Miller | KJ031020 | Owner Manual | Miller MW225 User manual

Miller MW225 User manual
OM 189 482
August
189 4828
1998
Processes
MIG
1~OLSfi
(GMAW) Welding
Flux Cored
(FCAW) Welding
Description
Arc
Welding Power Source
And Wire Feeder
MW225
OWNERS
MANUAL
____________
a
TABLE OF CONTENTS
The
following term is
interchangeably
throughout this manual:
SECTION 1
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
1
used
MIG=GTAW
i~i.
oyflluOi usage
1-4.
Welding Hazards
Symbols for Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-2.
Arc
1-3.
Additional
SECTION 1
1-1.
1-2.
1-3.
-
1
and Maintenance
3
4
CONSIGNES DE SECURITE
-
Signification des symboles
Dangers relatifs au soudage a Iarc
Dangers supplØmentaires en relation
LIRE AVANT UTILISATION
Principales
normes
1-5.
Information
sur
-
les
5
avec
linstallation,
le fonctionnement
7
de sØcuritØ
Volt-Ampere Curves
Duty Cycle And Overheating
Installing Work Clamp
2-6.
2-7.
2-8.
2-9.
9
9
2-2.
2-5.
8
INSTALLATION
Specifications
2-4.
8
champs electromagnØtiques
2-1.
2-3.
9
10
11
Installing Gas Supply
Installing Welding Gun
Setting Gun Polarity
Installing Wire Spool And Adjusting
Changing Input Voltage
11
12
12
13
Hub Tension
13
14
2-10. Electrical Service Guide
2-11.
2-12.
Selecting A Location And Connecting Input Power
Threading Welding Wire
14
15
16
2-13. Weld Parameter
2-14. Aluminum Weld Parameter For Use With
SECTION 3
3-1.
-
Optional Spoolmate
185
17
18
OPERATION
18
Front Panel Controls
SECTION 4- MAINTENANCE &TROUBLESHOOTING
19
4-1.
Routine Maintenance
19
4-2.
Circuit Breakers CB1 And CB2
19
4-3.
Changing Drive Roll, Inlet Wire Guide
Cleaning Or Replacing Gun Liner
Replacing Gun Contact Tip
Troubleshooting
4-4.
4-5.
4-6.
19
20
21
21
SECTION 5- ELECTRICAL DIAGRA~L
22
SECTION 6- MIG WELDING (GMAW) GUIDELINES
23
23
6-4.
Typical MIG Process Connections
Typical MIG Process Control Settings
Holding And Positioning Welding Gun
Conditions That Affect Weld Bead Shape
6-5.
Gun Movement
27
6-6.
Poor Weld Bead Characteristics
27
6-7.
Good Weld Bead Characteristics
27
6-8.
Troubleshooting
Troubleshooting
Porosity
Excessive Penetration
Troubleshooting
Troubleshooting Lack Of Penetration
Troubleshooting Incomplete Fusion
Burn-Through
Troubleshooting
Troubleshooting Waviness Of Bead
Distortion
Troubleshooting
Common MIG Shielding Gases
6-1.
6-2.
6-3.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
SECTION 7
WARRANTY
OM-189 482-B
5
5
et a maintenance
1-4.
SECTION 2
3
During Welding
-
-
-
-
-
-
-
-
-
PARTS LIST
Excessive
Spatter
24
25
26
28
28
29
29
29
30
30
30
31
.32
SECTION 1
SAFETY PRECAUTIONS
-
-
READ BEFORE USING
som
Symbol Usage
1.1.
hazards with this
shown in the
A
Marks
a
g~
Means
Note~
1-2.
The
Watch
Warning
Means
AA
A
The
are
possible
possible
hazards
are
This group
of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
special safety message.
not
safety
related.
Welding Hazards
Arc
are used throughout this manual
identify possible hazards. When you
shown below
symbols
seethe
There
Out!
procedure!
adjoining symbols.
to call attention to and
symbol,
watch out, and followthe related instructions
safety information given below is
to avoid the hazard. The
summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
follow all Safety Standards.
only
If earth
with
a
grounding
separate
of the
cable
-
workpiece is required, ground it directly
use work clamp or work cable.
do not
Do not touch electrode if you are in contact with the work,
or another electrode from a different machine.
ground,
a
A Only qualified persons
repair
A
_nd_5197
should install,
operate, maintain,
and
this unit.
During operation, keep everybody, especially children, away.
Use
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
Wear
a
Keep
all
panels
worktable
Insulate work
can
kill.
as near
clamp when
Do not connect
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
single
weld
more
above floor level.
in
securely
place.
metal-to-metal contact to
the weld
contact with any metal
live
Touching
working
and covers
Clamp work cable with good
or
ELECTRIC~ SHOCK
harness if
safety
as
workpiece
practical.
workpiece to prevent
not connected to
object.
than
one
electrode
or
work cable to any
output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Turn Off inverter, disconnect
Do not touch live electrical parts.
Wear
hole-free
dry,
insulating gloves
and
body protection.
I
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
FUMES AND GASES
Insulate
Do not
there is
a
Use AC
If AC
AC output in damp areas, if movement is confined,
danger of falling.
use
or
if
output
is
required,
use
remote
output control if present
on
unit.
Disconnect
Properly
Owners
input power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 191 0.147 (see Safety Standards).
this
to OSHA 29
install and
Manual and
ground this equipment according
national, state, and local codes.
to its
Welding produces
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
welding fumes and gases.
-
making input connections,
conductor first
-
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Turn off all
equipment
when not in
If ventilation is poor,
use an
Read
Safety
Material
the
manufacturers
exhaust at the
arc
to
worn,
drape
cables
over
your
body.
and the
coatings,
Data
Do not weld in locations near degreasing, cleaning, or spraying
The heat and rays of the arc can react with vapors to
toxic and
Do not weld
cadmium
or
(MSDSs)
-
use.
damaged, undersized,
Sheets
instructions for metals, consumables,
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
on
plated
weld area, the
use
approved air-supplied respirator.
cleaners, and degreasers.
operations.
form highly
-
Do not
use
Work in
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
Do not
be hazardous.
remove
servicing
When
=~ul~
Keep
output ONLY if required for the welding process.
can
-~
poorly spliced cables.
irritating gases.
coated metals, such as galvanized, lead, or
steel, unless the coating is removed from the
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-189 482
Page
1
ARC RAYS
BUILDUP OF GAS
burn eyes and skin
can
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Shutoff
gas
~nIure
supply
kill
or
when not in
Always ventilate confined spaces
approved air-supplied respirator.
I
~
shielding
can
use.
use
or
a welding helmetfitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
Wear
and 287.1 listed in
Wear
Safety Standards).
HOT PARTS
helmet.
Do not touch hot
protective screens or barriers to protect
glare; warn others not to watch the arc.
Use
Wear
can cause severe
burns.
with side shields under your
approved safety glasses
others from flash and
Allow
parts bare handed.
cooling period before working
on
or
gun
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
material
MAGNETIC FIELDS can affect pacemakers.
WELDING
can cause
fire
or
explosion.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, orfire. Check and besurethe
area is safe before doing any welding.
Protect
yourself
and others from
flying sparks
going near arc welding, gouging,
welding operations.
NOISE
can
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
strike flammable material.
(10.7 m)
them with
go
of the welding arc.
approved covers.
Be
that
aware
can cause
fire
keep
welding
on
a
fire
on a
Wear
on
processes
or
equipment
can
approved
ear
protection
if noise level is
high.
extinguisher nearby.
ceiling, floor, bulkhead,
or
CYLINDERS
partition
can
explode
if
damaged.
the hidden side.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Do not weld
some
If
welding sparks and hot materials from welding can
through small cracks and openings to adjacent areas.
Watch for fire, and
damage hearing.
damage hearing.
Be alert that
easily
spot
and hot metal.
Noise from
Do not weld where
or
closed containers such
as
as close to the welding area as
prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Connect work cable to the work
practical
Do not
to
use
welder to thaw frozen
mechanical shocks,
Install
pipes.
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Protect
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Remove stick electrode from holder
or
cut off
welding
wire at
Keep cylinders
away from any
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never
welding
Remove any combustibles, such as a butane
from your person before doing any welding.
Never weld
contact
tip
when not in
use.
Wear oil-free
FLYING METAL
can
lighter
or
matches,
drape
Never allow
a
a
welding
on a
torch
welding or other electrical
over a
gas
-
Injure eyes
OM-189 482
Page
2
approved safety glasses with
even
under your
welding
will result.
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
shields
cylinder.
explosion
Use
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear
cylinder.
electrode to touch any
pressurized cylinder
circuits.
helmet.
side
opening cylinder
and
and
valve.
Keep protective cap in place over valve except when cylinder is in
use or
connected for
use.
Read and follow instructions
associated
Standards.
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
1-3
Additional
Symbols
for Installation,
and Maintenance
Operation,
MOVING PARTS
FIRE OR EXPLOSION hazard.
Do not install
place
or
unit on, over,
Keep away
or near
combustible surfaces.
Do not install unit
Injury.
such
moving parts
as
all doors, panels, covers, and
closed and securely in place.
Keep
near
flammables.
fans.
guards
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
Do not overload
is
from
can cause
-
FALLING UNIT
can cause
injury.
H.F. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
can cause
interference.
Use
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
support unit.
lfusingliftforkstomoveunit,
long enough
to extend
only qualified persons familiar with
equipment perform this installation.
Have
besureforksare
electronic
beyond opposite side of
The
unit.
is
user
promptly
for
responsible
having
correct any interference
a
qualified
electrician
problem resulting
from the
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
STATIC
Put
or
(ESD)
on
handling
or
OVERHEATING
duty cycle.
follow rated
reduce
duty cycle
grounded
boards
or
wrist
strap
at once.
regularly
using
the
checked and maintained.
doors and
panels tightly shut,
Keep high-frequency
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
source
filter airflow to unit.
damage PC
by
Have the installation
before
again.
can
the FCC about interference, stop
If notified
equipment
boards.
BEFORE
parts.
ARC WELDING
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
can cause
interference.
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury
Keep away
from
moving parts.
Keep away from pinch points
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
Be
sure
according
Do not press gun
trigger
until instructed to do
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine
is installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using
Do not
line
filters,
or
shielding
the work
area.
other
1-4
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 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,
American Welding Society Standard AWS F4.1, from American
Rd, Miami, FL 33126
Code, NFPA Standard 70, from National Fire
Association, Batterymarch Park, Quincy, MA 02269.
Welding Society,
550 N.W. LeJeune
National Electrical
Protection
Safe
Handling
of
Compressed
Gases in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
1235
Jefferson
Davis
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
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.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-189 482
Page
3
1-5
EMF Information
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The
body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
2.
Arrange
3.
Do not coil
4.
cutting.
magnetic
procedures:
To
OM-189 482
Page
4
or
one
or
taping
side and away from the
them.
operator.
drape cables around your body.
Keep welding power
as practical.
source
Connect work
to
and cables
as
far away from opera-
5.
clamp
workpiece
as
close to the weld
as
possible.
About Pacemakers:
or
reduce
cables to
together by twisting
tor
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding
cables close
fields
in the
workplace,
use
the
following
Pacemakerwearers consult
then
following
the above
yourdoctorfirst. If cleared byyourdoctor,
procedures is recommended:
SECTION 1
CONSIGNES DE SECURITE
-
-
LIRE AVANT UTILISATION
som
Signification
1-1.
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
A
des
_nd_Fre 4/97
Identifie
message de sØcuritØ
un
Ce groupe de symboles signifie Mise en garde Soyez vigilant~ II y a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES.
Reportez-vousauxsymboles
mesures a prendre pour
etauxdirectives ci-dessous afin de connaitre les
~
Dangers relatifs
1-2
A
Łviter tout
nest pas re!atif A Ia sAcuritØ.
NOTA
Signifie
au
soudage a larc
Nutiliser quun materiel en bon Łtat. Reparer ou remplacer sur-le
champ les piŁces endommagŁes. EntretenirlappareilconformŁment
sont utilisØs tout au long du
manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnees afin dØviter tout
danger. Les consignes de sØcuritŁ prØsentŁes ci-aprŁs ne font
que rØsumer linformation contenue dans les normes de sŁcuritØ
ØnumŁrØes a Ia section 1-5. Veuillez lire et respecter toutes ces
Les
symboles prØsentØs ci-aprŁs
present
normes
A
Au
Porter
cours
de
qu
des personnes
ne
doi
avec
lutilisation, tenirtoute personne a lØcartet plus par
UN CHOC ELECTRIQUE
contact avec des
simple
en
Ne
contact avec le fil de
ou
toucher les
jamais
place
en
soudage
mal mis a Ia terre
piŁces Łlectriques peut
sont
piŁce a souder ou
on
travaille
tous es panneaux et
faon a obtenir un
a
hauteur.
en
capots.
bon contact mŁtal-mŁtal
table de travail, le
plus prŁs possible de Ia
Isoler Ia
de masse quand pas
obiet metallique.
pince
tout
mis a Ia
pour Łviter le contact
piŁce
peuttuer
provoquer une electrocution ou des blessures graves.
Lelectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et les
circuits internes de lappareil sont Łgalement sous
tension ace moment-l. En soudage semi-automatique ou automatique,
le fil, le dŁvidoir, le logement des galets dentraInement et les piŁces
matŁriels mal installŁs
Ia
quand
soudure.
avec
mŁtalliques
harnais de sŁcuritŁ
Maintenir solidement
ticuliŁrement les enfants.
Un
un
Fixer le cable de retourde
reparations
qualifiŁes.
et les
Iutilisation, lentretien
vent Œtre conflØs
A
ace manuel.
de sØcuritØ.
Linstallation,
danger.
sous
prŁsentent
tension. Des
un
danger.
liv
DU COU RANT CONTINU IMPORTANT dans les
a
convertisseurs
tion
aprŁs
Ia
suppression
de lalimenta
Ølectrique.
ArrŁter les convertisseurs, debrancher le courant
charger les condensateurs dalimentation
indiquŁes dans Ia partie entretien avant de
Łlectrique,
et de
selon Ies instructions
toucher les
piŁces.
piŁces Łlectriques sous tension.
protection secs ne comportant
Porter des gants et des vŁtements de
pas de trous.
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcherle contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
Sisoler
Ne pas
se
servir de
source
Łlectrique
humides, dans les endroits continŁs
Se servir dune
procŁdŁ
de
source
soudage
courant Łlectrique dans les
l o on risque de tomber.
~4b~LLEsFUMEEsET
zones
ou
Łlectrique courant Łlectrique UNIQUEMENT
si le
=9
Le soudage genere des fumŁes et des gaz. Leur
inhalation peut Łtre dangereux pour votre sante.
.....J
t~
le demande.
Eloigner
____________
Si lutilisation dune source Łlectrique Łcourant Łlectrique savŁre nŁces
saire, se servir de Ia fonction de tŁlŁcommande si rappareil en est ŁquipŁ.
Couper lalimentation ou arrŁter le moteuravantde procŁder a linstal
lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation selon Ia norme OSRA 29 CFR 1910.147 (voir normes
de sŁcuritŁ).
lnstalleretmettre a laterrecorrectement cetappareil conformŁment
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Toujours verifier laterre du
-
En effectuant les raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre appropriŁ et contre-vŁrifier les connexions.
frŁquemment le cordon dalimentation pour voir sil nest pas
endommagŁ ou dŁnudŁ remplacer le cordon immŁdiatement sil est
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
Verifier
-
-
Mettre
lappareil
hors tension
Ne pas utiliser des cables
sante ou mal ŁpissŁs.
quand
on ne
lutilise
pas.
uses, endommagŁs, de grosseur insufti
votre tŒte des fumŁes. Ne pas
respirer
les fumees.
A
etlou utiliser un echappement au ni
des fumŁes et des gaz de soudage.
insuffisante, utiliser un respirateur a alimenta
lintŁrieur, ventiler Ia
veau
zone
de larc pour lŁvacuation
Si Ia ventilation est
tion dair homologuŁ.
Lire les spŁcificationsdesŁcuritŁdes matŁriaux (MSDSs) et es ins
tructions du fabricant concernant les mŁtaux, lea consommables,
les revŒtements, les nettoyants et les degraisseurs.
espace fermŁ seulement siI est bien ventile ou
dair. Demander toujours a
un surveillant dOment formŁ de se tenir a proximitŁ. Des fumŁes et
des gaz de soudage peuvent dŁplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne presente aucun danger.
Travailler dans
Verifier et sassu
cordon dalimentation
que le fil de terre du cordon dalimentation est bien raccordŁ a Ia
borne de terre du sectionneurou que Ia fiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
rer
LESGAZ peuvent
:etre dangereux.
en
portent
un
un
respirateur a alimentation
Ne pas souderdans des endroits situŁs a proximitŁ dopŁrations de
de nettoyage ou de pulverisation. La chaleur et les
rayons de Iarc peuvent rŁagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
dŁgraissage,
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
cadmium a moms que le revŒte
galvanisŁ, plaque en p10mb ou au
ŁtŁ enlevŁ dens Ia zone de soudure, que lendroit soit
bien ventilŁ, et si necessaire, en portant un respirateur a alimenta
tion dair. Lea revŁtements et tous les metaux renfermant ces ele
ments peuvent degager des fumŁes toxiques en cas de soudage.
ment nait
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudŁe doit Łtre mise a laterre, letaire directement avec un
cable distinct
ne pas utiliser le connecteur de piŁce ou le cable de
-
retour.
Ne pas toucher lŁlectrode
terre
ou une
quand
on
est
en
contact
avec
Ia
piŁce,
Ia
electrode provenant dune autre machine.
OM-189 482
Page
5
LES
LES RAYONSDE LARC peuvent pro
voquer des br~Iures dans les yeux et
surlapeau.
de
arc du procØdØ de soudage
rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brOlures dans les yeux et sur Ia peau. Des Øtincelles sont projetees
Le
pendant
le
Veiller
protections approuvØs
Utiliser des Łcrans
pour
es
ou
des barriŁres pour
bien aØrer les espaces confines
dair homologuØ.
servir dun
respi
protØger des tiers de lØclair
ne
pas
Ne pas toucher des
re
larc.
parties
chaudes a mains
nues
Porter des vØtements de protection constituØ dans une matiŁre dura
au feu (cuir ou lame) et une protection des pieds.
ble, resistant
m
ou se
cas
DES PI¨CES CHAUDES peuvent pro~
voquer des brlures graves.
oreilles si le niveau sondre eat
IØblouissement; demander aux autres personnes de
garder
de
toujours a
trop ØlevØ.
et de
Fermer lalimentation du gaz protecteur en
non utilisation.
rateur dadduction
Porter un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans es normes de sØcuritØ).
Porter des
ou
des
soudage.
DE GAZ riS
de provoquer des blessures
mŒme Ia mort
rayonnement
gØnŁre
ACCUMULATIoNS
quent
~
LE
~1
incendie
SOUDAGEpeut provoquer
ou une explosion.
une
le
souda~e
provoquerleurØclatement. DesØtincellespeuventŒtre
Porteurs de stimulateur
projetØes de larc de soudure. La projection dØtincel
es, des piŁces chaudes et des Łquipements chauds peut provoquer des
incendies et des br~lures. Le contact accidentel de lØlectrode avec des
objets mŁtalliques peut provoquer des Øtincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne prŁsente pas de danger.
Se proteger et dautres
metal chaud.
personnes de Ia
projection dØtincelles
pŁriode de
pistolet ou Ia
refroidissemertt avant
torche.
LES CHAMPS MAGNETIQUES peuvent
affecter les stimulateurs cardiaques.~
effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Le
PrØvoir
dutiliser
cardiaque,
restez a distance.
cardiaque doivent
dabord consulter leur mØdecin avant de sapprocher
des operations de soudage a parc, de gougeage cu
de soudage par points.
Les
porteurs dun
stimulateur
et de
LE BRUIT peut affecter louie
Ne pas souder dans un endroit l o
sur des substances inflammables.
des Øtincelles
peuvent
tomber
Le bruit des processus et des
louIe.
DØplacertoutes les substances inflammables a une distance del 0,7
m de larc de soudage. En cas dimpossibilitØ les recouvrirsoigneuse
ment avec des protections homologues.
Des Łtincelles et des matŁriaux chauds du soudage peuvent facile
ment passer dana dautres zones en traversant de petites fissures et
Porter des
Øquipements peut
protections approuvØs pour
trop ØlevØ.
affecter
les oreilles si
le niveau sondre est
des ouvertures.
SurveillertoutdŁclenchementdincendie
mite.
Le
soudage effectuØ
peut dØclencher
un
Ne pas effectuer le
sur un
ettenirunextincteurproxi
plafond, plancher, paroi
Si des BOUTEILLES sont eridrnma
gØes, elles pourrontexploser.
separation
ou
incendie de lautre ctŁ.
soudage
sur
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille eat endomma
gee, elle peutexploser. Du faitque lea bouteilles degaz
font normalement partie du procØdŁ de soudage, les
des conteneurs fermØs tels que des
sous
reservoirs, tambours, ou conduites, a moms quils naient ŁtŁ prepa
rØs correctement conformØment a AWS F4.1 (voir lea normes de
sŁcuritØ).
Brancher le cable sur Ia piŁce le plus prŁs possible de a zone de sou
dage pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
Ne pas utiliser le poste de
lees.
soudage pour degeler
des conduites ge
En cas de non utilisation, enlever Ia baguette dØlectrode
electrode ou couper le fil a Ia pointe de contact.
du porte
Porter des vŒtements de
protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matŁriau lourd, des pantalons sans re
vers, des chaussures hautes et
chef.
un couvre
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
DES PARTICULES VOLANTES
~
:peuvŁntblesserlesyeux.
soudage, lØcaillement,
le passage de Ia piŁce
et le meulage generent
a Ia brosse en fil de fer,
desŁtincellesetdes particules metalliquesvolan
tes. Pendant Ia pØriode de refroidissement des soudures, elles risquent
projeter
du laitier.
Porter des lunettes de sŁcuritØ
OM-l89 482
avec
precaution.
les bouteilles de gaz comprime dune chaleur excessive,
des chocs mØcaniques, du laitier, desflammes ouvertes, des Łtin
celles et des arcs.
ProtØger
Placer lea bouteilles debout en les fixant dana un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de se renverser.
Tenir les bouteilles
cuits Ølectriques.
Ne
jamais placer
eloignees des circuits de soudage ou autres cir
une
torche de
Une electrode de
une bouteille.
soudage
Ne
une
jamais
souder
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille
pressurisØe
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, regulateurs,
tuyaux et raccords convenables pour cette application spØcifique;
lea maintenir ainsi que les ØlØments associŁs en bon Øtat.
Ne pas tenir Ia tŒte en face de Ia sortie en ouvrant Ia soupape de Ia
bouteille.
Le
S
de
manipuler
Page
6
avec
Øcrans latØraux
ou un
Øcran facial.
Mamntenir le chapeau de protection sur Ia soupape, saul
dutilisation ou de branchement de Ia bouteille.
en cas
Lire et suivre les instructions concernant les bouteilles de gaz corn
prime, lea equipements associØs et les publications P-l CGA Ønu
mŁrŁes dans lea normes de sŁcuritŁ.
1-3
Dangers supplementaires
en
relation
avec
linstallation, le fonctuonnement
et Ia maintenance.
DiNCENDIE
DEXPLOSION.
OU
Risque
Ne pas
placer lappareil
proximitØ
DES
ORGANES MOBILES
provoquer des blessures.
au-dessus
sur,
ou
a
peuvent
Rester a lØcart des organes mobiles
de surfaces infllammables.
le
comme
ventilateur.
Maintenir fermØs et fixement
lappareil a proximitØ de produits inflammables
Ne pas surcharger installation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
Ne pas installer
panneaux,
recouvrements
place les portes,
dispositifs de
en
et
-
LA CHUTE DE LAPPAREIL
protection.
LE RAYONNEMENT HAUTE FRE
QUENCE (H.F.) risque de provoquer
des interferences.
peut
bIesser~
Utiliser lanneau
lever
levage uniquement pour sou
lappareil, NON PAS les chariot, es bouteil
les de gaz
ou
tout autre accessoire.
Utiliser un engin dune
soulever lappareil.
capacitØ appropriee
pour
oppose
Demander seulement a des personnes qualifiØes familiarisØes
des Øquipements electroriiques de faire fonctionner installa
avec
tion.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que lesfourches sont suffisamment longues pourdØpasserdu ctØ
de
Le rayonnementhautefrequence peutprovoquer
des interferences avec les equipements de ra
dio-navigationetdecommunication, lesservices
de sØcuritØ et les ordinateurs.
de
lappareil.
LEMPLOI EXCESSIF peut
SURCHAUFFER LEQULPEMENT.
Lutilisateur est tenu de faire corriger rapidement par
les interferences resultant de linstallation.
Ølectricien
Si le FCC
reil.
signale des interferences, arrŒter immØdiatement lappa
Effectuer
rØguliŁrement
le contrle
et lentretien
de linstallation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources de haute frØquence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un
PrØvoir
un
qualifie
pØriode de refroidissement, respec
cycle opØratoire nominal.
RØduire le courantou le cycle opØratoire avantde
une
blindage
pour rØduire les inter
fØrences Øventuelles.
ter le
recommancer
le
SOUDAGE A LARC
risque de
:provoquer des interferences.
soudage.
Ne pas obstruer les passages dair du
LES CHARGES
LE
poste.
ELECTROSTATIQUES
peuveAt endommager
primes.
Utiliser des
pochettes et des boites antistatiques
ou
expØdier des cartes de
electromagnetique
risque
Veiller ace que tout
lequipement de Ia zone de soudage soit com
patible ØlectromagnØtiquement.
Pour rØduire Ia possibilitØ dinterfØrence, maintenir les cables de
soudage aussi courts que possible, es grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller a souder a une distance de 100 metres de tout
electronique sensible.
DES
RGANES
MOBILES
pØuvent
provoquerdesbiessures.
Ne pas
sapprocher
Veiller ~
ce que Ce poste de soudage soit
conformØment a Ce mode demploi.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
peuvent pro
voquer des blessures.
Ne pas
diriger
le
Ia
gachette
pistolet
vers
avant den avoir
soi, dautres
toute piece mecanique
soudage.
sonnes ou
le fil de
sur
en
et mis a Ia terre
lutilisation de filtres de
ligne ou
Ia pose de protecteurs dans Ia zone
de travail.
LESCHAMPS MAGNETIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur
Ne pas appuyer
recu linstruction.
pose
equipement
En cas dinterfØrences aprŁs avoir pris es mesures precØdentes, il
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cables blindØs,
des organes mobiles.
LES FILS DE SOUDAGE
de
provoquer des interferences pour lequipement
electronique sensible tel que les ordinateurs et
lØquipement commandØ par ordinateur tel que
les robots.
les circuits im
Etablir Ia connexion avec Ia barrette de terre
avant de manipuler des cartes ou des pieces.
pour stocker, deplacer
circuits imprimes.
Lenergie
per
engageant
cardiaque,
restez ~ dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage ou de soudage par points.
OM-189 482
Page
7
1-4
Prunc~paIes
normes
de securite
Safety in Welding and Cutting, normeANSl Z49.1, delAmericanWel
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards,
Superintendent
Printing Office, Washington, D.C.
Welding and Cut
of Containers That Have Held Hazardous
Substances, norme
IAmerican Welding Society, 550 N.W. Lejeune Rd, Mia
Code, NFPA Standard 70, de Ia National Fire Pro
Batterymarch Park, Quincy, MA 02269.
tection Association,
1-5.
Information
sur
les
sur le soudage electrique et sur les effets,
champs magnØtiques basse frequence
Broadway,
New
York, NY 10018.
Cutting and Welding Processes,
Protection Association,
norme
pour
Afin de rØduire les
lorganisme,
de travail,
champs electromagnØtiques dans lenvironnement
respecter les consignes suivantes
Background Paper, OTA-BP-E-53 (Washington DC: U.S. Govern
Printing Office, mai 1989), publiØ par le Office of Technology
2
Mettre tous
3
Ne pas courber pas et
ment
amØricain:
...
il existe maintenant dabon
dantes donnØes scientifiques compilØes a Ia suite dexpØriences sur
Ia cellule ou dØtudes sur des animaux et des humains, qui montrent
clairement que les champs ØlectromagnØtiques basse frØquence peu
vent avoir des effets sur lorganisme
et mØme y produire des
tableau densemble coherent. Pire encore, elle ne
permet pas de tirer des conclusions finales concernant les ris
ques Øventuels, ni doffrir des conseils sur les mesures a prendre pour
rØduire sinon Øliminer les risques Øventuels. (Traduction libre)
un
nous
OM-189 482
Page
8
es
cables du cOtØ
ne
es
torsadant
oppose
de
les
ou en
lopØrateur.
pas entourer pas es cables autour de
vous.
4
5
de travaux de trØs
grande qualitØ, les
complexes. Cette dØmarche scientifique ne nous persagit
NFPA 51 B, de Ia National Fire
MA 02269.
Batterymarch Park, Quincy,
Garder les cables ensembles en
attachant avec du ruban adhØsif.
rØsultats sont
met pas dØtablir
Pamphlet
1R3.
1
transformations. MŒme sil
CGA
Safe Practices For Occupation And Educational Eye And Face Protec
tion, norme ANSI Z87.1, de lAmerican National Standards Institute,
-
Congres
Cylinders,
de sØcuritØ en soudage, coupage et procØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
Lextrait suivant est tire des conclusions generales du document intitu
lØ Biological Effects of Power Frequency Electric & Magnetic Fields
Assessment du
in
champs ØlectromagnØtiques
DonnØes
des
Compressed Gases
ROgles
1430
National Electrical
of
me
Recommended Safe Practice for the Preparation for
AWS F4.1, de
mi FL 33126
Handling
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
OSHA 29 CFR 1910, du
of Documents, U.S. Government
20402.
ting
Safe
Garder le poste de
de vous.
Relier Ia
pince
de
soudage
masse
le
et les cables le
plus
plus prŁs possible
loin
de Ia
possible
zone
de
soudure.
Consignes relatives
aux
stimulateurs
mentionnØes
cardiaques
prØcØdemmentfont partie de celles desti
personnes ayant recours a un stimulateur cardiaque.
Veuillez consulter votre mØdecin pour obtenir plus de details.
Les
consignes
nØes
aux
SECTION 2- INSTALLATION
Specifications
2-1.
Amperes Input
Amperage
Range
Rated
Welding
Output
Open-Circuit
Voltage DC
at
Rated Load
Maximum
Output, 60 Hz,
Single- Phase
200V
Overall
Weight
230V
Dimensions
KW
KVA
Length: 36 in
(915 mm)
150 A @ 23 Volts
DC, 60% Duty Cycle
30
-
33
165
30
(1 .6)*
26
6
(1 .4)*
(0.27)*
5
(0.1 3)*
165 lb
Width: 18 in
(75 kg)
(457 mm)
Height: 27 in
(686 mm)
Wire
Solid Steel I
Stainless Steel
.023
(0.6
~WhiIe
2-2.
-
-
Calculated Wire
I
I
I
.035 in
0.9
Flux Cored
I
Range
Aluminum
Speed
Speed
Welding
Max Wire Feed
While
At No Load
I
.030
(0.8
mm)
And Diameter
Type
-
-
.045 in
1.2
mm)
I
.030
(0.8
.035 in
-
-
0.9
138
-
795 1PM
mm)
(3.5
-
20.3
650 1PM
rn/mm)
(16.5 m/min)
idling
Volt-Ampere Curves
Volt-ampere
curves
show
mini
voltage and
amperage output capabilities of
unit. Curves of other settings fall
mum
and maximum
between
curves
shown.
35
Cl)
~
0 30
>
uJ
0
< 25
li
0
>
c
20
<
0
-J
15
10
0
50
100
150
200
LOAD CURRENT, AMPS
vacurvel 4/95
-
SB-180 824
OM-189 482
Page
9
2-3.
Duty Cycle
And
Overheating
Duty Cycle
is
percentage of
10
minutes that unit can weld at rated
load without overheating.
RATED
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
OUTPUT~
200
voltage,
welding.
-~
A
U,
w
or
duty
cycle
before
Exceeding duty cycle
damage unit and
can
void
warranty.
w
~150
iiiiiiii~iiiii ii
0
-J
w
100
30
50
40
60
% DUTY
60%
6 Minutes
Duty Cycle
70
80
90100
CYCLE
At 150
Welding
Amperes
4 Minutes
Resting
Overheating
,
~AorV
I-,
-*
Reduce
Duty Cycle
Minutes
dutyl 4/95
OM-189 482
Page
10
-
SB-181 009
2-4.
Installing
Work
Clamp
1
Work Cable
2
Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
4
3
Negative (-) Output
cable
Connect
cover
Terminal
terminal
to
and
connection with boot.
5
4
Hardware
5
Work
Clamp
Route cable
and
1
2
through clamp
secure as
handle
shown.
Close door.
Tools Needed:
~ 1/2,3/4in
ST-801 566
2-5.
Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other sta
tionary support so cylinder cannot
fall and break off valve.
1
Cap
2
Cylinder
Valve
2
Remove cap, stand to
valve, and open valve
side of
slightly.
Gas flow blows dust and dirt from
valve. Close valve.
r-~
I
3
3
Cylinder
4
Regulator/Flowmeter
Install
5
so
face is vertical.
Regulator/Flowmeter Gas
Hose Connection
Argon Gas
6
Welding
Power Source Gas
Hose Connection
Connect customer
OR
hose between
ter
hose
gas
fitting
supplied gas
regulator/flowme
and
connection,
of
welding
power
flow rate is 20 cfh
(cubic
on
rear
source.
7
Flow
Typical
Adjust
feet per hour). Check wire
ufacturers
recommended
man
flow
rate.
CO2
8
CO2 Adapter (Customer
Supplied)
9
0-Ring (Customer Supplied)
Gas
Install
adapter with 0-ring
regulator/flowmeter
CO2 cylinder.
tween
be
and
Tools Needed:
~ 1-1/8,5/8
in
Ref. ST-148 265-B / ST-802 028
OM-189 482
Page
11
2-6.
Installing Welding Gun
1
Drive
2
Gun
3
Gun End
Assembly
Securing
Knob
Loosen
securing knob. Insert gun
through opening until it bot
toms
against drive assembly.
Tighten nut.
end
1
4
.2
3
Gun
Trigger Plug
Insert
plug
tighten
threaded collar.
into
receptacle,
and
Close door.
Ref. ST-801 936
2-7.
Setting
Gun
Polarity
1
Polarity Changeover
(Located
Label
Near Drive
Assembly)
Always
tures
Wire Drive Assembly Lead
To Positive (+) Output Terminal
Work Clamp Lead To
Negative (-) Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections
-
For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
s1444490
Tools Needed:
~
r
OM-189 482
Page
3/4,11/161n
12
read and follow manufac
recommended
polarity.
2-8.
Installing
Wire
Spool
And
Adjusting
Use
8 in
Hub Tension
compression spring
(200 mm) spools.
with
Tools Needed:
When
~
15/16 in
to turn
slight force is needed
spool, tension is set.
a
51-072573-B
2-9.
Changing Input Voltage
A
Turn Off
nect
unit,
and discon
input power.
Unit was shipped from
for 230 volts.
factory
1
Transformer Ti
2
Rear Of Power Switch Si
3
Lead Marked 230 Volt And
set
Fan Motor Lead
Disconnect 230 volt lead and fan
motor lead from rear of Si. Leave
fan motor lead connected to 230
volt lead.
4
Lead Marked 200 Volt
Remove cable tie, and slide short
of sleeving off 200 volt lead,
and slide sleeving over end of 230
volt and fan motor leads. Fold
sleeving over and secure in place.
piece
Connect 200 volt lead to SI where
230 volt lead
was
removed.
Reinstall wrapper.
4
Tools Needed:
~ 3/8,7/l6in
ST-801 580-A
OM-i89 482
Page
13
2-10. Electrical Service Guide
Input Voltage
Input Amperes
At Rated
200
230
30
26
45
40
10
10
Output
Max Recommended Standard Fuse Or Circuit Breaker
Rating
In
Amperes
Mm
Input Conductor Size
Max Recommended
Mm
Grounding
In AWG/KcmiI
Input Conductor Length
Selecting
OM-189 482
Page
(Meters)
97
Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code
2-11.
In Feet
14
10
(NEC).
A Location And
(29)
128
(39)
10
S-oo92-J
Connecting Input
Power
2-12.
Threading Welding
Wire
Tools Needed:
-4
~6in~
(150 mm)
Open
pressure
assembly.
Pull and hold wire; cut off end.
Push wire thru
guides into gun;
continue to hold wire.
ON
POWER
-*
00FF
I
Close and
assembly,
Remove gun nozzle and contact
tighten pressure
tip.
/
Turn On.
and let go of wire.
Cut off wire. Close
and latch door.
1111
-4
Press gun
out of gun.
trigger
until wire
comes
Reinstall contact
tip
and nozzle.
I
II
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Tighten
Cut off wire. Close and latch door.
Ref. ST-801 938) Ref. ST-149 326-A
OM-189 482
Page
15
2-13. Weld Parameter
Material Thickness
Wire
Wire
Type,
Shielding Gas,
Diameter
And Flow Rate
(inch)
Operator
Ofl ro ~
Vottage Tap
3/Bin
1/4 in
(9.5
mm)
(6.4
mm)
3/l6in
(4.6
mm)
1/Sin
(3.2
6
5
100
22 ga
12 ga
14 ga
16 ga
18 ga
20 ga
4
3
3
2
1
1
90
70
65
60
40
25
20
4
4
3
2
2
2
1
70
60
50
45
40
30
25
6
4
4
3
3
2
2
1
80
65
40
35
30
25
30
10
3
4
3
3
2
2
1
1
1
80
90
70
60
70
40
45
25
12
6
4
4
3
3
2
2
1
1
90
58
70
55
50
48
45
30
5
6
4
4
3
3
2
2
1
1
80
48
60
50
35
27
30
11
3
5
4
4
3
2
2
1
1
80
65
65
50
30
30
10
5
5
4
3
2
2
2
1
1
50
50
40
30
25
20
10
0
5
4
4
4
3
3
3
2
2
2
95
85
80
60
50
50
50
30
20
20
5
5
4
3
3
2
2
2
1
70
70
70
50
45
50
45
40
0
6
5
5
4
3
2
2
2
65
40
40
30
30
25
20
10
-
-
mm)
-
-
-
-
.023
Wire
Speed
Voltage Tap
E7OS-6
-
-
-
-
-
-
-
-
-
-
.030
Co2
20 cfh+
Wire
Speed
Voltage Tap
-
-
-
-
-
-
-
-
.035
Wire
Speed
Voltage Tap
-
WireSpeed
--
-
-
-
-
-
.023
E70S6
75%
Voltage Tap
Argon
-
-
-
-
-
-
-
-
.030
~
Wire
Speed
Voltage Tap
-
.035
Wire
Speed
VoltageTap
--
--
.030
Wire
E71T-GS
Flux Core
Speed
Voltage Tap
-
-
-
-
-
-
-
-
.035
Wire
Speed
VoltageTap
-
-
-
-
.023
Wire
ER 308
Speed
Voltage Tap
Stainless Steel
-
-
-
-
030
TC~
Wire
Speed
VoltageTap
--
--
.035
Wire
*Do not
change Voltage switch position
during welding.
fine tuned
OM-189 482
Page
16
Speed
while
welding
Wire
Speed
value in Table is
a
starting
value
only,
and Wire
Speed
-
control
-
-
setting
-
can
be
S-181 020-A
2-14. Aluminum Weld Parameter For Use With
Optional Spoolmate
185
Material Thickness
Wire
Wire
Type,
Shielding Gas,
Diameter
And Flow Rate
(inch)
Operator
Controls
Voltage Tap
3/16 in
1/8 in (3.2 mm)
14 ga
4
3
2
88
73
55
45
6
6
5
4
2
95
85
68
59
34
5
4
3
2
100
90
80
70
6
6
5
4
2
100
92
85
70
60
3/8 in (9.5 mm)
1/4 in (6.4 mm)
5
5
88
(4.8
m
m)
.030
Wire
4043 AL
100%
Argon
Speed
Voltage Tap
.035
Wire
Speed
Voltage Tap
-
.030
Wire
5356 AL
100%
Argon
Speed
Voltage Tap
-
.035
Wire
Speed
OM-189 482
Page
17
SECTION 3- OPERATION
3-1.
Front Panel Controls
Controls For Standard Units
Speed
Wire
1
Control
Use control to select a wire feed
around control is not
speed. Scale
actual wire feed
reference
speed,
but is ~or
only.
Voltage Switch
2
The
higher
the selected number,
the thicker the material that can be
welded (see Section
switch under load.
3
Pilot
4
Power Switch
2-13).
Do not
Light
1
~m
WIRE SPEED
2
3
4
Ret. ST-187 317
OM-189 482
Page
18
SECTION 4- MAINTENANCE & TROUBLESHOOTING
4-1.
4-2.
Routine Maintenance
Circuit Breakers CB1 And CB2
A
Turn Off unit.
1
Circuit Breaker CB1
CB1 protects the transformer from
overload. If CB1
opens, wire
feeding stops.
2
Circuit Breaker CB2
CB2 protects the trigger circuit
from overload. If CB1 opens, weld
output stops.
Press
button
to
reset
circuit
breaker. Close door.
Ref. ST.801 567
4-3.
Changing
Drive Roll, Inlet Wire Guide
1
Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2
Inlet Wire Guide
Remove
guide by pressing on
or cutting off one end
housing and pulling it out of
Push new guide into hole
rear until it snaps in place.
barbed area,
near
hole.
from
Tools Needed:
Ref. 5T-801 569
OM-189 482 Page 19
4-4.
Cleaning
Or
Replacing Gun
Liner
Tools Needed:
A
Disconnect gun first.
~
-~
3/8in
Head
3/8 in
Remove nozzle,
contact
tip,
and
liner collet.
\in
Remove liner.
11
To Reassemble Gun:
Gun/Feeder
out
ector
gun
casing.
Install contact
Insert
new
tip.
liner.
Install collet onto liner and tighten
into gun/feeder connector using
wrench.
Cut liner off near collet so that liner
end is as close to drive rolls as pos
sible without touching.
Install nozzle.
Ref. ST-155 509
OM-189 482
Page
20
Replacing
4-5.
Gun Contact
Tip
A
Turn Off unit.
1
Nozzle
2
Contact
Cut off
Tip
welding
wire at contact
tip.
Remove nozzle.
Remove contact
Tools Needed:
contact
tip.
tip
and install
new
Reinstall nozzle.
ST-149 326-B
4-6.
Troubleshooting
Welding
No weld
output;
Trouble
wire does not feed.
Remedy
Secure power cord
Check and
receptacle (see Section 2-11).
in
plug
switch if necessary.
replace power
Check circuit breakers CB1 and/or
Replace building
line fuse
Secure gun
in
plug
output; wire feeds.
Connect work
Replace
Low weld
Low, high,
erratic wire
contact
speed.
Readjust
Change
front
or
to
tip (see
Section
Replace
feeding stops during
2-6).
to metal contact.
check for low line
or
voltage (see Section 2-11).
panel settings (see Section 3-1).
guide,
contact
(see Section 4-3).
(see Section 2-12).
liner if necessary
tip, and/or
Wire Drive/Gun Trouble
Electrode wire
4-2).
4-5).
input voltage
drive roll pressure
inlet
Section
(see Section 2-Il).
Section
(see
(see
Allowfan to run; the thermostat will close when the unit has cooled
get good metal
to correct size drive roll
Readiust
leads
repair
(overheating).
Connect unit to proper
output.
or
clamp
reset if necessary
reset circuit breaker if open
receptacle
Thermostat TP1 open
(see Section 2-3).
No weld
or
C82, and
(see Sections 2-12,
and
4-4).
Remedy
Straighten
gun cable and/or replace
damaged parts (see Section 4-4).
welding.
Adjust
drive roll pressure
Readjust
hub tension
(see
(see
contact
tip
Clean
replace
wire inlet
or
Replace
drive roll if
Secure gun
plug
in
Section
if blocked
Replace
Section
2-8).
(see Section 4-5).
guide
worn or
2-12).
or
liner if
or
repair
leads
Check and clear any restrictions at drive
Have nearest
Factory
or
Section
slipping (see
receptacle
dirty
plugged (see
(see
Agent
4-4).
4-3).
assembly
Authorized Service
Section
Section
2-6).
and liner
(see Section 4-4).
check drive motor.
OM-169 482 Page 21
SECTION 5- ELECTRICAL DIAGRAM
Lfl
SB-186 065
Figure
OM-189 482
Page
22
5-1. Circuit
Diagram
SECTION 6- MIG WELDING
(GMAW) GUIDELINES
~1 ~
6-1.
Typical
MIG Process Connections
A
Weld
current
can
damage
electronic parts In vehicles.
Disconnect
both
battery
cables before
welding on a
clamp
vehicle. Place work
as
close
to
the
weld
as
possible.
Regulator!
Flowmeter
Wire Feeder!
Power Source
Gun
Shielding
Gas
Workpiece
Work
Clamp
light mig 51967 I ST-801
909
OM-189 482 Page 23
6-2.
Typical MIG Process Control Settings
N OTE
settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
These
~
Material thickness determines weld
1/8
parameters.
or
125 in
Convert Material
Thickness to
Amperage (A)
(.001
in
=
.125 in
1
ampere)
=
125A
Amperage Range
30
40
90 A
-
Select Wire Size
145 A
-
50- 180A
Select Wire
Speed
(Amperage)
Wire
Speed
(Approx.)
Wire
Recommendation
Size
.023 in
3.5 in per ampere
3.5
.030 in
2 in per ampere
2
.035 in
1.6 in per ampere
1.6
x
125 A
125 A
x
x
=
=
125 A
437
250
=
ipm
ipm
200
l25Abased
on
1/8 in
material thickness
ipm
ipm
=
inch per minute
~~1~
Low
voltage:
High voltage:
Set
wire stubs into work
arc
voltage midway
is unstable
between
(spatter)
Select
Voltage
high/low voltage.
Wire speed (amperage) controls
penetration (wire speed burn-off
weld
=
Ref. ST-801 865
OM-189 482
Page
24
6-3.
Holding
N OTE
And
Positioning Welding Gun
~ ~i
Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
1
Hold Gun and Control Gun
Trigger
2
2
Workpiece
3
Work
4
Electrode Extension
Clamp
(Stickout) 1/4
13mm)
5
to
1/2 in (6 To
Cradle Gun and Rest Hand
on
Workpiece
4
(~
End View Of Work
Angle
Side View Of Gun
~)
Angle
GROOVE WELDS
End View Of Work
Angle
Side View Of Gun
Angle
FILLET WELDS
S.0421-A
OM-189 482
Page
25
6-4.
Conditions That Affect Weld Bead
N OTE
~
Shape
shape depends on gun angle, direction of traveI~ electrode extension
(stickout),
speed, thickness of base meta~ wire feed speed (weld current),
and voltage.
Weld bead
travel
I,~~41O0
Push
p
Perpendicular
Drag
GUN ANGLES AND WELD BEAD PROFILES
y
Short
Long
Normal
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
FILLET WELD ELECTRODE EXTENSIONS
Slow
Normal
Long
(STICKOUT)
Fast
GUN TRAVEL SPEED
S-0634
OM-1 89482
Page
26
6-5.
Gun Movement
N OTE
~
During Welding
Normally,
I
a
single stringer bead is satisfactory for most narrow groove weld joints
or bridging across gaps, a weave bead or
howeve, for wide groove weld joints
multiple stringer beads works better.
1
Stringer
Bead
Movement
1
2
2
~
Weave Bead
Movement
3
Steady
Along Seam
-
-
Side To Side
Along Seam
Weave Patterns
Use
weave
wide area
electrode.
patterns
in
one
to
cover
pass
of
a
the
4~(((
s-oos4-A
6-6.
Poor Weld Bead Characteristics
1
Large Spatter Deposits
2
3
Rough, Uneven Bead
Slight Crater During Welding
4
Bad
5
Poor Penetration
Overlap
5
S-0053-A
6-7.
Good Weld Bead Characteristics
1
Fine
2
Uniform Bead
3
Spatter
Moderate Crater
During
Welding
Weld
a new
bead
or
layer
for each
1/8 in (3.2 mm) thickness in metals
being
welded.
Overlap
4
No
5
Good Penetration into Base
Metal
S-0052-B
OM-189 482
Page
27
6-8.
Troubleshooting
I
-
-
.
.
~
~
-
-
Excessive
Spatter
I
,~
ExcessiveSpatter-scatteringofmoltenmetalparticlesthat
cool to solid form
-
near
weld bead.
S-0636
Possible Causes
Wire feed
Voltage
speed
too
too
Corrective Actions
Select lower wire feed
high.
Select lower
high.
Electrode extension
(stickout)
too
long.
voltage range.
Use shorter electrode extension
Remove all grease,
Workpiece dirty.
speed.
(stickout).
oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient
shielding gas
Dirty welding
at
welding
arc.
wire.
Increase flow of
Use clean,
Eliminate
6-9.
Troubleshooting
-
shielding gas
dry welding
pickup of
oil
at
regulator/flowmeter and/or prevent
drafts
near
welding
arc.
wire.
or
lubricant
wire from feeder
welding
on
or
liner.
Porosity
Porosity
-
small cavities
holes
or
resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient
shielding gas
at
welding
Corrective Actions
arc.
Increase flow of
shielding gas
at
regulator/flowmeter and/or prevent
drafts
near
welding
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in
Hold gun
Use
Wrong gas.
Dirty welding
wire.
near
(6-13 mm)
from
bead at end of weld until molten metal solidifies.
welding grade shielding gas; change
Use clean,
Eliminate
dry welding
pick
up of oil
to different
gas.
wire.
or
lubricant
on
welding
Remove all grease, oil, moisture, rust,
Workpiece dirty.
workpiece.
wire from feeder
paint, coatings,
or
liner.
and dirt from work surface before
welding.
Use
Welding
wire extends too far out of nozzle.
OM-189 482
Page
28
Be
a more
sure
highly deoxidizing welding
welding
wire extends not
more
wire
(contact supplier).
than 1/2 in
(13 mm) beyond
nozzle.
arc.
6-10.
Troubleshooting
-
Excessive Penetration
Excessive Penetration
(
and
:~
Excessive Penetration
hanging
-
weld metal
melting through base metal
underneath weld.
Good Penetration
S-0639
Possible Causes
Excessive heat
Corrective Actions
Select lower
input.
voltage range
Increase travel
6-11.
Troubleshooting
-
and reduce wire feed
speed.
speed.
Lack Of Penetration
Lack Of Penetration
shallow
fusion between weld metal and
-
)
II
Lack of Penetration
~J~7
base metal.
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Improper
weld
Material too thick. Joint preparation and design must provide access
maintaining proper welding wire extension and arc characteristics.
Maintain normal gun
technique.
Keep
Be
Insufficient heat
arc on
sure
Select
input.
leading edge
welding
Troubleshooting
-
Incomplete
of 0 to 15
of weld
wire extends not
wire feed
higher
Reduce travel
6-12.
angle
degrees
to achieve maximum
to bottom of groove while
penetration.
puddle.
than 1/2 in
more
speed and/or
select
(13 mm) beyond
nozzle.
higher voltage range.
speed.
Fusion
Incomplete
Fusion
base metal
or a
-
failure of weld metal to fuse
completely
with
weld bead.
preceeding
S-0637
Possible Causes
Workpiece dirty.
Corrective Actions
Remove all grease, oil, moisture, rust,
paint, undercoating,
and dirt from work surface before
welding.
Insufficient heat
input.
Improper welding technique.
Select
Place
higher voltage range and/or adjust
stringer
Adjust
work
bead in proper
angle
or
widen groove to
Momentarily
hold
Keep
leading edge
arc on
Use correct gun
location(s)
arc on
angle
wire feed
at
joint during welding.
access
bottom
groove side walls when
of weld
of 0 to 15
speed.
during welding.
using weaving technique.
puddle.
degrees.
OM-189 482
Page
29
6-13.
Troubleshooting
-
Burn-Through
ipletely through
base metal
Iris
S-0640
Corrective Actions
Possible Causes
Excessive heat
Select lower
input.
voltage range
Increase and/or maintain
6-14.
Troubleshooting
-
and reduce wire feed
steady
travel
speed.
speed.
Waviness Of Bead
Waviness Of Bead
joint formed by
-
weld metal that is not
parallel and does not cover
base metal.
S-0641
Corrective Actions
Possible Causes
Welding
wire extends too far out of nozzle.
Unsteady
6-15.
Be
sure
Support
hand.
Troubleshooting
-
welding
hand
on
wire extends not
solid surface
more
or use
than 1/2 in
(13 mm) beyond
nozzle.
two hands.
Distortion
Distortion
-
contraction of weld metal
base metal to
during welding
that forces
move.
Base metal moves
in the direction of
the weld bead.
S-0642
Corrective Actions
Possible Causes
Excessive heat
input.
Use restraint
(clamp)
Make tack welds
Select lower
Weld in small
Page
30
along joint
before
voltage range and/or
Increase travel
OM-189 482
to hold base metal in
position.
starting welding operation.
reduce wire feed
speed.
speed.
segments
and allow
cooling
between welds.
6-16. Common MIG
This is
Shielding Gases
general chart for common gases and where they are used. Many different combinations (mixtures) of
gases have been developed over the years. The most commonly used shielding gases are listed in the
table.
a
shielding
following
Application
Gas
Short
Spray
Arc Steel
Short
Circuiting Steel
Circuiting
Stainless Steel
Argon
Argon
25%
+
CO2
Flat & Horizontal1 Fillet
All Positions
Horizontal1 Fillet
All Positions
Flat &
Tn-Mix3
1
Globular Transfer
2
Single
3
90% HE
+
Circuiting
Aluminum
All Positions
CO2
Pass
Short
All
Positions2
All Positions
Welding Only
7-1/2% AR
+
2-1/2% co2
OM-189 482
Page
31
SECTION 7- PARTS LIST
C
Hardware is
common
and
not available unless listed.
It)
I
--~
C
C~
C
N
UC)
C
c\j
co
C~
r
C~
C
0)
C
C
/
Lf)
~-~
C~)
ST-801 572
Figure
OM-189 482
Page
32
7-1. Main
Assembly
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
1
089 899
..
2
134 464
..
+151 565
..
3
4
Fig
7-2
181 012
180 920
D1,2
D3,4
...
037306
...
037 305
152 862
026947
C1-4
..
..
7-1. Main
Quantity
Assembly
LATCH, slide flush
LABEL, warning general precautionary
1
WRAPPER
1
CENTER BAFFLE, w/components
RECTIFIER ASSEMBLY, (consisting
....
....
....
....
....
1
1
of)
1
BRACKET RECTIFIER
1
DIODE, rect 15OA300VR
DIODE, rect 150A 300VS
GROMMET, SCR .250 panel hole
2
STAND-OFF
2
2
8
4
125785..
CAPACITOR, cer disc .Oluf 1000VDC
THERMOSTAT, NC open 211F
MOTOR, fan 230V 60/50 Hz 3000RPM
BLADE, fan 6.000 4wg 30 deg .175 bore
PANEL, rear
BEZEL, front rear
BRACKET, bottle retainer
CHAIN, weldless 2/0 x 27
NU1~ 750-14 knurled 1.68dia
CORD SET, 250V 6-50P l2ga 3/c
BUSHING, strain relief
VALVE, 24VAC 2 way
.16
180916..
BASE
1
.17
147893..
.18
186758..
.19
602250..
.20
121614..
AXLE, running gear
WHEEL, lOin dia x 2.25
WASHER, fIat .812 ID x 1.469 OD
RING, rtng ext .750 shaft
180989..
STABILIZER
...
048 420
...
604 515
....
TP1
....
....
1
123 468
....
1
7
005 656
....
1
8
180918
FM
6
..
9
190773..
11
602387
180923..
12
..
605227..
13.... PLG1
...
181 072
..
111443..
.15....
GS1
...
Z
.21
TP2
...
...22
Ti
...23
....
.24
S2....
...25
...26....
RC2
Si
...
048282..
..
180917..
...29
148956..
1
1
1
2
4
2
1
RECEPTACLE W/SOCKETS
SWITCH, tgl DPST 40A 600VAC
PANEL, front
1
2
1
1
1
1
1
scr
1
1
035897..
POTENTIOMETER
1
NAMEPLATE, (order by model and serial number)
1
HANDLE
CLAMP, work 300A
CABLE, weld copper
1
147571
..
600318..
Fig7-3..
165 745
173 374
183581
ordering
1
097924..
130750..
+When
1
HANDLE, switch
KNOB, pointer
...32
.33
1
THERMOSTAT~ NC
008999.. CASTER, swvl 4.00 in plastic
180925.. TRANSFORMER, power main
180924.. PANEL, side lower
153197.. SWITCH, selector 6 position
124511
Ri....
1
163266..
...28
.31
1
2
..
..
..
1
1
(order by if)
loft
MWG-160
HOUSING & PINS
REGULATOR/FLOWMETER, dual
1
2
scale
1
HOSE,gas5ft
1
component originally displaying
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
a
To maintain the
OM-189 482
Page
33
U? Hardware is
common
and
not available unless listed.
2
4
10
5
6
7
9
8
11
~12
Fig.7-4
20
26
21
ST-801 631-C
Figure
OM-189 482
Page
34
7-2. Center Baffle
w/Components
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
058 427
..
085 980
..
605 941
..
4
186 437
5
057 971
..
..
6
057 745
..
...
7
186435
..
..
8
186 436
..
180 915
..
181 013
..
11
178 796
.
.
.
...
12
180 921
.
.
.
...
13
180 922
.
.
.
14
158 832
.
.
.
15
083 147
.
.
.
16
180 927
..
17
057357
..
....
091 685
..
....
189 486
..
...
171 986
..
..
..
...
...
...
..
...
..
..
..
...
..
...
..
...
9
C6
10
18
R2
20
W
21
....
PCi
....
22
23
24
134 201
....
....
CB1
CB2
183 492
..
...
180 912
..
25
097 421
..
26
097 416
..
27
....
CR1
..
...
..
...
..
...
28
072 817
Fig
7-4
PLG3.... 115 093
RC3
131 059
...
..
..
..
..
..
..
7-2.
Battle, Center w/Components (Fig
Quantity
7-1 Item
4)
RING, retaining spool
NUT, 625-11 .94 hex
WASHER, flat
SPRING, cprsn .84500 x .110W
WASHER, flat .632 ID x 1.500 OD x .12
SPRING, cprsn 2.430 OD x .90 wire x 2.500
HUB, spool
WASHER, brake stl
BAFFLE, center
CAPACITOR ASSEMBLY, (consisting of)
CAPACITOR, elctlt 20000uf
BUSS BAR, positive
BUSS BAR, negative
SCREW, .010-32 x .50 hex hd-slt S
GROMMET, scr No. 8/10 panel hole
1
1
1
1
1
1
1
2
1
1
6
.
1
.
1
.
.
12
.
8
REEL SUPPORT
1
BUSHING, snap-in nyl .937 ID x 1.l2Smtg hole
RESISTOR, WWfxd 50W
CONTACTOR, def prp 40A 3P
CIRCUIT CARD ASSEMBLY, control
STAND-OFF SUPPORT, PC card
CIRCUIT BREAKER, man reset 1OA 250V
CIRCUIT BREAKER, man reset 5A 250V
TERMINAL, pwr output red
TERMINAL, pwr output black
RELAY, end 24VAC DPDT 20
DRIVE ASSEMBLY, wire
1
1
1
1
4
1
1
1
1
1
1
CONNECTOR & SOCKETS
CONNECTOR & PINS
1
1
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 482
Page
35
Item
No.
Part
No.
Description
Figure
1
110793
2
110795
7-3.
Quantity
Complete Assembly (MWG-160 Gun)(Fig
HANDLEASSEMBLY
3
4
110779
5
110781
6
128878
7
+118570
8
154826
8
154825
8
154824
9
+154822
9
154821
1
2
JACKET, head tube
1
STOP, nozzle
ADAPTER, head tube nozzle
SPRING, nozzle (3 pack)
TIP, contact .023 (6 pack)
TIP, contact .030 (6 pack)
TIP, contact .035 (6 pack)
NOZZLE, slip type 1/2 orifice
NOZZLE, slip type 3/8 orifice
1
1
1
1
1
1
1
1
10
110 794
TRIGGER SWITCH ASSEMBLY
11
080 565
12
110 792
1
15
120 715
16
079 974
17
110 796
TERMINAL, frict uninsul fern 22-l8ga
CABLE, lOft
SLEEVE, rubber
LINER, monocoil .023-.035 wire lOft (consisting of)
COLLET, liner .035 wire
0-RING, 1/2 ID x .103
CONNECTOR, gun/feeder
18
079 878
CONNECTOR & PINS
19
048 834
CONNECTOR, circ clamp
110 797
14
167 440
~ Hardware is
common
36)
1
TUBE, head (consisting of)
110780 ....NUT,MlOxl
13
7-1 Item
.2
2
1
1
str rlf
sz
11
Amp
1
206062-4
and
not available unless listed.
2
14
16
17
3
18
19
Ref. ST-liD 832-0
Figure
7-3.
Complete Assembly (MWG-160 Gun)
OPTI ONAL
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 482
Page
36
Item
No.
Part
No.
Figure
7-2 Item
29)
174 609
ROLL, drive
058 549
GUIDE,wireinletl/16
1
010 224
PIN,springCS.187x1.000
1
.3
126 838
.4
092 237
090 415
085 244
085 242
090 416
124 817
090 443
111 622
11
112031
12
151 828
124 778
.17
Assembly, Wire (Fig
090 423
180 929
.14
7-4. Drive
MOTOR, gear 24VDC
HOUSING, motor drive
DRIVE ASSEMBLY, wire (consisting of)
KNOB, adjustment tension
SPRING, cprsn .720 OD x .072 wire x 1.250
WASHER, cupped stl .328 ID x .812 OD x .125 lip
FASTENER, pinned
PIN, hinge
HOUSING, wire drive
BEARING, ball rdl sgl row .315 x .866 x .27 (consisting of)
SPACER, bearing .196 ID x .310 OD x .500 collar
LEVER, pressure roll
PIN, cotter hair .054 x .750
KNOB,T2.000 bar w/.312-l8st
SCREW, M61.0x20
180 926
.2
.7
Quantity
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
V groove .023-035
1
1
2
Hardware is
common
and
not available unless listed.
13
ST-181 053
Figure
To maintain the
Replacement
7-4. Drive
Assembly,
Wire
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-189 482
Page
37
Warranty
Effective January 1, 1998
(Equipment with a serial number preface ot ii
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
Limited
warranties expressed
1.
implied.
or
LIMITED WARRANTY
-
below, warrants to its
Subject
original
newer)
apply
to:
Items furnished by manufacturer, but manufactured by
others, such as engines or trade accessories. These
items
to the terms and conditions
retail purchaser that new
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped from factory. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
OF
WARRANTIES
IMPLIED,
MERCHANTABILITY AND FITNESS.
Warranty
or
shall not
covered
are
by
the manufacturers
warranty, if
any.
Consumable components; such
2.
as contact lips, cuffing
nozzles, contactors, relays, brushes, slip rings, or parts
that fail due to normal
wear.
that has been modified by any party other
manufacturer, or equipment that has been
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has
not had reasonable and necessary maintenance, or
Equipment
3.
than
Within the
warranty periods listed below, manufacturer will
replace any warranted parts or components that fail
due to such defects
in
material
or
workmanship.
Manufacturer must be notified in writing within thirty (30) days
repair
or
of such defect
or
provide instructions
on
equipment which has been used for operation
specifications for the equipment.
the
warranty
claim
procedures
to be
followed.
Manufacturer shall honor warranty claims on warranted
equipment fisted below in the event of such a failure within the
warranty time periods. All warranty time periods start on the
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
MANUFACTURERS
PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAI.JINDUSTRIAL
USERS AND PERSONS TRAINED AND EXPERIENCED IN
USE
THE
AND
OF
MAINTENANCE
WELDING
EQUIPMENT.
In the event of
2.
3.
3 Years
-
Parts and Labor
*
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Engine Driven Wetding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
Power Sources
Cutting
any kind will be allowed.
the
Parts and Labor
*
Motor Driven Guns
*
Process Controllers
(w/exception of Spoolmate 185)
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
Water Coolant
*
HF Units
*
Grids
*
Spot Welders
Load Banks
*
SDX Transformers
*
Running Gear/Trailers
Options
(NOTE: Field opt ions are covered under the limited
warranty for the remaining warranty period of the
product they are installed in, or for a minimum of one
whichever is greater.)
year
Field
4.
6 Months
5.
90
Days
Batteries
Parts and Labor
*
MIG Guns/TIG Torches
*
Plasma
Cuffing
Torches
*
Remote Controls
*
Accessory Kits
Replacement Parts
Spoolmate 185
*
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
ANY
IMPLIED WARRANTY,
GUARANTY
OR
AND
Systems
*
*
or
manufacturer in
3 Years Labor
main power rectifiers
Original
1 Year
warranty claim covered by this warranty, the
be, at manufacturers option: (1)
(2) replacement; or, where authorized in writing by
appropriate cases, (3) the reasonable cost
of repair or replacement at an authorized service station; or
(4) payment of or credit for the purchase price (less
reasonable depreciation based upon actual use) upon return
of the goods at customers risk and expense. manufacturers
option of repair or replacement will be FOB., Factory at
Appleton, Wisconsin, or F.O.B. at an authorized service
facility as determined by manufacturer. Therefore no
compensation or reimbursement for transportation costs of
repair;
5 Years Parts
*
a
exclusive remedies shall
distributor.
1.
outside of
the
at which time manufacturer will
failure,
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
MIGHT
ARISE
BY
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
WITH
RESPECT
TO
ANY
AND
ALL
PURPOSE,
EQUIPMENT
FURNISHED
BY
MANUFACTURER IS
EXCLUDED AND DISCLAIMED BY MANUFACTURER.
Some states in the U.S.A. do not allow limitations of how long
implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
an
In
Canada, legislation in
additional
warranties
herein, and
some
or
provinces provides
remedies
to the extent that
other than
they may
not be
for certain
as
stated
waived,
the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may
province.
be
available, but may vary from province
to
brand_warr 1/98
N
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date
which
equipment
was
delivered to
original customer.)
Distributor
Address
City
Zip
State
Resources AvaHahie
Always provide Model Name and SerialIStyle Number.
Contact your Distributor for:
N
Welding Supplies
and Consumables
...
Options and Accessories
Personal
Safety Equipment
Service and
Repair
Replacement
Owners
Circuit
Parts
Manuals
Diagrams
N
Contact the DelIvering Carrlertor:
File
a
claim for loss
or
damage during
shipment.
For assistance in
filing
contact your distributor
manufacturers
PRINTED IN USA
settling claims,
and/or equipment
or
Transportation Department.
N
N
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