 13
C. Motor Fuse F1
“A "CAUTION
STATIC ELECTRICITY can damage parts on circuit boards.
® Put on grounded wrist strap BEFORE handling boards or parts.
warns, 1" 9/91
Tum Off and unplug unit. Unlatch
door, and remove doorwrapper.
1 Motor Control Board PC1
2 Fuse F1 (See Parts List For
Rating)
Pull fuse from fuse holder on PC1,
and check and replace if needed.
To reinstall, push fuse into fuse
holder,
3 Control Relay CR1
Reinstall wrapper, and latch door.
Ref. ST-150 194-B / ST-149 921-A
Figure 5-3. Fuse F1 Location
5-3. Cleaning Or Repairing Drive Assembly
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Tools Needed:
Turn Ott and unplug unit,
1 Wire Spool
2 Gun Contact Tip
Cut welding wire off at contact tip.
Retract wire onto spool and
secure,
3 Pressure Roll Arm
4 Cotter Pin
5 Pin
6 Screw
7 Bearing
Remove bearing as shown. Install
new bearing if needed, and secure
with screw. Reinstall arm.
8 “Securing Screw
9 Washers
10 Drive Roll
Remove drive roll as shown.
Use a wire brush to clean drive roll.
Push drive roll onto shaft and
secure with washers and screw.
11 Wire Inlet Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole
from rear until it snaps in place.
Thread welding wire (see Section
3-7). Close door.
Ref. ST-801 172-A / ST-155 578
Figure 5-4. Removing Drive Roll, Drive Bearing, And Wire Inlet Guide
OM-1310 Page 14
5-4. Changing Contact Tip, Liner, And Head Tube
Section 5 before proceeding.
“A warnnc — я READ SAFETY BLOCKS at start of |
A. Changing Contact Tip
Tools Needed:
FE
ar
TT 3/8in
Turn off welding power source/wire
feeder. Cut off wire at nozzle.
1 Nozzle
2 Contact Tip
3/8 in 3 Contact Tip Adapter
Ref. 5T-800 797-A,
Figure 5-5. Changing Contact Tip
OM-1310 Page 15
B. Changing Liner
XE
ark FLYING METAL CHIPS AND DIRT can cause injury and damage equipment.
® Point gun away from people and in a safe direction when blowing out with compressed air.
< Dor A Turn off welding power source/wire feeder. Tools Needed:
/ 1 = Lead = FB
/ | Tube TT
| 3/8 in
| Remove nozzle,
contact tip, adapter,
3/8 in and wire outlet quide.
Wire Outlet Guide
A
Remove liner.
ON
- > Lay gun cable out
-— siraight before
- installing new liner.
Blow out To Reassemble Gun:
gun casing. Insert new liner.
Install and tighten wire outlet
guide.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
Rel. ST-800 797-A
Figure 5-6. Replacing Gun Liner
OM-1310 Page 16
C. Replacing Switch And/Or Head Tube
Turn off welding power source
/wire feeder and disconnect gun.
3 Slide handle.
1 Remove handle Remove switch housing. Note: If installing new
locking nut. switch, push switch lead connectors onto terminal of
new switch {polarity is not important). instakl switch
back into handle, and secure with handle locking
nut. If replacing head tube, continue to end of figure.
4 Secure head 5 Remove shock wash- 6 Loosen jam nut. Remove
tube in vice. ars from front and from vice and turn head
rear of head tube. tube out by hand.
Do not disturb cable connection between
cable connector and connector nut.
7 install both existing shock washers | 8 Place head tube in vice and tighten
to new head tube and hand-tighten to within 1/8 in (3.2 mm) spacing
head tube into connector cable. between connector cable and body.
m y LS
<
9 Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
Tools Needed: “
Это зп +
— Ref. ST-B00 795-А
Figure 5-7. Replacing Switch And/Or Head Tube
5-5. Unicable Repair
To repair or replace unicable, order Unicable Clamp Kit, part number 172 017. Kit includes all required instructions,
clamps, inner support tube, compression clip, switch leads, and connectors.
OM-1310 Page 17
5-6. Troubleshooting
<A WARNING
| ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
MOVING PARTS can cause injury.
e Keep away from moving pans.
e Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
>
a
servicing. —
HOT PARTS can cause severe burns. e
® Allow cooling period before servicing gun or unit. =
e Keep away from pinch points such as drive rolls.
Troubleshooting to be performed only by qualified
bersons,
swarn9,2 2/93
Table 5-1. Welding Trouble
Trouble Remedy Section
No weld output; wire does not feed; fan |— — | Secure power cord plug in receptacle. — 3-5
does not run.
Replace line disconnect fuse or reset circuit breaker if open. — — = 3-5
Secure gun trigger plug in receptacle or repair leads, or replace |—— -» 3-4
trigger switch.
No weld output; wire does nol feed; fan I— — -=] Thermostat TP1 open (overheating). Allow fan to run; the thermo- | — -= 5-2A
motor continues to run. stat will close when the unit has cooled,
Check motor fuse F1, and replace if necessary. —— 5-26
No weld output; wire feeds. | — -»| Connect work clamp to get good metal-to-metal contact. — — -m| Figure 4-2
Check for proper connections at polarity changeover board. — — = 3-3
Replace contact tip. — — | 5-2B,5-4A
Low weld output. B= — =| Connect unit to proper input voltage or check for low line voltage. = — = 35 |
Table 5-2, Wire Drive/Gun Trouble
Trouble | Remedy Section
Electrode wire feeding stops during |— — -=| Straighten gun cable and/or replace damaged parts. 5-48
welding.
Adjust drive roll pressure. 3-7
Change to proper groove. 5-3
Headjust hub tension. 3-6
Replace contact tip if bfocked. 5-44
Clean or replace wire inlet guide or liner if dirty or plugged. - 5-3, 5-4B
Replace drive roll or pressure bearing if worn or slipping. 5-3
Secure gun trigger plug in receptacle or repair leads, or replace 3-4
trigger switch.
Check motor fuse F1, and replace if necessary.
Check and clear any restrictions at drive assembly and liner.
Have nearest Factory Authorized Service Station/Service Distrib-
utor check drive motor.
OM-1310 Page 18
SECTION 6 ~ ELECTRICAL DIAGRAMS
Y RCS
| |.
IN
<< 12 PCI
<< 19 MOTOR CONTROL
RCI/PLG2
<< 4
<< 3
T . TORCH
IDENTICAL CONNECTED VOLTAGE(S}
200 VOLTS _
220 VOLTS A T Â
a
Jr
58-162 243
Figure 6-1. Circuit Diagram For Welding Power Source
OM-1310 Page 19
RC3
27AICR2 TOP)
1}
EB (PLG2-9
8
|
Hi
r
h
[4
PLG2
in
FALPLGZ-10
14
RCI
SA[S52 WIPER)
POWER CORD)
DRIVE
MOTOR
32
WORK NEG | 31AarPLG2- 12)
Ene ICtSAZ -
` © Ue J
POS TORCH
TE!
C1 (POS)
Cl
R3; |\RZ | R4| [RD
З18{
3IC{TE1-NEG)]
a
|
CTINEG)
POWER CORD
(РСС!)
56-162 244
Figure 6-2. Wiring Diagram For Welding Power Source
OM-1310 Page 20
À =»
?
ELECTRIC SHOCK can kill.
e Always wear dry insulating gloves.
e Insulate yourself from work and ground.
® Do not touch live electrical parts.
® Keep all panels and covers securely in place.
SECTION 7 — WELDING METHODS & TROUBLESHOOTING
mod4d.1 4/42
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
® Wear welding helmet with correct shade of filter.
e Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
e Keep away from pinch points such as drive rolls.
w
a
S
FUMES AND GASES can be hazardous
to your health.
e Keep your head out of the fumes.
e Ventilate area, or use breathing device.
e Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
e Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
® Pacemaker wearers Keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
de $
WELDING can cause fire or explosion.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
tions.
WELDING CURRENT can damage elec-
tronic parts in vehicles.
e Disconnectboth battery cables before welding ona
vehicle.
® Place work clamp as close to the weld as possible.
See Safely Precautions at beginning of manual for ba-
sic welding safety information. swamn6.2 10/91
7-1.
Flux Cored Arc Welding (FCAW) And Gas Metal Arc Welding (GMAW)
NOTE (7
Welding wire is not energized until gun trigger is pressed; therefore, welding wire
should extend not more than 1/2 in (13 mm) beyond edge of nozzle and tip of wire
placed on seam before lowering helmet and pressing trigger.
Hold Gun And Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension
(Stickout) 1/4 To 1/2 in (6 To
13 mm)
Cradle Gun And Rest Hand
On Workpiece
) >
End View Of Work Angle Side View Of Gun Angle
GROOVE WELDS
> 2
End View Of Work Angle
Side View Of Gun Angle
FILLET WELDS
5-0421-A
Figure 7-1. Holding And
Positioning Welding Gun
OM-1310 Page 21
NOTE (PF Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
5 5
Perpendicular
GUN ANGLES AND WELD BEAD PROFILES
Short Normal Long
ELECTRODE EXTENSIONS (STICKOUT)
Short Normal Long
FILLET WELD ELECTRODE EXTENSIONS {STICKOUT)
¿ 3 < >
Normal Fast
GUN TRAVEL SPEED 3.0634
Figure 7-2, Conditions That Affect Weld Bead Shape
N OTE Г’Р Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
1 Stinger Bead — Steady
Movement Along Seam
2 Weave Bead - Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a
wide area in one pass of the elec-
trode. Do not let weave width ex-
ceed 2-1/2 times diameter of
electrode.
5-0054-4
Figure 7-3. Gun Movement During Welding
OM-1310 Page 22
Large Spatter Deposits
POCH WELD BEAD
Rough, uneven bead
Slight Crater During Welding
Bad Overlap
a. eh N =—
Poor Penetration
3-0053-A
1 Fine Spatter
GOOD WELD BEAD 2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded,
4 No Overlap
5 Good Penetration Into Base
Metal
5-0052-B
Figure 7-4. Weld Bead Characteristics
7-2. Welding Troubleshooting
Table 7-1. Porosity
Porosity — small cavities or holes
resulting from gas pockets in weld
metal.
5-0635
Possible Causes
Corrective Actions
Inadequate shielding gas coverage.
Check for proper gas flow rate.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Eliminate drafts near welding arc,
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire {contact supplier).
nozzle.
Welding wire extends too far out of
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
OM-1310 Page 23
Table 7-2. Excessive Spatter
Excessive Spatler — scattering of
molten metal particles that cool to
solid form near weld bead.
5-0636
Possible Causes Corrective Actions
Wire feed speed too high. Select lower wire feed speed.
Voltage too high, Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension {stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Table 7-3. Incomplete Fusion
<
Incomplete Fusion — faifure of weld
metal to fuse completely with base
metal or a preceeding weld bead.
5-0837
Possible Causes
Carrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
Table 7-4. Lack Of Penetration
Lack Of Penetration —- shallow fu-
sion between weld metal and base
metal.
Lack of Penetration
Good Penetration
5-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while maintain-
ing proper welding wire extension and arc characteristics.
Improper weld technigue.
Maintain normal gun angle of 0 fo 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in {13 mm} beyond nozzle.
Insufficient heat input,
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
OM-1310 Page 24
Table 7-5. Excessive Penetration
Excessive Penetration — weld metal
melting through base metal and hanging
underneath weld.
Excessive Penetration Good Penetration 5-0639
Possible Causes Corrective Actions
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase travel speed,
Table 7-6. Burn-Through
Burn-Through — weld metal melting
completely through base metal
resulting in holes where no meial
remains.
5-0640
Possible Causes Corrective Actions
Excessive heat input, Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
Table 7-7. Waviness Of Bead
Waviness Of Bead - weld metal
that is not parallel and does not
cover joint formed by base metal.
5-0641
Possible Causes Corrective Actions
Welding wire extends too far out of Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
nozzle.
Unsteady hand, Support hand on solid surface or use two hands.
Table 7-8. Distortion
Distortion — contraction of weld
metal during welding that forces
base metal to move. ;
Base metal moves
in the direction of
the weld bead. 3.0842
Possible Causes Corrective Actions
Excessive heat input. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-1310 Page 25
SECTION 8 — PARTS LIST
19
_
23
=
/
E.
ST-149 416-E
Figure 8-1. Main Assembly
OM-1310 Page 26
Quantity
Item Dia. Part
No. Mkgs. No. Description
Figure 8-1. Main Assembly
a V Lace sec a neue 0 089 899... LATCH, slide flushstyle ............. coin AG
гу, A sa u ua 00 +151 565... WRAPPER . ...... i i a aa a na
C3 RE 134 464 ... LABEL, warning general precautionary .................... co...
Cd nue e 117 860... BLANK, snap-in nyi .187mtg hole ............ cc. iii,
CB Fig 8-2... BAFFLE, center w/components ............ coven,
6... 147 576... PANEL, side lower ..... ci i ie i is ie Ne
A 121 614 ... RING, retaining ext .750 shaft x .085grvdepth ........... 0... 0...
8 еуунуукеквао. 602 250... WASHER, flat stl SAE 750 ...... iii i a irae ea
A 090 693 ... WHEEL, rubolene spoke 8 in x 2.000 wide x .760 bore ................
10... ... ...... 022 160... CLAMP, capacitor 3.000dia ......... oii i A
11.... C1 ..... 162 245... CAPACITOR, elctlt 140000uf 35VDC .... cocoon
E PAT 123770... RESISTOR ASSEMBLY, (consisting of) .............e..erecereveeren
aaa R2-5..... 117 116..... RESISTOR, WW fxd 20W 50 ohm -.......eo_.esrveoererervrarer ee
13.... FM ..... 112 475 ... MOTOR, fan 200V 2600RPM w/124V sec (208V model) ..............
e 13... FM ..... 117 014... MOTOR, fan 230V 2600RPM .1818dia shaft (230V model) ............
add ae 0e 0000 005 656 ... BLADE, fan 6 in 4wg 30deg .175 bore CW 1201120100 aa ane ana en ue 0
e [PO 147 635 ... HOSE, SAE .187 ID x 410 OD x 32.000 1.222222 0 aa aa ae na en aan une
AB en 149 332 ... CLAMP, hose .405-.485clp dia slfttng 000000 seen ea ee
….17...GS1..... 128 751... VALVE, 230VAC 2 way custom port 1/8 Orf ........... oot,
E: 605 227... NUT, nyl hex jam .750NPST .........00000rerer ere a eee
Mueren eue ee 156 339 ... BRACKET, mtg bottle .........0222 200000 < 00e aa aa aa ae ae a aan en 6
1 602 389... HOOK, S blunt 1.500 in ..........ee_eserevvedrearas 2er ae aras area
LL 2T a a aan 00 156 340 ... CHAIN, weldless 2/0 x 11.000 ....... cc. ci i ire iia De
22 anse» 602 384... SNAP, chain ..........._—reeeseescsriran rencor ereteerere retener
23... PLGÍ .... 120 964... CORD SET, 125V 5-15P 14ga 3/c 7ft (208V model) ..................
23... PLG1 .... 152 118... CORD SET, 250YV 6:50P 12ga 3/0 12ft (230V model) .................
BALL a aa aa ae 111 443 ... BUSHING, strain relief 240/510 ID x 875mig hole ..................
1 2D 1110000 146 619... BEZEL i ee re aa
26... 147 443... PANEL, FAI. oot tiie Ada 4 aa ae 4e 0 aa a aa a a da de a ne da aa 00
RAA 147 572... BRACKET, mtg fan .......224 024040 a ea ea ea re ae eee san ea ee a ea»
7: 152 872... BASE ........rrrreserececaaía ere rre evoca raraerrerresmereverev
29 inner 147 893... AXLE, running gear ......2020 00400000 0 ea a 4e ee ee ea eee ane en 0
. 30... 7A 147 315... STABILIZER .............es0reerer e: ereerececeecereore rene e, 6
2 GÙ 111111111000 109 318... CASTER, swvl cushionex 2.500 x .812x .312-18 ....................
„32.,... T1...... 156 305... TRANSFORMER, pwr main 208V (consisting of) ............—.... Ce
Ce eae 154001 ..... COIL, PrifSBC ... i ii i cit tii ie iia ea
‚ 32..... T1...... 147 313... TRANSFORMER, pwr main 230V (consisting of) .....................
Ce ieee 146 943 ..... COIL, pri/sec ..........eeeereíeascarvenrererrera recrea evi ecene—
33....RC3..... 048 282 ... CONNECTOR w/SOCKETS, (consisting of) ..........e._.e.eervecreo
AAA AAA ee 079534 ..... CONNECTOR, circ skt push-in 14-18 amp 66358-6 ..........—...e..
A 147 442... PANEL, front .........._.ev0evec0rere econ ere reraaenve nevera e
REC AAA AS 600 325 .. . CABLE, weld cop strd No. 6 (order by ft) ............_..e.eeeesrreciies
2. 836 ,............. 026 843... INSULATOR, vinyl blK ..... к. сек ie iste vanes
BT ee 010368... CLAMP, grd 200A ii rea
BB aaa 169 903... M-15 GUN, (Fig 8-3) 1.112111 4 004 a sea aa aa sa a aa A Sea See eee ea ae
ni 004 214 ... BUSHING, snap-in nyl 1.625 ID x 2.000mighole .....................
‚ 40 eee 147 571... HANDLE ......e.e0000erecereieaerecrerecme nera reere ena.
AR KK NAMEPLATE, (order by model and serial number) ...................
A 097 922... KNOB, pointer .............eeeerrecsrreerrerca recen eee es
AB aras ++127 023... KNOB, pointer ...........e._eerexerve career ercer EE
‚. 44..... S2...... 116 830... SWITCH, rocker DPST 10A 250VAC ........ oii AD
AB iia 111 644... BUSHING, strain relief .370/.430 ID x .875mtg hole ..................
46... RA ..... 072 623... POTENTIOMETER, C sitd sft 1/T 20 1000 ohm .....................
Y AO S1...... 111 897 ... SWITCH, rotary 4posn B00V i ee
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
++Part of Rotary Switch (51).
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1310 Page 27
ST-153 515-A
Figure 8-2. Baffle, Center w/Components
OM-1310 Page 28
Item Dia. Part |
No. Mkgs. No. Description Quantity
Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 5)
Ll 058 427 ... RING, retaining spool. oo. iii i eet etree a a ea a aa 6 1
1 D Lecce ca ana neue 085 980 .. . NUT, sti hex fuit 625-11 1L.1120 2010004 ea eue a aa ad ieee ican 1
E ранен кенаноо, 605 941 .., WASHER, flat sti .640 ID x 1.000 OD x td4gathk ..................... 1
Ba 057 543... SPRING, cprsn .845 OD x .091 wire x 1.500 .,......... ..... e ee canne 1
e Driarereanen. 057 971... WASHER, flat sti keyed 1.500diax .125thk ..................... ..... 1
2 6 Lecce ce an na ne 010 191 ... WASHER, for 656 ID x 1.500 0D x .125thk ......................... 2
Ar AAA AAA 058 628... WASHER, brakestl .............. tera, 2
A 057 745... SPRING, cprsn 2.430 OD x .090 wire x 2,500 ........._.e.eerrerrcan. 1
E: aan eue 058 428... HUB, spool..........e eeeeeeeceeordrrcererererereereacanenr eee. 1
a | .............. 134 201... STAND-OFF SUPPORT, PC card ........ e... een deerd ire een nada 4
TEE LL ea a 14411100 e 057 358... BUSHING, snap-in nyl 1,000 ID x 1.37bmtghole ..................... 1
E AS 147 569 ... BAFFLE, center ..........eorercierrorereserrererearenrerer tae aa + 1
….13....CR2..... 108 358... CONTACTOR, def prp 25A 2P 24VAC 1.121212 ea aa ea en a nes a eau à 1
e 14... PC aa. 169 538... CIRCUIT CARD, motor speed control (consisting af) ................. 1
015.0... F1..... "125847 ..... FUSE, mintrgi slo-blo 12A o.oo ieee cian à 1
Cee 40 PLG2 .... 113149... CONNECTOR, rect 14skt plug Amp 1-640250-4 ceed
Ce i 079 747 ... CONNECTOR, rect skt 24-18ga Amp 350980-1 ..................... 14
….16....CRt..... 072 817... RELAY, encl 24VAC DPDT i ie ra ae ee aa ea ea aan 1
….17.... VR1..... 087 156 ... VARISTOR, 10 joule 68VDC ii iii iii ii icine, 1
..18.... 5R2..... 155056... RECTIFIER, si diode (consisting of) ............. a ae a a aa aa a na 1
Cee TP1 ..... 155055 ..... THERMOSTAT, NC ....... 7
Ce eee A 026 701 ..... INSULATION, thermostat .............. iii 1
...19.... TE1 ..... 152 214 ... TERMINAL ASSEMBLY, chgov (consisting Of) ....................... 1
2011121211 000 0 601835... NUT, brs hex 10-32 i i i te ae ea eee da aa a aa ea a a 8
E 11e ae e eee 038887..... STUD, pribd brs 10-32 x 1,375 1.122000 a aa a a a a ae ea na aa na eau ne 4
не. PO aa e en a 6 116 620..... TERMINAL BOARD, chgov ..........eesñ.ir2 recae icereomaa, 1
RC AS 174504 ..... LINK, jumper term bd pri .......... ee e_ecririrrrer nee ane» 4
7 ..... M...... 090 087 ... MOTOR, gear 24VDC iii i tet tee aa ane 0 1
RL nirvana 112 583... INSULATOR, motor to drive housing ..................... RS 1
TL EE 604 657... SCREW, cap sil hexhd .375-16 x 1.250 ...........ees=esresrierervere0.. 1
SA a aa eee 602 213... WASHER, lock stl split 375 2000000400708 ie ee teeta 6 1
28. 010910... WASHER, flat stl SAE 375... iii ie eis, 1
зе. 29 ...,.......... 147 573... BRACKET, mtg drive system .......c._——evrererrarecoranrererenen na 0 1
‚. 90 LL 14140 111 912... INSULATOR, housing drive .........e__—eeccrracesececerreraa aa e 1
lee een ane Fig 8-4... DRIVE ASSEMBLY, wire L.....212 RK ena. 1
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1310 Page 29
Ge
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LL Ws) sapnioul,
ST-801 140
Figure 8-3. M-15 Gun
OM-1310 Page 30
item Part
No No. Description Quantity
169 903 Figure 8-3. M-15 Gun (Fig 8-1 Item 38)
Ns 169715 .. NOZZLE, slip type .500 orf flush ........._.eeeecorveare rrerenenrence eee 1
oo 2... 4087299... TIR contact scr .023 wire x 1.125 LL ee ee. 2
Duna. 000 067 .. TIP, contact scr .030 wire x 1.125 LL...1 1202044004 ea aa aa ie 2
.. 2... 000068 ., TIP, contact ser .035 wire x 1.125 .,..........eo-rir.riíeserenerieresarera re. 2
.. dr... 189716 .. ADAPTER, contact tip ...........e_eeeoé.eooveeriera deecodererri a aan ena na 1
M 0.0.0. 170470 .. RING, retalning 0.000700 i i ie it eae ia aa 1
e Bonao 170471 .. O-RING ii ii ett ett tc tae ena 1
> 169 717 .. WASHER, shock ...........ee0ecrecasrerracedmeonerrerrvrarenereori ano e 2
Pana 169718 .. TUBE, head ............e-—.esecereerereriere ter ernreerrrecoaaavrerrervma re 1
a: 169738 .. NUT, locking handie ,...........2.....0reereevareraeresecerrerene recio, 2
C9. 169719 ,. NUT, jam (gun end) oo... iia eae eae 8000 1
9... 169 732 .. NUT, aM i i i it i te et etter tea certs mate ae 1
10..... 169720 .. CONNECTOR, cable{gunend) ............c toi, 1
10..... 169733 .. CONNECTOR, cable ..........eeseeocevorereneoaevarererereaeeneereveoave, 1
11... 169721 .. NUT, connector ...........o_ _.eeeeacacacaari in anada a ee ea eee ea ea en 2
„12..... 172017 .. M15 UNICABLE CLAMP KIT, (consisting Of) ............. oii. 2
13... 169 735 .... CLIP, Compression citi iit ie ct etree eee ceca aa 1
LC 169 742 .... TUBE, support ......e..ex.esesirererererrreonr ate env ene darereceaverae ro 1
Burro, 169 743 .... CLAMP Inner ........._e se errrredcareo,.sadamareaarancaceredrrnred vaa 1
,16..... 169 740 .... CLAMP, jacket 221041204440 aa a eee aa ee ee 4 A ee da ea eee A1 Se ee ane 0 1
„17..... 169746 .... CONNECTOR, switch lead ........... cc iii iii cians 2
. 18... 169 737 .. HANDLE ........ 2.000 rmeexreeoeeceare ra aenaretrcaneercornorene re rear ia ae 2
. 19... 169 741 .. STRAIN RELIEF, cable ..........e o 0es.eerrarverrearracenv arena ana an, 2
e 20... 169 736 .. BLOCK, terminal ............eereeoeecarariaren vocento ieorrar are tai nena. 1
21... 172565 .. CABLE, pwr 21 in 18ga 2/0 .LLLL 1100044444 aa ee ee ee a a ee ea 8e ee aa 1
…. 22... 173521 .. CONNECTOR, feeder (consisting Of) 1.222000 0204004 eee ee a a ae ee ee ea es ane 0 1
23... 079 974 .... O-RING, .500 1D x .103CS rbr LL. 120042 e ea cee te ree a 2
.. 24... +172 257 .. KIT, liner monocoil .023/025 wire x 15ft (consisting of) .............. essere. 1
24... 172 258 .. KIT, liner monocoil .030/.035 wire x 15f (consisting of) ........................ 1
e 2D. 079975 .... O-RING, .187 ID xXx .103CS rbr .........es.erevrarveaerr e rente incor esa. 1
...26,.... 169 723 .. GUIDE, outlet 110100000444 44e ee a 4 ee 4 4 ie tite ee enana 1
QT nue. 169739 .. SWITCH, trigger ..........e..ee__esreerererereteaa 020 rerererCe recono. 1
+ OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT FARTS.
OM-1310 Page 31
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1310 Page 32
_-——
Figure 8-4. Drive Assembly, Wire
item Part
No, No. Description Quantity
Figure 8-4. Drive Assembly, Wire (Fig 8-2 item 31)
2. 1 ..... 128 189 .. SCREW, capstihexhd 312-18 X 1.750 ............00r0xecrecereeerere e ee 1
2. D Lane 602 211 .. WASHER, lock sti split .312 111112200444 4 aa a eee ea a a ra da ee ae a ADA 1
Bn 604 538 .. WASHER, flat stl SAE 312 ........... 0.0080 8.000eríre aer errecar era 5
‚ 4 ..... 126 651 .. WASHER, shidr nyi .437 OD x .328 1D x .703shldr ..........ee.eevereevereee.s 1
E 126 838 .. DRIVE ASSEMBLY, wire (consisting Of) ..............e2eeerererie arar 1
A: 090416 .... PIN, hinge ..............0.000800ráe0er eiii 0 revararecarari on eaór rev 1
CT 124 817 .... HOUSING, wire drive oo. ii sities i ii teat inte iain ae 1
Bi... 114 415 .... SCREW, mach stl phfih 10-24 X 825 ........... iii iia 1
„9..... 090 443 .... BEARING, ball rdl sgl row ‚315 x .866 x .27 {consistingof) ................... 1
Cee 111 622 ...... SPACER, bearing .196 ID x .310 OD x .500 collar ........e...ee.e000000eaa À
‚10..... 112 031 .... LEVER, pressure roll... iii iii i i vie eee 1
11... 151 828 .... PIN, cotter hair 054 x 750 ..... 110112014046 aa aa da 0 a ee ae a ee see a aa ar 1000 1
E 010 224 .... PIN, spring CS 187 x 1.000 LL... 2202000444 ee ae 0 a 0 see a ee eee ee a ea eee» 1
e 13 aos 058 549 .... GUIDE, wire inlet 1/16 .............s merecedores riviera deneaer errar 00 1
14... 085 242 .... FASTENER, pinned ERKRANKEN 1
15... 085 244 .... WASHER, cupped st! 328 ID x 812 OD x 125 Hip ........... erre нноо 1
e. 1B..... 090415 .... SPRING, cprsn .720 OD Xx .072 wire X 1.250 .......e.-—eserrieerrerermecer. 1
2017000. 092 237 .... KNOB, adjustment tension ........ ccc iii iii iia, 1
...18..... 126 652 .. KNOB, plste T 2.000 lg x 312-18 oi ie 1
e ee, 126 653 .. WASHER, flat ny! .312 1D x .625 OD x .O94thk ........—ererererreonrreareer e... 1
.. 20... 502 238 .. WASHER, flatst| 18/7 LL. 1420400004 4 4 4 ee ee 1
...21..... 602 203 .. WASHER, lock stl split No, 10 111120044460 0ER REF EKRKEER 3
Ca 22 090 105 .. SCREW, cap stl hexhd Smm X 22mm... iii canes 3
1020.00 090106 .. SCREW, capstihexhd mmx 16mm ......... ci iii A. 1
1.024.000. 602 207 .. WASHER, lock stl split .250 ee 1
25... 602 240 .. WASHER, flat stl std 250 ....112 20000444 ea ae ae 4e ee a a a a ee ee se 1
206.1... 090 423 .. ROLL, drive U groove .023-.030 wire 1.122.020 0 ee aa aa eee ee re ea aa ea 1
1 Da
2 A”
ol 3 и |
4 pr | 5
FA | |
7 | | 6 7 Includes!
| Items
Hag ~ | 8 thru 17
~ I
i o |
в
| 0 Cs 0 > _
| > > > DU
17 ir > A _ 7 10
48 CE
16 _ 7 N <
15 æ e IT 12 `
13
ST-001 180-G
OPTIONS AND ACCESSORIES
.045 IN. (1.2 MM) CORED
WIRE KIT
(#152 100)
For gasless, flux-cored wire only.
Includes liner, contact tube, nozzle,
and drive roll.
GUN CABLE HOLDER
(#042 701)
A convenient way to store gun and
cable.
GUN HOLDER
(#042 710)
installs onto side of power source.
Provides convenient way to store
gun when not in use.